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Metal or thermal spraying is a technology which protects and extends the life of a variety of equipment in hostile environments. This paper presents an experience in utilizing Thermal Spray Coating Technology on top of weld build-up of CS Pressure Vessel eroded shell.
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Atmospheric corrosion monitoring has traditionally been a lengthy and costly discipline. Visual inspection and weight loss testing is commonly applied, and this requires years of testing and on-site inspections with regular intervals. Furthermore, inspections and surveys in marine environments are troublesome, expensive and sometimes dangerous.
Corrosion under Insulation (CUI) is accelerated corrosion that takes place under insulation typically used to conserve energy, help with process control, and protect workers from temperature extremes. CUI is an issue for facility owners in many industries that use heat or cold in their industrial processes, including chemical processing, refining, fertilizer manufacturing, and power generation. Insulation used in these applications is generally mechanically attached to the substrate vessel or pipeline and is typically covered with cladding. Cladding is typically made out of metal or plastic and is applied to protect the insulation from physical damage and to keep water away from the insulation and substrate.
Coating standards specify the required surface conditions needed prior to coating. A maximum amount of soluble salts of 20 mg/m2 is widely adopted as acceptation criteria, according to standard NORSOK M-5011. However, meeting these requirements for thermal spray aluminium coatings (TSA) in offshore environments is challenging due to the ubiquitous nature of water-soluble salts.
Metalizing is not a new technology. It has been in use since the 1930s. Although it has seen limited use in comparison with conventional coatings, this is primarily due to economics. In past years, application rates for metalized coatings have been slow, making the process an expensive alternative to conventional coatings.
This paper provides an objective review of the life cycle costs of zinc-rich coating systems used in moderate industrial exposure environments. The coating systems include conventional inorganic/organic coatings, galvanizing, and thermal sprayed metal coatings (metallizing). Service life and installation cost data from previous studies is used to calculate the life cycle costs over a specified design life of an industrial structure.
Reinforced concrete structures are subject to many types of deterioration. Many of these are visible; however, one that is not is the crevice corrosion that occurs internally at the reinforcing bars. To detect, mitigate and delay this type of insidious corrosion, a form of cathodic protection in the form of thermal sprayed coatings will be discussed. To implement this as a corrective action as well as a preventive action is the theme of this paper.
TSA is mainly used to protect offshore steel structures, including atmospheric, splash and immersed zones. During installation or in service, the coating is likely to be damaged due to erosion, wear, scratch etc. TSA coatings protect by acting as a barrier and offering cathodic protection even if the substrate is exposed to seawater.
Metallizing in NH was a coating used only sparingly in the past at critical locations on two major bridges. Its greater use was severely limited by the lack of qualified applicators, absence from bridge fabricator operations, and overall excessive cost. This picture changed dramatically with the impetus of the new metallized Memorial Bridge project and the massive investment in metallizing equipment at a large local bridge fabricator that made metallizing possible for this bridge. The successful use and ten-year performance of the thermal spray coating (TSC), i.e. metallizing, on this bridge has had a significant impact on metallized New England bridges tofollow.
Thermal spray coatings (TSC) have been successfully used in all major sectors of the marine and industrial corrosion control coatings market.