cdb corroded beam reinforcement in thai gas seperation plant.pptx

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Corroded Beam Reinforcement in Gas Separation Plant

Cold Bonding Solution

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Corroded Beam ReinforcementCase Study

Major Petrochemical Plant , Rayong , Thailand Severe corrosion and metal loss on Pipe rack beam

throughout the plant can lead to Pipe rack collapse and serious accident.

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The corrosion was caused by “crack cementitious-fireproof ”.

The corrosion hided under thick fireproof paint and was not detected by visual inspection.

Inspection in 2007 was decided to remove crack fireproof paint for inspection

Pipe rack beam arrangement

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Corrosion on Beam after Grit blast to remove Fireproof paint

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Typical arrangement of Cementitioius fireproof on Beam

Cause of corrosion was the result of cementitious fireproof Cracking & deterioration.

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SOLUTION : Severe metal loss raised concern about Beam

strength and integrity. External Engineering specialist was contacted by

client to verify the Beam strength and they recommended to reinstate the Beam.

Available solutions were

1. Replace the new Beam

2. Hot Welding to reinstate the Beam

3. Cold Bonding to reinstate the Beam

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SOLUTION : Available solutions

1. Replace the new Beam is not possible because ;

Pipe rack beam run throughout the plant Complexity of Pipe rack arrangement Some areas were hard to access Very Expensive and Partial Plant shutdown required

2. Hot Welding to reinstate the Beam Possible but too risky because the Beam was

supporting Hydrocarbon Pipeline Many technical limitation for welding efficiency

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SOLUTION : The Cold Repair by BELZONA Cold Bonding Method

was considered only the reasonable solution Client requested us to do “Load test” to prove that

BELZONA Cold Bonding can reinstate the Beam strength

Testing was agreed to carry out by Pan Mechanic and Client

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TEST OBJECTIVE :

The test was carried out to calculate the “Deflection”

comparing between

1. Standard Beam

2. Defected Beam + Reinforced with Metal plate by BELZONA Cold Bonding

the Item 2 shall provide equal or less deflection than Item 1 when applied at the same load to prove that Reinforced by Cold Bonding can reinstate the Beam strength.

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TESTING : Load Test Table

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TESTING : Beam Preparation

Beam and Reinforcement Plate Belzona 1121 Super-XL Metal(as Cold Bonding Material)

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Cut of some of Beam surface to Stimulate the corrosion/metal loss

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Grit Blast the Beam / Plate to SA2.5 roughness > 75 microns

Blasted Beam & Plate

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Mix Belzona 1121 Super-XL Metal Apply to the prepared area

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Put thickness shim 2mm on the plate to control the thickness of the Bonding

Bond the plate to prepared area

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Leave the Plate to be cured , then remove the clamp

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(Another Beam) Bond the plate underneath the bottom beam

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Leave the Plate to be cured , then remove the clamp

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TESTING : Test Equipment

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TESTING : Test Equipments

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TESTING : Load & Deflection Calculation

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TESTING : Load Test

Standard Beam Test , read dial gauge and pressure gauge

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TESTING : Load Test

Reinforced Beam Test (Uniform / Point Load )

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TESTING : Load Test

Reinforced Beam Test (Uniform / Point Load ) , test until failure

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TEST

RESULT :

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TESTING : Test Summary

1. Reinforced beam have less deflection compared to the standard beam thus providing more strength than standard beam.

2. From the calculation , the maximum deflection of Standard Beam length 0.8 m. shall not more than 1.32 mm. From the graph , at 1.32 mm deflection , all reinforced Beam will provide more load bearing capability.

3. At 1.32 mm deflection , Belzona Bonding was still adhere well to the Beam

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TESTING : Test Result

BELZONA Cold Bonding was selected as the repair solution for the corroded beam

Material used : Belzona 1121 Super-XL Metal approx 1,000 kg Belzona 1121 will provide long working time to apply on large metal plate.

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Beam and Reinforcement Plate were Grit blast to SA2.5 and

Roughness more than 75 microns

REPAIR APPLICATION

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Belzona 1121 Super-XL Metal as bonding materials

REPAIR APPLICATION

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Apply Belzona 1121 on the reinforcement plate and Beam

REPAIR APPLICATION

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Put the 2 mm-thick washer on the plate as the shim

REPAIR APPLICATION

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REPAIR APPLICATION

Adhere the plate to the Beam securing with clamps

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REPAIR APPLICATION

Adhere the plate to the Beam securing with clamps

Leave the bonding material to cure for 2 hours before removing the clamp.

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BENEFIT of BELZONA Cold Bonding

1. No Hot Work (Except Grit Blasting )

2. No partial plant shutdown

3. Short repair time

4. Economic

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LESSON LEARN FROM THIS CASE

1. Although not every cases , Cold Bonding Repair can replace many conventional hot work in your plants with comparable efficiency but less risk / less production loss

2. Severe corrosion problem may hide in some places in your plants such as under insulation , under damaged fireproof system , under pipe support , under tank base , splash zone, underwater…etc.

Inspection plan shall also focus on these invisible areas apart from the general areas.

cdb corroded beam reinforcement in thai gas seperation plant.pptx

Documents

beam preparation beam

beam possible

beam preparationgrit

beam preparationcut

beam surface

beam strengthtesting

beam preparationmix

belzona cold bonding