Citation
(2009), "A polymer solution to in-service deterioration of heat exchangers", Anti-Corrosion Methods and Materials, Vol. 56 No. 5. https://doi.org/10.1108/acmm.2009.12856eab.002
Publisher
:Emerald Group Publishing Limited
Copyright © 2009, Emerald Group Publishing Limited
A polymer solution to in-service deterioration of heat exchangers
Article Type: Methods From: Anti-Corrosion Methods and Materials, Volume 56, Issue 5
Belzona Polymerics Limited, providing solutions to industry for over 55 years through the design and manufacture of polymer repair composites and industrial protective coatings has a proven solution to prevent the detrimental effects of erosion corrosion within heat exchangers (Figure 2).
In-service deterioration can occur through erosion damage and galvanic corrosion due to contact between dissimilar metals, commonly used in the construction of heat exchangers. If this damage is not addressed the efficiency of the system will be seriously undermined with the potential for complete failure of components, resulting in expensive operational downtime, and potentially high-replacement costs.
In 2003, a heat exchanger in a major power station in the UK had been removed for refurbishment. Following inspection, it was discovered that galvanic corrosion, coupled with erosion had caused a loss of metal thickness on the tube sheet surface. Consequently, coolant was able to contaminate the process fluid, necessitating immediate shutdown of the system, with the customer facing potentially high-cost maintenance repairs.
Belzona was able to provide a cost-effective solution, utilising maintenance techniques that have been developed, whereby components can be both rebuilt and protected using polymeric compositions. A multi-purpose, two-component system, based on a ceramic steel reinforced polymer was used to rebuild the eroded tube sheet and seal the leaks. To prevent future deterioration, a low-temperature curing, high-performance erosion corrosion resistant coating system was applied. The electrically insulating Belzona materials isolated the dissimilar metals used in heat exchanger construction, thereby eliminating further galvanic corrosion.
By treating heat exchanger components in this way, efficiency can be restored to levels approaching the original design parameters and can be maintained without subsequent deterioration.
During a recent maintenance outage, Belzona’s team of power industry specialists revisited the heat exchanger and found it to be in excellent operational condition, without the need for further maintenance repairs.
Said Gordon Cairns, National Sales Manager, “Our technology and experience has culminated in a cost-effective repair and protection system that can prevent the associated implications of in-service deterioration within heat exchange equipment.”
This is just one of the numerous Belzona product applications that have stood the test of time, remaining in service many years after installation. Owing to this proven longevity, many product applications have been internationally approved by engineers, contractors, and maintenance personnel.
Meanwhile, according to Gordon Cairns, Belzona has, of late, seen a significant increase in the use of Belzona products for new equipment. He commented, “Several of the major and specialist original equipment heat exchanger manufacturers are considering coating new equipment with Belzona’s range of protective coatings due to the outstanding performance they offer under many and varied arduous service conditions.”
David Norton of Wellman Hunt – Graham, an international leading supplier of vacuum and heat transfer equipment explains, “Belzona materials were recently used on a major heat exchanger project as an alternative to titanium with great effect.”
“Traditional methods of manufacture involve machining an expensive titanium tube sheet. The short application time of the Belzona solution coupled with the inexpensive coated carbon steel fabricated components, ensured the heat exchanger offered the same performance and reliability of a titanium manufactured heat exchanger – Belzona is a real alternative to high grade expensive alloys.”
For further information, please visit the web site: www.belzona.com