In-Situ Restoration of Corroded Ethylene Tank Roof and Staircase Using Belzona 1161
In this case study, we present a scenario where an Ethylene tank in a Chemical Plant suffered significant damage to its roof and staircase due to severe corrosion in the skirt area. Rainwater accumulation and harsh environmental conditions were the primary causes of the corrosion. The client sought a quick and efficient solution to address the issue without taking the tank out of service. NESL was contracted to provide an in-situ repair solution, and the process involved manual surface preparation using non-sparking tools, epoxy-grade filling to repair and smooth corroded areas, and the application of Belzona products for priming and restoration.
1. Problem Statement
The Ethylene tank’s roof and staircase were facing a critical issue due to severe corrosion on the skirt area caused by rainwater accumulation. The damage compromised the structural integrity and safety of the tank, making it essential to address the issue promptly. However, taking the tank out of service was not a viable option, which presented NESL with the challenge of finding an in-situ repair solution that could restore the tank’s integrity without interrupting its operations.
2. Client’s Requirements
The client required a quick and efficient solution to repair the corroded areas of the tank without taking it out of service. The primary goals were to:
a. Restore the structural integrity of the tank’s roof and staircase.
b. Prevent further corrosion and damage.
c. Enhance the tank’s longevity and operational safety.
NESL’s Solution
After a thorough assessment of the tank’s condition, NESL proposed a multi-step restoration process using Belzona products. The following steps were undertaken:
Step 1: Surface Preparation
Given the limitation of the tank remaining in service, NESL opted for manual abrasion using non-sparking tools as the surface preparation method. This approach ensured that the corroded areas were properly cleaned, providing a suitable surface for the subsequent repair procedures.
Step 2: Epoxy Grade Filling
To repair and smoothen off the worst of the corrosion, an epoxy-grade filler Belzona 1111 was applied to the prepared surface. The filler was carefully applied to the damaged areas, restoring the structural integrity and preventing further deterioration.
Step 3: Belzona 1161 Application
NESL used Belzona 1161 to prime the repaired surface and fill additional rough areas. Belzona 1161 is a high-performance epoxy coating known for its excellent adhesion and resistance to various environmental factors. The application of Belzona 1161 further enhanced the tank’s protection against corrosion and provided a durable base for the final restoration compound.
Step 4: Belzona Cold Repair Compound
The final step involved applying Belzona Cold Repair Compound to fully restore the integrity of the corroded tank areas. This compound is specifically designed for in-situ repairs and provides exceptional mechanical strength and corrosion resistance. Its cold application eliminates the need for hot work, making it safe and convenient for repairs in operational facilities.
Execution and Results
The entire restoration process was carried out in-situ, adhering to strict safety protocols to ensure the well-being of the personnel involved. NESL’s skilled technicians worked diligently to execute each step with precision.
Upon completion of the restoration process, the results were remarkable. The corroded roof and staircase were effectively repaired and restored to their original structural integrity. The application of Belzona products provided long-lasting protection against corrosion and harsh environmental conditions. The tank’s operational safety and longevity were significantly improved, meeting the client’s requirements.
