BELZONA SOLUTION FOR REBUILDING AND COATING OF CHILLERS

KHIA ID: 9762
Industry: Heating, Ventilation & Air Conditioning (HVAC)
Application: HEX-Heat Exchangers (HEX)
Substrate: Carbon steel
Customer Location: DUBAI, UNITED ARAB EMIRATES
Application Date: January 2025
Products: Belzona 1121 (Super XL-Metal),Belzona 5821
Problem: The tube sheet and end cover of the chiller units experienced severe corrosion, resulting in a significant decline in efficiency. Additionally, the wear around the gasket seals prevented a proper seal, further impacting the chiller's performance.

Tube sheet and end cover of the chiller units experienced severe corrosion.

Surface was grit blasted and thoroughly cleaned.

Belzona 1121 (Super XL-Metal) was used to rebuild and resurface the worn areas.

Belzona 5821 was applied as a two-coat system to protect the tube sheet and end cover from corrosion and erosion.

Application Situation
The client selected Belzona for its exceptional corrosion and erosion resistance, which has been consistently proven over the years.
Our key selling point was the extended durability that Belzona coatings provide for valuable assets. We also emphasized that merely chemically cleaning the corrosion is not a sufficient solution, as the damage continues to progress even after cleaning. Additionally, we highlighted a major advantage—the ability to return the chillers to service in less than 48 hours after the repair.
Application Method
1. The surface was grit blasted and thoroughly cleaned.
2. Plastic/rubber plugs were inserted during surface preparation to prevent media from entering the tubes. These plugs were then removed and reapplied before the product application.
3. Belzona 1121 (Super XL-Metal) was used to rebuild and resurface the worn areas, while Belzona 5821 was applied as a two-coat system to protect the tube sheet and end cover from corrosion and erosion.
Belzona Facts
The customer benefited from a proven, high-performance solution that minimized downtime and enhanced the longevity of their equipment. The durability and reliability of Belzona products also contributed to lower maintenance costs over time, making it a cost-effective choice for their ongoing operational requirements.
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