Belzona prevents prolonged shutdown due to sulfuric acid flange leak

KHIA ID: 8857

Industry: General Industry (GIND)
Application: VPF-Valves, Pipes and Fittings (VPF)
Substrate: Steel

Customer Location: Chemical Manufacturer, Warrington
Application Date: August 2022

Products:
Belzona 1392 (Ceramic HT2)

Problem: The client had an emergency shut down due to hot sulphuric acid leaking from a flange which had previously been coated with a fluoropolymer. The job was very small but was enough to shut the plant down as the existing coating had failed causing a serious and dangerous leak.

Photograph Descriptions

1. Areas of concern

2. Close-up of the fluoropolymer coating

3. Belzona 1392 repair

Application Situation

Damaged flange in a suction chamber.

Application Method

The flange was taken out of service and taken to the Belzona workshop in Wrexham for repair. The applications team prepared the defective areas using mechanical tools to make the surface as rough as possible, angle out the grooves and get down to steel where possible. The surface was also cleaned and degreased prior to the application of a thick coat of Belzona 1392. The product was applied level with the remainder of the flange face to ensure the gasket sat tightly on the surface. Once the product had cured, the component was transported back to the customer's facility.

Belzona Facts

The sites operating conditions were a maximum of 40% concentration of Sulfuric acid at 55℃ making a high build coating of Belzona 1392 the ideal repair solution. Inspection reports from the site after a weekend in service deemed the repair to be very successful. The overall cost of the repair was less than £800 total.

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