Cracked coke gas pipe

KHIA ID: 9848
Industry: Steel & Metal Processing (STEL)
Application: VPF-Valves, Pipes and Fittings (VPF)
Substrate: Carbon steel
Customer Location: Middle of Sweden
Application Date: May 2024
Products: Belzona 1212,Belzona 1391T,Belzona 1511 (Super HT-Metal)
Problem: The customer had problems cracking and leaking. This had to be both sealed and reinforced. Hot work was not possible as the pipe transports combustible gases. This process could not be shut down, so we had to find a solution together with the customer to be able to perform this during operation.

Our solution was to perform this using a mechanical clamp together with grouting the space between the pipe and clamp with Belzona 1391T. This sealed and fixed the area to ensure it was tight and able to withstand future movement in the area.

Here we have the area with the crack, tar has leaked out and at the moment the pressure is reduced so no smoke is leaking out

Here the crack is clearly visible after blasting. We have drilled holes at the ends of the crack to minimise the risk of the crack moving on.

Installation of the reinforcement plate and clamps and sealing of the edges with Belzona 1511

Injecting with Belzona 1391T to fill the space between the sheet and the pipe. We started at the bottom and worked our way up. This way we both bond and seal the whole system.

Application Situation
Given the circumstances and the fact that they were unable to decommission the equipment, there were major benefits both in terms of time and cost savings. We did it with a cold method during full operation
Application Method
Prior to this project, a site visit was made to identify the damage, and to measure what the reinforcement sweep would look like.
Once on site, we blasted the area to see the damage in its entirety and drilled holes at the ends of the crack to prevent it from travelling further. Patched the damage with Belzona 1212. Welded off the area again and the sheet metal sweep. Fitted the sheet metal sweep. Patched the edges with Belzona 1511 to prevent leakage during injection with Belzona 1391T.
Belzona Facts
The cost saving is difficult to evaluate as they cannot run down operations. But if they had been able to shut down, they would have lost large sums per hour
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