Repair Corroded Cooling Tower Pipe with Belzona

KHIA ID: 5414
Industry: Chemical & Petrochemical (PETR)
Application: VPF-Valves, Pipes and Fittings (VPF)
Substrate: Carbon Steel
Customer Location: Petrochemical Plant Southeast Texas
Application Date: April 2013

Belzona 1211 (E-Metal)

Belzona 1111 (Super Metal)

Belzona 4151 (Magma-Quartz Resin)

Belzona 5111 (Ceramic Cladding)

Belzona 9731

Problem: Non-destructive testing (NDT) showed where heavy corrosion had caused major pitting resulting in thin walled pipe in many areas and through wall in one spot.
Photograph Descriptions
  1. Close-up of heavy corrosion
  2. Original leak and new through wall due to blast
  3. Belzona 1111 applied to fill the pits
  4. Finished project
Application Situation
3 sections of 30" x 10' Suction Pipe and 3 sections of 30" x 10' Discharge Pipe on Cooling Tower
Application Method
Application carried out in accordance with Belzona Know How System Leaflet VPF-11. After proper surface preparation Belzona 1211 was used to fix the live leak.  Belzona 1111 was then used to fill the pitting.  Belzona 4151 with Belzona 9731 reinforcement tape were used to form a pipe wrap for stregth. A final coat of Belzona 5111 was used for UV and environmental protection.
Belzona Facts
The original plan was to replace 30 linear feet of discharge pipes of 30 inches in diameter at a cost of almost $90,000 for materials only. The Belzona solution saved the customer over $75,000 and was completed in just 2 days. It was so successful that and addition 30 linear feet of suction piping was done within 2 weeks saving the plant over $150,000.