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Corroded Beam Reinforcement in Gas Separation Plant
Cold Bonding Solution
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Corroded Beam ReinforcementCase Study
Major Petrochemical Plant , Rayong , Thailand Severe corrosion and metal loss on Pipe rack beam
throughout the plant can lead to Pipe rack collapse and serious accident.
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Corroded Beam ReinforcementCase Study
The corrosion was caused by “crack cementitious-fireproof ”.
The corrosion hided under thick fireproof paint and was not detected by visual inspection.
Inspection in 2007 was decided to remove crack fireproof paint for inspection
Pipe rack beam arrangement
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Corroded Beam ReinforcementCase Study
Corrosion on Beam after Grit blast to remove Fireproof paint
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Corroded Beam ReinforcementCase Study
Typical arrangement of Cementitioius fireproof on Beam
Cause of corrosion was the result of cementitious fireproof Cracking & deterioration.
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Corroded Beam ReinforcementCase Study
SOLUTION : Severe metal loss raised concern about Beam
strength and integrity. External Engineering specialist was contacted by
client to verify the Beam strength and they recommended to reinstate the Beam.
Available solutions were
1. Replace the new Beam
2. Hot Welding to reinstate the Beam
3. Cold Bonding to reinstate the Beam
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Corroded Beam ReinforcementCase Study
SOLUTION : Available solutions
1. Replace the new Beam is not possible because ;
Pipe rack beam run throughout the plant Complexity of Pipe rack arrangement Some areas were hard to access Very Expensive and Partial Plant shutdown required
2. Hot Welding to reinstate the Beam Possible but too risky because the Beam was
supporting Hydrocarbon Pipeline Many technical limitation for welding efficiency
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Corroded Beam ReinforcementCase Study
SOLUTION : The Cold Repair by BELZONA Cold Bonding Method
was considered only the reasonable solution Client requested us to do “Load test” to prove that
BELZONA Cold Bonding can reinstate the Beam strength
Testing was agreed to carry out by Pan Mechanic and Client
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Corroded Beam ReinforcementCase Study
TEST OBJECTIVE :
The test was carried out to calculate the “Deflection”
comparing between
1. Standard Beam
2. Defected Beam + Reinforced with Metal plate by BELZONA Cold Bonding
the Item 2 shall provide equal or less deflection than Item 1 when applied at the same load to prove that Reinforced by Cold Bonding can reinstate the Beam strength.
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Corroded Beam ReinforcementCase Study
TESTING : Load Test Table
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Corroded Beam ReinforcementCase Study
TESTING : Beam Preparation
Beam and Reinforcement Plate Belzona 1121 Super-XL Metal(as Cold Bonding Material)
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Corroded Beam ReinforcementCase Study
TESTING : Beam Preparation
Cut of some of Beam surface to Stimulate the corrosion/metal loss
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Corroded Beam ReinforcementCase Study
TESTING : Beam Preparation
Grit Blast the Beam / Plate to SA2.5 roughness > 75 microns
Blasted Beam & Plate
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Corroded Beam ReinforcementCase Study
TESTING : Beam Preparation
Mix Belzona 1121 Super-XL Metal Apply to the prepared area
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Corroded Beam ReinforcementCase Study
TESTING : Beam Preparation
Put thickness shim 2mm on the plate to control the thickness of the Bonding
Bond the plate to prepared area
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Corroded Beam ReinforcementCase Study
TESTING : Beam Preparation
Leave the Plate to be cured , then remove the clamp
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Corroded Beam ReinforcementCase Study
TESTING : Beam Preparation
(Another Beam) Bond the plate underneath the bottom beam
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Corroded Beam ReinforcementCase Study
TESTING : Beam Preparation
Leave the Plate to be cured , then remove the clamp
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Corroded Beam ReinforcementCase Study
TESTING : Test Equipment
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Corroded Beam ReinforcementCase Study
TESTING : Test Equipments
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Corroded Beam ReinforcementCase Study
TESTING : Load & Deflection Calculation
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Corroded Beam ReinforcementCase Study
TESTING : Load Test
Standard Beam Test , read dial gauge and pressure gauge
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Corroded Beam ReinforcementCase Study
TESTING : Load Test
Reinforced Beam Test (Uniform / Point Load )
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Corroded Beam ReinforcementCase Study
TESTING : Load Test
Reinforced Beam Test (Uniform / Point Load ) , test until failure
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Corroded Beam ReinforcementCase Study
TEST
RESULT :
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Corroded Beam ReinforcementCase Study
TEST
RESULT :
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Corroded Beam ReinforcementCase Study
TESTING : Test Summary
1. Reinforced beam have less deflection compared to the standard beam thus providing more strength than standard beam.
2. From the calculation , the maximum deflection of Standard Beam length 0.8 m. shall not more than 1.32 mm. From the graph , at 1.32 mm deflection , all reinforced Beam will provide more load bearing capability.
3. At 1.32 mm deflection , Belzona Bonding was still adhere well to the Beam
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Corroded Beam ReinforcementCase Study
TESTING : Test Result
BELZONA Cold Bonding was selected as the repair solution for the corroded beam
Material used : Belzona 1121 Super-XL Metal approx 1,000 kg Belzona 1121 will provide long working time to apply on large metal plate.
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Corroded Beam ReinforcementCase Study
Beam and Reinforcement Plate were Grit blast to SA2.5 and
Roughness more than 75 microns
REPAIR APPLICATION
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Corroded Beam ReinforcementCase Study
Beam and Reinforcement Plate were Grit blast to SA2.5 and
Roughness more than 75 microns
REPAIR APPLICATION
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Corroded Beam ReinforcementCase Study
Belzona 1121 Super-XL Metal as bonding materials
REPAIR APPLICATION
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Corroded Beam ReinforcementCase Study
Apply Belzona 1121 on the reinforcement plate and Beam
REPAIR APPLICATION
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Corroded Beam ReinforcementCase Study
Put the 2 mm-thick washer on the plate as the shim
REPAIR APPLICATION
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Corroded Beam ReinforcementCase Study
REPAIR APPLICATION
Adhere the plate to the Beam securing with clamps
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Corroded Beam ReinforcementCase Study
REPAIR APPLICATION
Adhere the plate to the Beam securing with clamps
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Corroded Beam ReinforcementCase Study
REPAIR APPLICATION
Adhere the plate to the Beam securing with clamps
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Corroded Beam ReinforcementCase Study
REPAIR APPLICATION
Adhere the plate to the Beam securing with clamps
Leave the bonding material to cure for 2 hours before removing the clamp.
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Corroded Beam ReinforcementCase Study
BENEFIT of BELZONA Cold Bonding
1. No Hot Work (Except Grit Blasting )
2. No partial plant shutdown
3. Short repair time
4. Economic
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Corroded Beam ReinforcementCase Study
LESSON LEARN FROM THIS CASE
1. Although not every cases , Cold Bonding Repair can replace many conventional hot work in your plants with comparable efficiency but less risk / less production loss
2. Severe corrosion problem may hide in some places in your plants such as under insulation , under damaged fireproof system , under pipe support , under tank base , splash zone, underwater…etc.
Inspection plan shall also focus on these invisible areas apart from the general areas.