Case Studies
Chesterton ARC S2 Solves Process Water Tank Leakage Issue
Challenge
Background
The process water tank (metal) is experiencing severe corrosion due to exposure to a combination of mine process water and seawater. The liquid is corrosive, slightly abrasive, and sticky, containing fine sand and light mineral slurry diluted with seawater. Corrosion has resulted in leakage of the tank.
The previous coating system, Amercoat 395, achieved a service life of only 6 months.
Corroded wall of tank after 6 months.
Solution
Product
Chesterton ARC S2 was selected for its ability to withstand both the erosive conditions and the acidic nature of the process liquid. Initial on-site patch testing was conducted and evaluated after 18 months in service, with the coating performing exceptionally well. A total of 11 tanks, each with an approximate surface area of 5,400 m’, were subsequently specified for coating application.
Following abrasive blasting to Sa 2.5 with a 75 pm surface profile, surface testing and stripe coating of joints and critical areas were completed prior to application. ARC S2 was then spray applied. Upon curing, holiday testing was carried out to confirm lining integrity.
The decision to proceed with ARC S2 was also supported by the ease and speed of spray application, as well as Chesterton’s ability to meet the required lead time and budget.
Application of Chesterton ARC S2.
Results
Increase Reliability
The tanks were progressively returned to service, with the customer providing positive feedback on both the application process and overall project execution. ARC S2 is expected to provide a service life of 5 to 10 years without requiring major repair work.
Previously, the tanks experienced ongoing leakage issues, resulting in frequent clean-up activities, reduced operating capacity due to the inability to fully fill the tanks, and continual patch repairs at an estimated annual cost of approximately USD $300K.
The total cost of the Chesterton solution was approximately USD $750K with an expected minimum service life of 5 years. Based on the reduction in maintenance and repair costs, the project is expected to deliver savings of approximately USD $150K per year, resulting in a maximum payback period of approximately 2.5 years.
Process water tanks on site.
About Us
Chesterton® is a world leader in helping process industry companies and manufacturers improve the reliability and efficiency of their rotating, stationary, and fluid power equipment platforms. We are known across a wide range of industries for our award-winning pump and valve sealing solutions, applications expertise, equipment maintenance and wear-prevention products, and knowledgeable hands-on local service. Chesterton product range includes mechanical seals, packing and gaskets, industrial lubricants and coatings.
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