Case Studies

Background

Holes had developed in the floor surface of a dust collector in the flue-gas desulphurisation plant of a major oil refinery due to corrosion. The equipment was repaired using a coating recommended by the equipment manufacturer, but leaks occurred three times a year, forcing the plant to shut down each time. 5 days were required to restore the equipment after each shutdown, resulting in a loss of 100 million yen in breakdowns during that period.

The coating material used required a certain amount of time to cure completely, so it could not cure in time for sites that needed to start up in a short period of time. Insufficient metal surface treatment (blasting, degreasing, etc.) led to poor adhesion and premature peeling of the coating material.

The floor surface is corroded and pitted.

Preparation

Perform surface treatment by blasting to ensure a recommended metal surface roughness of 80-125㎛. Ensure that any holes are plugged with a plate.

Recommended products/solutions

• Adhere the plate to the floor of the insulator chamber using ARC 858.
• Apply three layers of ARC S7 on the bonded shingles and floor surface, with an average film thickness of 1000㎛.
• The inside of the dust collector is also coated with four layers of ARC S7, with a film thickness of 1000㎛.

Improvements
ARC S7 is resistant to high temperature specifications and fast to fully cure.
Thorough construction control prior to application ensures that the recommended roughness is achieved.

ARC 858 is used to glue the guess board to the floor surface.

Customer Report

In 2 years and 9 months, not a single leakage due to pitting has occurred. Calculated over 2 years and 9 months (comparison of pre-and post-improvement costs)
Conventional system (life span: 4 months)
800,000/times x 8 times = 6,400,000 yen
Production stoppage loss = ¥ 100,000,000/times x 8 times = ¥ 800,000,000

Chesterton Solution
First time only: JPY 7,517,500
Production stoppage loss = 0 yen

Total Savings
2 years and 9 months = ¥ 806,400,000 – ¥ 7,517,500 = 798,882,500 yen

The floor surface as well as above the guessboard area are all protected with ARC S7 (3 layers).

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