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Live High Temperature Repair of Vapour Tank

Overview

A vapour tank vessel had suffered chloride induced corrosion that required an urgent repair without the use of hot work. The design of the repair required a defect model that would reflect complete section loss of the welded connections for a series of nozzles, and the vessel head circumferential weld.

Scope

The tank had the following specifications:

Structure Vapour tank vessel
Surface Preparation Sa 2.5
Design Pressure 340 kPa
Design Temperature 2200C
Application Temperature 50-1100C
Design Life 5 years
Wrap Length 6.5 m
Vessel Diameter 2.0 m
Geometry Vessel circumference, nozzles on dome end, lifting lugs on vessel side
Corrosion Type External
Defect Details 3mm loss on circumferential weld and 25mm through-wall defect on nozzle welds

Solution

  • Technowrap 2K™ HT system with temperature capability up to 220°C
  • A highly skilled team of wrapping specialists with experience in high temperature applications
  • Vacuum bag consolidation for the component onto the dome ends
  • Coverage of a large part of the vessel dome end - circumference weld line, nozzles and lifting lugs, supplementing steel with fibre reinforced epoxy

Benefits

  • Repair completed without hot works
  • No impact on production, tank remained live (at high temperature) during the repair
  • Wide chemical resistance, capable of constant exposure to chloride in various forms
  • Documented QA/QC procedures provide an excellent record of the repair materials and application process for future reference

ICR.IAS JV 

iasgroup is a partner in the ICR.IAS JV, providing leading production critical cold work solutions that remove or minimise the need for shutdowns. The JV is home to market leading technologies TechnowrapTM and QuickflangeTM  https://icrias-jv.com.au/