011150 011151 011152 011153 011154 011155 011156 011157 011158 011159 0111510 O111S11 [DUrOmMaB Case Histories FGD Reaction Tank Lining FGD Outlet Duct Lining Hastaloy Stack Repair Cast Iron Waterbox Rebuild Cast Iron Waterbox Rebuild Waterbox Lining Demineralizer Floor Repair Coal Exhauster Wear Plate Repair Coal Mill Classifier Repair Bottom Ash Elbow Repair Westinghouse Turbine Flange Repair Phosphate Railcar Lining 76 Washinglon Steet, Pornbroke, MA G2869 USA Tal (781) 626-2505 - Fax (781) 826-2180 ‘uramar comDUFOMaBy’ Case Histry-011180 FGD Reaction Tank Lining PROBLEM. RESULTS: A South-Central Utility installed limestone ‘SO; scrubber systems on their 720 MW units in 1985 and 1987. The Reaction Tank walls and ceilings were originally lined with a thick FRP mat product. This lining started to Jail within the first year of operation. The {failure mode ‘was delamination between coats and disbondment between the lining and the substrate (carbon steel). The linings ‘on all nine tanks on each wnit were failing and the tanks corroding. SOLUTION: Tn November of 1987, after complete removal of the failed material from the walls and in spots on the ceiling, DUROMAR'S HPL 2131, 100% solids, high abrasion resistant product was used to reline one tank. We used a special DUROMAR designed "Grout Pump" system which allows up to 80 mils of material to be applied in one application. Since we require no primers and apply the complete lining in one coat, we climinate the major causes of lining failure. HPL 2131 was applied at 50-60 mils on the walls and ceiling. The joint between the walls and the conerete floor was filled with a closed-cell foam backer rod and topped with additional HPL-2131. After six months of operation the HPL 2131 Jining was still in perfect condition. On that basis, the go-ahead to do the other tanks was given. A second inspection after 18 months of service again showed the HPL, 2131 to be in perfect condition. CURRENT STATUS: Today, after over 13 years of service, the HPL-2131 is still in excellent condition and continues to protect the tank walls. COMMENTS: DUROMAR'S HPL 2131 is a versatile product, Because of its excellent performance in the Reaction Tanks, it was successfully used to repair andior replace failed gunite lining in the scrubber outlet duct, replace failed FRP lining in @ limestone ballmill sump, replace a failed rubber lining in another limestone ballmill sump, and patch the glass lined additive feed tanks. DUROMAR'S HPL 2131's excellent abrasion resistance and chemical resistance (PH range of 1.5 - 12.5) allow it to be used in many different environments. The simplicity of the one-coat system makes it the most easy to apply and failure free lining system in the industry. "708 Washington Steot, Pombroka, MA 02859 USA Tel (761) B262525- Fax (781) B26-2150 wo euromar.eomDUromMar’ Case History 11181 FGD Outlet Duct Lining PROBLEM: A Mid-Central Utility installed limestone ‘$0; scrubber systems on their three 700+ MIV units in 1978, 1980 and 1984. As early as 1982, the ductwork from the scrubber outlet t0 the stack inlet was showing severe corrosion and metal loss. A particular problem with finding a suitable lining product was that the duet temperatures reached 400°F during startup and shutdown. SOLUTION: DUROMAR, INC, who has the only organic lining product which would standup to the temperature requirements, was given the project to line the entire duet from serubber outlet to the stack. The product used was HPL 2131 (formerly HPL 400) which was trowel applied at 80 miles DFT. HPL 2131 is a heavily filled (A1s0,) 100% solid epoxy lining system, which like all DUROMAR products, requires no primer. RESULTS: The first unit was complete in 1982. In 1985, after about 3 years of successful operation with no signs of failure, the second unit ductwork was Tined with HPL 2131, and the third unit in was lined in 1988, CURRENT STATUS: In 1991, the HPL. 2131 linings were inspected. Aside from some surface darkening due to the high temperatures, all the linings were in excellent condition with little, if any, ‘material loss. However, the plant personnel, being very sensitive to the corrosion potential fiom their acid gases, decided to add @ thin film topcoat of DUROMAR HPL 4320 to the existing lining. The existing lining was cleaned, neutralized, and brush blasted prior to recoating. After sandblasting, a few areas required patching with HPL 2131 before overcoating. The HPL 4320 was then spray applied in two (2) coats to give a 40 mil DFT. This improved the acid resistance of the system to a pH range of 0.5 - 12.5. COMMENTS: DUROMAR'S HPL 2131's excellent abrasion, chemical (pH range of 1.5 - 12.5), and temperature (400+°F) resistance allow it to be used in many different environments. The simplicity of the one-coat system makes it the most easy to apply and failure free lining system in the industry. DUROMAR'S HPL 4320's superior chemical resistance (pH range of 0.5 - 12.5) and ease of application make it the product of choice whether used alone as a thin-film lining (40 mils DFT) or as a topcoat for enhanced chemical protection. 706 Washingion Steet, Pembroke, WA 02058 USA + Tal (781) 626-2525 Fax 761) 626-2160 ‘wa uromer comDUrOoMaR’ Case History-011182 Hastaloy Stack Repair PROBLEM: RESULT! A South-Eastern Utility installed limestone 50> scrubber systems on their 280 MW units between 1977 and 1981. The outlet ducts were wallpapered with Hastaloy, to prevent corrosion, from the scrubber outlets to the stack inlet. They found that the stack wall direcily opposite the outlet duct was being subject to excessive corrosion/abrasion from impingement of the moist flue gas. The Plant decided to install a partial Hastaloy stack liner at that point. However, they were concerned that the edges of the new Hastaloy would be subject 10 the same accelerated corrosion rate as they were seeing at the edge where the existing Hastaloy lined outlet duct ended. SOLUTION: DUROMAR, INC. was contacted, end we recommended coating a 12" strip of HPL 4330 around the Hastaloy edge, about 3" onto the Hastaloy and 9" onto the concrete stack surface to prevent the accelerated corrosion being experienced. The product selected was DUROMAR HPL 4330, a thick film product which was applied in one ‘coat at about 60-80 mils DFT. This novolac based resin system gave the acid, temperature and abrasion resistance required. In addition to this arca, the HPL 4330 was used to coat the existing Hastaloy line outlet duct edge to prevent further corrosion. After six months of operation, the HPL 4330 lining was still in perfect condition. More importantly, the Hastaloy was also in perfect condition with no edge corrosion ot other effects. A. second inspection after 12 months of service again showed the HPL 4330 to be in perfect condition, protecting the alloy CURRENT STATUS: After about 18 months of service the uncoated Hastoloy stack liner was found to be severly corroded from the condensing acids in the stack gases. The stack liner was removed and a more chemical resistant alloy Was installed. COMMENTS: DUROMAR'S HPL 4330 is an excellent lining material for use in highly acidie, high temperature, abrasive applications. It can tolerate pH ranges from 0.5 to 12.5 and temperatures over 400°F. Because of it’s paste like consistancy, during epplication, it also fills any corrosion pits present. Since Hastoloy tends to “worm hole”, this is an excellent benefit. 706 Washington Steet, Pembroke, MA 02850 USA » Tol (781) A25-2505 Fax (781) B26-2180 wiv duromarcom(Ser) Cast Iron Waterbox Rebuild PROBLE! By 1983, at a New England utility, the cast iron waterboxes, were subjected t0 many years of salt water attack The corrosion was almost 10 the failure point, and the waterboxes were leaking at a few points. Replacement of the old waterboxes, ieven if possible, would take from 1.5 to 2 years to have them fabricated, Welding was not considered as the heat stress might cause cracking and complete failure of the waterboxes and shutdown of the plant. SOLUTION: DUROMAR, INC. was contracted to rebuild the surface using our thick film, permeation and abrasion resistant epoxy lining, SAR. After completely removing the thick crust of scale and digging out the graphitized pits, the surface was steamed to remove chlorides, dried and sandblasted to near-white metal. The rough surface was reprofiled with SAR which in some areas required over 1" of material. Then the complete surface was covered with a minimum film thickness of 80 mils DFT. To decrease drag and improve impact resistance, a topeoat of EAC @ 40 mils DFT was applied. RESULTS: The DUROMAR lining of approximately 120 mils of heavily filled, SAR and EAC, was found to add considerable strength to the now thinned cast iron surfaces. It has bbeen shown that at this thickness, 1/3 t0 1/2 the original strength can be added back to the lined surface. The work was performed Guring a normal outage time period and the waterboxes were put back into service with no additional downtime. The system was stable and leak free, CURRENT STATUS: ‘The plant was decommissioned in 1993, but the rebuilt waterboxes performed perfectly during this period with no leaking or lost ‘generation due to waterbox problems. COMMENTS: As with all DUROMAR products, the SAR and EAC are 100% solids, Zero VOC, solvent free, and contain no carcinogens or heavy metals, This makes application easy and safe for both the applicators and the environment. This process has also been successfully used to line carbon stee! waterboxes with similar ‘excellent long term results. eee ES 705 Washington Steet, Pembroke, MA 2860 USA > Tal (701) 6252505 Fax (761) 626-2160 ‘www. duromar.comDUromMaR’ Case History 011184 Cast Iron Waterbox Rebuild PROBLEM: In 1985, the Cast Iron Waterboxes at the San Juan Station of Puerto Rico Electric Authority, after being subjected to many years of salt water attack, were corroded 10 the failure point and were leaking in numerous areas. Replacement of the old waterboxes, if even possible, would take about 2-3 years, but the power generation was needed immediately. SOLUTION: DUROMAR, INC. was contracted to rebuild/teprofile the surface with our thick film, permeation and abrasion resistant epoxy lining, SAR. After completely removing the thick crust of scale and digging out the graphitized pits, the surface was steamed to remove chlorides, dried and sandblasted to white metal. The rough surface was reprofiled with SAR which in some areas required over 1" of material. Large sections of the waterbox severely weakened from metal loss were reinforced with carbon steel plates glued in with SAR. Then the complete surface was covered with ‘additional SAR to a minimum film thickness of 80 mils DFT. To decrease drag and improve impact resistance, a topcoat of HPL-2510 @ 40 mils DT was added. RESULT! The DUROMAR lining of approximately 120 mils of heavily filled, SAR and HPL- 2810, was found to add considerable strength to the now thinner cast iron surfaces. It has been shown that at this thickness, 1/3 to 1/2 the original strength can be added back to the lined surface. The project was completed on schedule and immediately returned to service. CURRENT STATUS: ‘The waterboxes are inspected yearly during cach annual outage. The last inspection was in the fall of 1999, and the lining was found to be in excellent condition. Additionally, the comment was made that the waterbox remains free of marine growth and deposits. COMMENTS: DUROMAR SAR and HPL-2510 have been used throughout the Circulating Water System for patching and lining metal, conerete, fiberglass, and rubber lined surfaces. Since these, like all DUROMAR epoxy products, are 100% solids, Zero VOC, and contain no carcinogens or heavy metals. They make application easy and safe for both the applicators and the environment, 706 Washington Steet, Pembroke, MA 02859 USA » Tel (781) 8252525 - Fax (761) BIETIED ‘www duromar.comDUrOoMaR’ (Case History 11158 Waterbox Lining PROBLEM: RESULTS: In 1993, Israel Electric Corporation was concerned about the failing rubber lining and subsequent pitting and corrosion throughout the circulating water systems especially in their salt water cooled power plants. Specifically, the debris filters and waterboxes all showed varying degrees of rubber lining failure. They decided to repair the rubber lining where possible and reline where necessary. SOLUTION: DUROMAR, INC. through our Distributor, LAOR Engineering, was contacted to supply products to both repair failed rubber lining and reline the most severely damaged areas. Where small faults were present, the failed rubber was removed. The arca from which the rubber was removed was grit blasted and the rubber lining roughened. The metal/rubber joint area was filled with DUROMAR SAR ‘and sloped both onto the rubber and the exposed metal surface. The metel and SAR was then topcoated with two coats of DUROMAR EAC. For areas of severe failure, the remaining rubber was removed and the surface grit was blasted and, any deep pits were filled with SAR. The total surface was then lined with two coats of EAC as above. The lining and repair project was completed on schedule, and the unit was retumed to serviee with no evidence of problems, CURRENT STATUS: ‘The initial unit continues to have minor rubber failures, but these are quickly repaired using DUROMAR SAR. No damage to the DUROMAR repaired areas have occurred. Because of the success of this project, similar repairs have been done at a second power plant with the addition of a thick film (180 mil) epoxy cladding on the tubesheets face for complete long term protection. c ENTS: As with all DUROMAR products, the SAR and EAC are 100% solids, with Zero VOC. ‘These Epoxy systems contain no carcinogens or heavy metals. This makes applications ‘easy and safe for both the applicators and the environment. This process has also been successfully used to line Cast Iron Waterboxes with similar excellent results B 706 Washington Steet, Pembroke, MA 02368 USA > Tel, (781) 808-2505 Fax 781) B26-2150 ‘wns. duromar.camDUFrOMaB’ {Case History 011156 Demineralizer Floor Repair PROBLEM. A Mid-West Utility had installed an “acid resistant” tile floor in their demineralizer room 10 resist attack from concentrated sulfuric acid and caustic spills. In 1983, much of the tiled floor exposed to chemical spills was failing due to the attack on the grout and subsequent undercutting which resulted in release of the tile and attack on the concrete subfloor. Water leaking through the floor also added to the problem. SOLUTION: The entire floor was high pressure water washed to remove any chemical deposits, loose grout and old concrete. Grit blasting was not allowed in the area to profile the “good” tile to be left in place, but the excellent bonding strength of the Chemerete Flooring was deemed sufficient to hold it onto the tiled surfaces. Chemerete Flooring wwas therefore used to repair and reprofile the floor areas where the tile was missing and coat the surface of the remaining tiled areas (60-120 mil DFT), Trowels and “no nap" rollers were used to obtain a flat finish In the acid areas, a single 30 mil coat of HPL-4320 was applied over the Chemerete Flooring including the inside and outside of the sulfuric acid tank. The caustic arca was lined with 30 mils of HPL-2201. The areas away from the acid and caustic tanks did not require any additional protective linings as the Chemerete Flooring has sufficient chemical resistance to resist any occasional chemical contact. RESULTS: The project was completed on schedule, and all corrosion and water damage was repaited, and the acid and water leaking was stopped. CURRENT STATUS: The repair is still in excellent condition. Based on this performance, all the damaged demineralizer floors throughout the Utility system have been repaired using these DUROMAR products COMMENTS: DUROMAR products were selected for this application because of their overall chemical resistance, eases of application, and the safety offered to both the applicators and plant personne! due tothe solvent and carcinogen free formulations used by DUROMAR. These products were selected due to the extensive damage existing at that time. For areas Jess damaged but needing complete corrosion protection, DUROMAR HPL 1301 and HPL 3320 could be used. "705 Washingion Street Pembroke, MA 02350 USA - Tal (81) 625.2525 - Fax (761) B2EZI60 ‘ww. duromar comDUFOMaR’ (Case History-O11187 Coal Exhauster Wear Plate Repair PROBLEM: A southeastern utility was experiencing excessive material loss on the wear plates around the outlets of the coal crusher exhausted fans. Since these plates were made of special hardened alloys, welding repair was expensive and time consuming, Aitempts at rebuilding with a troweled on epoxy mastic over thick metal support sereens, only gave a short time protection. Also, the work involved in welding the Support screens and then troweling the ‘material to a depth of up to I inch was still time consuming and expensive. SOLUTH ‘The wear plate resembled an 8! diameter washer with a 3.5' inner hole. The heaviest wear was in the 10-12 o'clock position. DUROMAR HAR, 100% solids, high abrasion resistant product was used to reprofile and line the effected arca. The final average film thickness was 50 mils DFT. No support screen or welding was required. RESULTS: Afier 14 months of operation, the wear plate ‘was examined. Only about 1/3 10 1/2 of the DUROMAR HAR remained but the wear plate itself did not show any additional metal loss. The surface was washed with MEK to remove loose duct and oils. Additional DUROMAR HAR was added to give a thickness in the heavy wear areas of about 90 mils DFT and 60 mils elsewhere to ‘ensure year to year protection with no wear plate material loss. CURRENT STATUS: During each subsequest outage the wear plates were inspected and additional HAR was added as needed. The origional wear plate is still in service and only small amounts of HAR are used for each outage. Since HAR is easily mixed and applied and cures quickly, repairs can be easily done, even during a short emergency outage, if necessary. COMMENTS: ‘The epoxy matrix makes HAR an excellent choice for many high abrasion applications. DUROMAR HAR uses silicon carbide as its abrasion resistant filler. This, coupled its high temperature resistance, over 400°F, and wide pH range, makes it an outstanding selection in areas requiring both chemical and abrasion resistance. 706 Washington Siroet, Pembroke, MA 02850 USA > Tal (781) 826-2505 « Fax (TBI) B26 2760 ‘vw. duromar.comDUromMaB’ Case History 011188, Coal Mill Classifier Repair PROBLEM: The Coal Mill Classifier Cone directs the pulverized coal out of the mill and into the Siurnace. Hot air, from the air side of the air preheater, is pulied through the coal mill by the exhaust fan (refer CH-801) picking up the fine coal dust and feeding it to the furnace. The classifier cone is generally lined with thick Alumina wear plates to Protect the cone from the abrasive coal particles. With time, these plates wear down and must be replaced. Replacement is done both in the field and at the manufacuterer. The replacement wear plates are metal backed with a hole in the center to allow welding 10 the metal classifier cone, The problem is to protect the weld holes after installation, and to a lesser extent, the edges where each plate meets the next one. SOLUTION: After trying a number of products to fill in the weld hole and edge openings, DUROMAR HAR was used and found to have both the abrasion resistance and ease of application required for field or factory installation, DUROMAR HAR is a 100% solids, two- part epoxy system heavily filled with Silicon Carbide to impart both excellent abrasion resistance and temperature tolerance. The DUROMAR HAR is mixed as needed and troweled into place and allowed to cure forming a tightly bonded, abrasion resistant plug. RESULT: DUROMAR HAR was applied to the weld areas and around the plate edges. Inspections confirmed that the HAR was wearing at about the same rate as the Alumina plates. No failures had occurred uc to adhesion problems, and no plates had failed due to the weld areas being attacked. CURRENT STATU On the yearly inspections, it was found that the DUROMAR HAR continued to wearing similar to the Alumina plates, No plate failures had occurred due to adhesion problems or weld failure. Many additional crushers have been rebuild using this procedure, COMMENTS: DUROMAR HAR is now used as a part of the standard repair system when relining CE. Raymond Mills and for many other types of Classifier Cones. In many instances, when excessive wear has been found on the Alumina Plates themselves, field repairs have been made by troweling the DUROMAR HAR over the effected areas. 708 Washington Sireei, Pembroke, MA 02559 USA + Tal (761) 826-2825 Fax (761) A262750 wor duromar comDUrOMaR’ ase History 011159 Bottom Ash Elbow Repair A Western Utility experienced leaking in their bottom ash transfer line. This allowed flue gas to be released into the air, and there was concern of an immediate pipe failure requiring an emergency shudowm. Since this was the weekend, there was no chance of getting an immediate replacement, This is a common problem as transfer lines carrying pulverized coal, fly ash, or bottom ash are subject to serious abrasion effects especially in the elbows and transition points. The enhanced abrasion occurs as the particulate stream is forced to change direction, impacting much of the particulate on the turning radius. Of the three materials, bottom ash is the most severe. Bottom ash, in addition to being extremely hard and crystalline has a wide range of particulate ‘sizes. For example, “Black Beauty", a commonly used Grit-Blast ‘Media, is made from screened bottom ash. SOLUTION: DUROMAR HAR, a two part, 100% solids, silicon carbide filled epoxy product was used to repair the elbow as it could be done ina relatively short time period To repair the damaged Cast Iron Pipe, the worn part was grit blasted to remove all surface contamination and oils. The part was steamed at 180°F for 4 hours and allowed to cool. The surface was reblasted and the steaming repeated. A final grit blasting is done to remove any released contamination and to give the surface a 3-5 mil profile. Any wor areas were rebuilt with HAR, and the entire surface coated with an additional HAR at 80-120 mils DFT. For the large surface, a 5/32" notched trowel was used to apply a first, grooved coat. This was allowed to become Tack Free, about 2 hours, and a final build coat is applied with a smooth, rubber trowel. The HAR was heated to Force Cure the repair @ 180°F for 34 hours, cooled, and retuned to service RESULTS: ‘The cast iron elbow was repaired during an eight (8) hour work shift. It was returned to service, and the plant resumed operation. The repair performed so well that the replacement piece was not installed until the plant was shut down during it’s next scheduled outage, over a year later. URRENT STATUS: HAR is now used as the repair of choice when dealing with wom bottom ash piping. In many cases, itis applied to new pipes and elbows to make repairs faster and simpler as they wear. COMMENTS: DUROMAR HAR has been formulated for use in hot, highly abrasive environments, Heavily filled withthe highly abrasion resistant silicon carbide, HAR may be built up to over an inch without effecting performance. 706 Washington Stooi, Pambreke, MA 02350 USA Tel (781) B26-2505 Fax (781) 626-2160 \wn.curomar.comDUromMaR’ (Case Hsin 011110 Westinghouse Turbine Flange Repair PROBLEM: RESULTS: During Westinghouse Turbine overhauls, all manway doors and flange are removed for access. When reassembling the wnits, these flanges and manway doors must be sealed to prevent iydrogen gas leakage during operation. Their existing sealer, a gasket varnish, Westinghouse Part Number SIN 32101, is no longer being mamdactured and a replacement Product has not proven satisfactory. SOLUTION: Any substitute product had to have the ability to remain soft or flexible during assembly and, yet when cured, prevent Hydrogen Gas leakage at pressures up to 75 psi. We recommended DUROMAR EEU- Fluid which has a slow curing time but greater than 50% elongation after curing. Added, but significant benefits, are that the 100% solids, "0" VOC elastomeric epoxy urethane is not flammable, has no odor, and is easily mixed for use EEU-Fluid was applied to the flange and door faces at about 120 mil DFT. The unit ‘was assembled and inspected. No evidence of joint cracking or other problems were found. A Hydrogen Gas was performed at pressures up to 90 psi with no leakage or other problems. The system was put into service, and no problems were encountered from the normal vibration of the power plant JRRENT STATUS: ‘The EEU-Fluid has not shown any leakage with time, Based on these results, the Utility now stocks EEU-Fluid for all their Westinghouse Turbine overhauls. It’s use has been extended to other plants requiring the same system. COMMENTS: We are now evaluating the use of EEU- Fluid in other flange areas as a substitute for, or in addition to, the existing gasket materials. It also may be used as a quick fix ofa failing gasket when the time required to take out and replace the gasket might be critical. 706 Washington Siroat, Pombroxe, MA O2359 USA - Tel (78%) A2E-2525 Fax (781) B2E-2160 ‘ww duromar comDUFOMaB’ ave History 0111S Phosphate Railcar Lining > PROBLEM: Carbon Steel Railears are used to transport wel, coarse Phosphate Rock from the mine separation plant to the Chemical Plant for processing into Phosphoric Acid. The existing railcars were lined with a 40 mil Urethane coating which was failing after a few years of service. The failure was from a combination of abrasion and the acids leaching from the course, wet Phosphate Rock. SOLUT! DUROMAR was asked to supply a product which would resist both the abrasion and acidic conditions of this service. At the time, 1994, we were in the final test stage of our new, flexibilized epoxy lining product, HPL 2221. This product had demonstrated all the required performance characteristics required for this project. It has a pH tolerance of 1.5 to 14, excellent temperature resistance, and most importantly, a Tabor Abrasion Wear Index (ASTM 4060) of 12 milligrams/1000 cycles using a CS-17 wheel. This outperforms all other epoxy, vinyl ester, and urethane lining systems. ‘The HPL-2221 was sprayed on in one coat as follo a) Side Walls - 20 mils (450 microns) b) Sloping Walls and Braces - 40 mils (900 microns) The lining was allowed to cure for 5 days @ 70° F (21°C) before returning the railears to service. RESULTS: This project was started in December 1994, A total of 120 cars have been lined, averaging about two per month. Each year, a selection of the cars previously lined were inspected for coating thickness, appearance, and evidence of sticking product. 'URRENT STATUS To date, NO CARS HAVE FAILED INSPECTION. Lining thickness has remained constant, no pinholes ot other failures have been noted, and the cars remain easy to empty with no. significant “hang-up” reported. COMMENTS: Since the introduction of the HPL 2221, it has found numerous applications both relating to it’s unique abrasion resistance and it's resistance to concentrated Hydrochloric Acid. HPL 2221 has been used as floor and secondary containment coatings, tank lining, and most recently, a UV resistant version is being applied on a large water slide at a major theme park in Florida, sa 706 Washington Siraet, Pembroke, MA 2350 USA » Tal (781) 826-2525 Fax (781) B2BZI50 ww duromar com