Petrochemical, Oil & Gas Industries

Belzona repair solutions cater to the complex and demanding production techniques of the Oil & Gas Industry where high temperatures, pressures, aggressive chemicals, and erosion / corrosion place major demands on processing equipment throughout the plant. Specifically formulated Belzona protective coatings and repair compounds can protect and repair equipment, reduce downtime, and minimize replacement costs.

Applications include:

  • Protective coatings for High Pressure Vessels and Storage Tanks.
  • Specialized Pipe work
  • Rebuilding and protecting Absorption Towers, Heat Exchangers, Filters, and Pumps subject to erosion / corrosion
  • Specialized High temperature Coatings
  • Many more.

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  • CUSTOMER: Refinery, UK
  • APPLICATION DATE: November 2005
  • APPLICATION SITUATION: Severe Corrosion Under Insulation (CUI) on columns
  • PROBLEM: Water ingress into the lagging caused corrosion which was accelerated by the elevated temperatures of the column which operated up to 185 ⁰C.
  • PRODUCTS:
    Belzona 5851 (HA-Barrier)
  • SUBSTRATE: Carbon steel
  • APPLICATION METHOD: Application was carried out in accordance with Belzona Know-How System Leaflet TCC-5. The Belzona 5851 was hand applied as a two coat system to grit blasted 8m sections of the column that were then re lagged before moving on to the next section. vessel remained in service throughout the application.
  • BELZONA FACTS: Having tried numerous other products and rejecting them either for application or Health & Safety issues, Belzona was selected as the only product capable of being safely and easily applied online. An inspection in November 2007 showed no visible signs of degradation.

  • CUSTOMER: Gas plant - Alberta, Canada
  • APPLICATION DATE: May 1990
  • APPLICATION SITUATION: Amine reboiler heat exchanger
  • PROBLEM: Severe pitting at froth line top and side walls.
  • PRODUCTS:
    Belzona 1311 (Ceramic R-Metal)
    Belzona 1311 (Ceramic S-Metal)
  • SUBSTRATE: Carbon steel
  • APPLICATION METHOD: The application was carried out in accordance with Belzona Know-How System Leaflet HEX-3.
  • BELZONA FACTS: The Belzona System was more cost effective than the alternative of a metalizing spray weld repair. The repair has held up and the heat exchanger is still in operation, 11 years later.

  • CUSTOMER: North Sea Platform, UK
  • APPLICATION DATE: Nov 1997
  • APPLICATION SITUATION: In situ re-coat of the 1st stage separator in a time restricted shut down. Inspection in August 2006.
  • PROBLEM: Previous glass flake system had failed and had suffered corrosion damage to the vessel wall. Belzona inspected after 9 years and only problems caused by local areas of mechanical damage.
  • PRODUCTS:
    Belzona 1111 (Super Metal)
    Belzona 1391 (Ceramic HT)
  • SUBSTRATE: Carbon Steel
  • APPLICATION METHOD: Application was carried out in accordance with Belzona Know-How System Leaflet TCC-3.
  • BELZONA FACTS: After 9 years in service, the vessel was returned to service with only the need for localized repairs.

  • CUSTOMER: Oil Production Platform in Saudi Arabia
  • APPLICATION DATE: April, 1995
  • APPLICATION SITUATION: Water-proofing of control rooms for offshore oil-gas separation plants
  • PROBLEM: The control rooms require complete encapsulation (roof and sides) to prevent water penetration. The structures are subject to constant salt water spray and wave splash.
  • PRODUCTS:
    Belzona 3111 (Flexible Membrane System)
    Belzona 1111 (Super Metal)
  • SUBSTRATE: Steel
  • APPLICATION METHOD: The application was carried out in accordance with Belzona Know-How System Leaflets RPA-1 and Tcc-1.
  • BELZONA FACTS: The customer could have replaced the defective sheets with new ones but the use of a Belzona repair method saved considerable time and also afforded protection to the existing structural components.

  • CUSTOMER: Oil & Gas Producer - North Sea. UK
  • APPLICATION DATE: August 2006
  • APPLICATION SITUATION: Internal surfaces of first and second stage separators on an FPSO
  • PROBLEM: Internal surfaces of first and second stage separators on an FPSO
  • PRODUCTS:
    Belzona 1111 (Super-Metal)
    Belzona 1391 (Ceramic HT-Metal)
  • SUBSTRATE: Steel
  • APPLICATION METHOD: The application was carried out in accordance with Belzona Know-How System Leaflets TCC-3 & -5.
  • BELZONA FACTS: Belzona 1391 was chosen because of its proven record in high temperature environment and particularly resistance to explosive decompression.

  • CUSTOMER: Oil separation equipment manufacturer
  • APPLICATION DATE: April 1997
  • APPLICATION SITUATION: Oil/Gas Test Separator designed to operate up to 150 ⁰C.
  • PROBLEM: Severe erosion/corrosion to internal surfaces.
  • PRODUCTS:
    Belzona 1591 (Ceramic XHT Metal)
  • SUBSTRATE: Steel
  • APPLICATION METHOD: Application was carried out in accordance with Belzona Know-How System Leaflet TCC-3.
  • BELZONA FACTS: Regular refurbishment was necessary as previous coatings had failed due to high temperatures and explosive decompression. Belzona 1591 specified to enable longer service life in extreme well conditions.

  • CUSTOMER: Production Rig North Sea
  • APPLICATION DATE: May 2007
  • APPLICATION SITUATION: Weathering of the original paint system on high temperature Duplex lines.
  • PROBLEM: The loss of the original paint system exposed the pipe work to a risk of stress corrosion cracking whenever the fire protection Deluge system were tested.
  • PRODUCTS:
    Belzona 5851 (HA Barrier)
  • SUBSTRATE: Duplex
  • APPLICATION METHOD: Application carried out in accordance with modified Belzona Know-How System Leaflet VPF-2. The pipework was wet-blasted to remove poorly adhering paintwork and any salts from the substrate.
  • BELZONA FACTS: Allowing the application to be carried out whilst the platform was live meant that the platform did not have to shut down. Cost of shutdownin lost production is measured in millions of dollars a day. Testimonial received from RBG highlighting the benefits of the System.

  • CUSTOMER: Offshore Oil Company - UK
  • APPLICATION DATE: October 2003
  • APPLICATION SITUATION: This FPSO now had increased levels of water from the well which required modifications to the internal furniture of the process vessels, and the installation of additional separation equipment.
  • PROBLEM: To avoid the nedd for welding to the vessel shell, and additional post weld heat treatment, the internal equipment was installed using a mixture of mechanical and adhesive methods. In addition, the vessel shell had been coated from new with Belzona 1391 and this was required to be removed in key areas prior to installation of the new equipment.
  • PRODUCTS:
    Belzona 1111 (Super Metal)
    Belzona 1391 (Ceramic HT Metal)
  • SUBSTRATE: Coated steel.
  • APPLICATION METHOD: The original coating was removed in localised areas by blasting. The surrounding coating was cleaned and flash blasted. Once completed, mounting clips were bonded into position using Belzona 1111. The clips were then coated using Belzona 1391 which was overlapped onto the surrounding prepared coating in accordance with Belzona Know-How System Leaflet TCC-5.
  • BELZONA FACTS: This application was extensively designed to minimise undue to stresses on the Belzona adhesive material, and facilitated a rapid turnaround for the vessel refurbishment. The use of adhesive materials in this particular application reduced the need for welding and costly post-weld heat treament as well as eliminating the need for 'hot work' on this operational facility.

  • CUSTOMER: FPSO North Sea, UK
  • APPLICATION DATE: August 2002
  • APPLICATION SITUATION: Oil Transfer Hose on FPSO in the North Sea Oil & Gas Industry
  • PROBLEM: failed its pressure test prior to being built into a replacement string.
  • PRODUCTS:
    Belzona 1321 (Ceramic S Metal)
  • SUBSTRATE: Belzona 1321 (Ceramic S Metal)
  • APPLICATION METHOD: Application carried out in accordance with Belzona Know-How System Leaflet VPF-13.
  • BELZONA FACTS: Hose would have been scrapped at a cost of £25,000,000, the string change out would have been delayed leading to a reduction in the unloading frequency from the FPSO. Belzona repair in excellent condiion after 5 years in service.

  • CUSTOMER: Offshore Oil Company - UK North Sea
  • APPLICATION DATE: Offshore Oil Company - UK North Sea
  • APPLICATION SITUATION: Flange faces on 16", 300lb crude oil transfer hoses
  • PROBLEM: External corrosion on the flange faces had resulted in the hoses not being able to seal correctly and as a result were considered no longer fit for purpose.
  • PRODUCTS:
    Belzona 1321 (Ceramic S-Metal)
    BElzona 9411 (Release Agent)
  • SUBSTRATE: Galvanished steel.
  • APPLICATION METHOD: A procedure based around Belzona Know-How System Leaflet VPF-9 was used to reform the flange faces.
  • BELZONA FACTS: The four hoses shown in the picture represent a cost to the customer if replaced of approximately £100,000 ($160,000). All four hoses were effectively covered and tested to 18 bar according to International (OCIMF 1991) and Dunlop Oil & Marine Test Guidelines. This was done for a fraction of the cost of replacement hoses.

  • CUSTOMER: Engineering Consultants - UK Oil & Gas Industry
  • APPLICATION DATE: March 2002
  • APPLICATION SITUATION: Isolation spools for titanium cooler
  • PROBLEM: Installation of a titanium cooler offshore, into a steel pipework system, increased the possibility of galvanic corrosion between the two dissimilar metals. The traditional approach involves the installation of rubber lined isolation spools adjacent to the cooler. However, in this instance the elevated operation temperature increased the likelihood that the rubber would disbond, a commonly found problem, so an alternative was sought.
  • PRODUCTS:
    Belzona 1391 (Ceramic HT Metal)
    Belzona 1591 (Ceramic XHT Metal)
  • SUBSTRATE: Steel and stainless steel.
  • APPLICATION METHOD: Belzona 1391 and Belzona 1591 were applied to the internal surface of each of the spools in accordance with Belzona Know-How System Leaflet VPF-2. To eliminate the possibility of defects, which would allow very rapid corrosion, the coating materials were applied as two coat systems. Immediately following application of the second coat, the flange faces were reformed according to Belzona Know-How Sytem Leaflet VPF-13.s
  • BELZONA FACTS: A total of four flange pipespools were coated and the flange faces reformed using this process. Subsequent inspection some 12 months later revealed the pipespools to be in perfect condition.

  • CUSTOMER: Oil Refinery, U.K.
  • APPLICATION DATE: 1996
  • APPLICATION SITUATION: The light ends tower within the Catalytic Cracker
  • PROBLEM: Extensive erosion-corrosion on the shell wall caused by the hot Hydrocarbon mixture
  • PRODUCTS:
    Belzona 1311 (Ceramic R-Metal)
    Belzona 1391 (Ceramic HT-Metal)
  • SUBSTRATE: Carbon steel
  • APPLICATION METHOD: Application was carried out in accordance with belzona Know-How System Leaflet TCC-5
  • BELZONA FACTS: Metal loss if allowed to continue would have led to the structural integrity of the structure being compromised. Repair or replacement would have led to a major shutdown of the Refinery with its major associated loss of revenues. The Belzona products lent themselves to application within the confines of the tower and allowed its return to service with minimal down-time.

  • CUSTOMER: International Oil Company
  • APPLICATION DATE: 1996
  • APPLICATION SITUATION: Building of a totally new oil refinery was being completed. Chemicals being handled include 98% sulphuric acid and 36% hydrochloric acid.
  • PROBLEM: A reliable, high performance protection system was required for the many different process areas in the plant.
  • PRODUCTS:
    Belzona 4311 (Magma CR1)
    Belzona 4111 (Magma-Quartz)
    Belzona 4151 (Magma-Quartz Resin)
  • SUBSTRATE: plus Steel supports
  • APPLICATION METHOD: Application was carried out in accordance with Belzona Know-How System Leaflets TCC-9, TCC-10, TCC-11, TCC-12 and TCC-15.
  • BELZONA FACTS: Belzona 4311 capable of resisting the many different chemicals on the plant and ease of use without the need for specialized equipment allowed application around installed equipment. Belzona Distributor provided essential on-site support at the request of the client dur to the size of the project.

  • CUSTOMER: Oil producer
  • APPLICATION DATE: April 1997
  • APPLICATION SITUATION: Coalescer Vessel for installation on a Floating Oil Production and Storage vessel (an FPSO) destined of the North Sea.
  • PROBLEM: Corrosion was anticipated in the lower 1/3rd of the vessel. Design Temperatures were up to 150 ⁰C with sea water present.
  • PRODUCTS:
    Belzona 1591 (Ceramic XHT Metal)
  • SUBSTRATE: Carbon steel
  • APPLICATION METHOD: Application was carried out in accordance with Belzona Know-How System Leaflet TCC-5.
  • BELZONA FACTS: Belzona was chosen for vessel protection following extensive testing simulating the operating conditions expected. No other coating was available to withstand the operating temperatures and pressures. Metal cladding could not be carried out within the time constraints of this fast track project.

  • CUSTOMER: National Oil Company
  • APPLICATION DATE: May, 1996
  • APPLICATION SITUATION: The Evaporator units in SIDEM Distillation unit are constantly immersed up to 30cm (12 ins) at a temperature of 55-60C. Regular washing is also carried out using 10-15% Sulphamic acid.
  • PROBLEM: Floor plate in No.4 Distillation unit was showing considerable corrosion and weld repairs, including welding in of new plate sections had already been carried out previously.
  • PRODUCTS:
    Belzona 1391 (Ceramic HT Metal)
  • SUBSTRATE: steel 317L
  • APPLICATION METHOD: Application was carried out in accordance with Belzona Know-How System Leaflet TCC-3. Extreme care was taken to ensure all salt contamination was removed and de-humidification equipment installed to prevent moisture contamination during application.
  • BELZONA FACTS: Recent inspection has shown Belzona 1391 in perfect condition and customer can now look forward to many years service from the units without constant shut-downs for weld repairs. The other 5 units will also be coated shortly with Belzona 1391.

  • CUSTOMER: Chevron Pembroke
  • APPLICATION DATE: Ongoing since October 1996
  • APPLICATION SITUATION: Pressurized LNG storage spheres.
  • PROBLEM: Water penetration through insulation causes severe Corrosion under Insulation.
  • PRODUCTS:
    Belzona 3211 (Lagseal)
  • SUBSTRATE: Foam Glass Insulation
  • APPLICATION METHOD: Application carried out in accordance with the Belzona Know-How System Leaflet TCC-4.
  • BELZONA FACTS: There have been several trials with alternative products, however, Belzona 3211 is so far the preffered option. Main reason for this is the first sphere coated with the system has given 11 years service thus far, with no requirement for renewal. So far five spheres coated and further spheres planned to be coated in 2009.

  • CUSTOMER: International Oil Company
  • APPLICATION DATE: October, 1996
  • APPLICATION SITUATION: Pressurized storage spheres for Liquefied Petroleum Gas (LPG)
  • PROBLEM: Water penetration through original insulation system had allowed severe underlagging corrosion to occur. The site is an exposed marine site and deluge system on the shere are regularly tested so that watertightness is imperative.
  • PRODUCTS:
    Belzona 3211 (Lagseal)
  • SUBSTRATE: Foam glass insulation
  • APPLICATION METHOD: The insulation was re-installed using a closed cell foam glass that is impervious to water and Belzona 3211 applied in accordance with belzona Know-How System Leaflet TCC-4.
  • BELZONA FACTS: Trials with two alternative system were not successful. Use of Belzona 3211 in conjunction with a closed cell foam insulation will provide maximum resistance to water penetration. To date three spheres have been protected on the site.

  • CUSTOMER: International Equipment Manufacturer to the Oil Industry
  • APPLICATION DATE: 1994
  • APPLICATION SITUATION: Two standard designs of test separators used around the world and particularly in the Middle and Far East.
  • PROBLEM: Severe deterioration to the internal surfaces of the vessels due to erosion-corrosion and SRB attack.
  • PRODUCTS:
    Belzona 1391
  • SUBSTRATE: Steel
  • APPLICATION METHOD: The application was carried out in accordance with the Belzona Know-How System Leaflet TCC-3
  • BELZONA FACTS: Belzona 1391 is now specified by this company for refurbishment of oil/gas separators and also for new separators. The alternative is replacements at $200,000. Belzona refurbishment saves about $150,000 per separator. Total worldwide refurbishment programme is going to be worth approximately $2 million.

  • CUSTOMER: International Oil Producer
  • APPLICATION DATE: 1992
  • APPLICATION SITUATION: Production Oil/Glass Separator
  • PROBLEM: Previous experience indicated that the lower 1/3rd of this new vessel would be subjected to sand erosion and Sulphate Reducing Bacteria (SRB) attack.
  • PRODUCTS:
    Belzona 1321 (Ceramic S-Metal)
  • SUBSTRATE: Duplex steel
  • APPLICATION METHOD: Application was carried out in accordance with Belzona Know-How System Leaflet TCC-5. A 3 coat system of Belzona 1321 was applied as the operating temperature was 85A °C.
  • BELZONA FACTS: Despite the use of corrosion resistant Duplex, SRB attack and sand erosion induced by the jet wash system in the base of the tank was expected to cause shell damage without protection. Previously used glass flake systems had been unable to resist the sand erosion and required regular refurbishment necessitating hugely expensive interruptions to oil production. Since application the vessel has been routinely inspected and the coating is still in excellent condition and no un-scheduled shut-downs have been incurred.

  • CUSTOMER: Oil producer
  • APPLICATION DATE: April 1997
  • APPLICATION SITUATION: The Oil/Gas Separators (Production and Test) and Flare Knock-Out vessels for installation onboard a Floating Oil Production and Storage vessel (an FPSO) being fast track built for operation in the North Sea.
  • PROBLEM: There was insufficient time available to construct vessels with internal metal cladding.
  • PRODUCTS:
    Belzona 1591 (Ceramic XHT Metal)
  • SUBSTRATE: Carbon steel
  • APPLICATION METHOD: Application was carried out at a Specialist applicators workshop in accordance with Belzona Know-How System Leaflet TCC-5. They were then transported for fitting out and installation on the FPSO.
  • BELZONA FACTS: This project is to develop a small oil field and so costs and particularly timing were critical. Belzona 1591 was seen as the only coating available to protect the equipment at the operating temperatures expected (up to 150A °C).

  • CUSTOMER: Offshore oil drilling platform in the Gulf of Mexico.
  • APPLICATION DATE: July, 1995
  • APPLICATION SITUATION: Mud pumps, casings and wear plates.
  • PROBLEM: Severe erosion.
  • PRODUCTS:
    Belzona 1311 (Ceramic R-Metal)
    Belzona 1321 (Ceramic S-Metal)
  • SUBSTRATE: Cast iron
  • APPLICATION METHOD: The application was carried out in accordance with Belzona Know-How System Leaflets CEP-3 and CEP-5.
  • BELZONA FACTS: The use of Belzona doubled the life of the casing and saved the replacement costs. Originally, the equipment lasted 3 months before being discarded and now it lasts 6 months and can be refurbished again and again.

  • CUSTOMER: Offshore oil production company
  • APPLICATION DATE: June 1997
  • APPLICATION SITUATION: Flange faces of gas cooler
  • PROBLEM: Incorrect joint material caused extensive crevice corrosion on 2 separate coolers
  • PRODUCTS:
    Belzona 1111 (Super Metal)
  • SUBSTRATE: Inconel
  • APPLICATION METHOD: Application was carried out in accordance with Belzona Know-How System leaflets VPF-1 and VPF-13. Only the localised corrosion pitting was rebuilt on these units and dressing back to profile was carried out using hand tools.
  • BELZONA FACTS: Belzona repairs were completed in just six hours avoiding the need to weld and machines to size which would have taken several days. This saved gas production losses estimated at tens of thousands of pounds.

  • CUSTOMER: Major Oil Producer, North Sea, Norway
  • APPLICATION DATE: October 2011
  • APPLICATION SITUATION: A six inch diameter pipe, carrying water and condensate, operating at 30-50 C and 31 Bar pressure.
  • PROBLEM: An area of the pipe system has lost 2/3 of its original wall thickness due to internal corrosion. The affected area was expected to go through-wall within the next 2-3 years. The client needed a compliant repair designed for a minimum of 5 years.
  • PRODUCTS:
    Belzona SuperWrap
  • SUBSTRATE: Carbon Steel
  • APPLICATION METHOD: A Belzona SuperWrap reinforced repair, compliant to ISO/TS24817 and ASME PCC-2 Article 4 was designed and applied by validated applicators.
  • BELZONA FACTS: Large parts of the system were planned to be removed by the end of 2011 due to these defects. Using Belzona SuperWrap, the client was able to significantly extend the lifetime of the system without the need for hot work. The repair was completed within twelve hours and after a 48 hours cure period the system was back in service. The Belzona SuperWrap was designed so that integrity in the system was maintained even after the defect goes through-wall. The Belzona SuperWrap repair is compliant untill 2016.