Primary Gas Coolers Corrosion Protection

/0 Comments/in /by


Primary Gas Coolers (PGC) are experiencing severe degree of corrosion as these are getting exposed to ammonia vapors, hot humid steam and other chemicals of the process plant. High condensation rates at this torrid zone has been accelerating the rate of corrosion much faster.

These PGC’s stand tall about 30 meters above ground level. In order to access all the parts of this equipment surface, ProCoat team has carried out the surface preparation and application works with the help of hanging platform administered by safe working methods. Initially the surface was detergent cleaned and water washed thoroughly to eliminate the adsorbed chemicals from the surface, making the surface free from external contaminations.

Over the dry contamination free surface, copper slag abrasive blast cleaning method was implemented to attain the surface roughness essential for coating application making sure the surface profile is to an average of 75+ microns with Sa 2.5 surface finish.


Portion by portion of this gigantic structure was coated using ProCoat chemical and abrasion resistant coating system, to the desired thickness levels as per the requirements.


Inherent quality checks all along the surface neutralization, surface preparation & execution of coating application works have been incorporated to establish the sustainable performance of coating for longer durations of time.

Preheater Structural Saline & Chemical Corrosion Protection

/0 Comments/in /by

These mid steel structures of the Preheater in a cement industry are experiencing severe degree of corrosion due to the chemical exposure conditions of the cement plant and also getting accelerated with the saline working environmental conditions. Though these structures have been regularly painted with conventional paints, yet the rate of corrosion phenomena is thick and faster. The adjacent images reveal the condition of mild steel surface adversely affected in the corrosion bound operating zone.

Looking at the past experience & proven performance of ProCoat coating systems, this cement unit has decided to get these structures also to be protected against the corrosion formation. Uncompromising to the quality application standards, team ProCoat has carried out contamination removal using water washing & surface preparation by means of copper slag blasting to Sa 2.5 surface profile, cross-checking the surface to ensure contamination free from any kind of salt precipitates.



Upon attaining the desired surface roughness , application of ProCoat coating system was carried out to the desired thickness levels as per the requirement. The thickness being deposited on the surface was examined using Elcometer WFT Gauge. Once the coating was cured the dry film thickness was measured using the Elcometer DFT Gauge.

Holiday Spark Testing was carried out on the entire surface of the applied coating system to make sure a flawlessness coating application & also to ensure complete coating integrity. Over and top of the ProCoat coating a blue colour weather resistant colour coding system was applied as per the customers need.

A tailor made scaffolding system was arranged to access all parts of these structural equipments which are mounted up to a height of 50 meters above ground level in a phased manner.


Pipeline Internal Chemical Corrosion Protection

/0 Comments/in /by

Corrosive sludge from gas scrubbers which contains chemical traces, abrasive particles along with temperature is causing severe degree of chemical corrosion to these gas ducts having an 8mm shell thickness leading to punctures within a span of 2-3 years resulting to forced shutdowns of equipment for replacement of ducts. Internal surface is undergoing abrasion, localized corrosion and uniform reduction of metal has been taking place as they are continuously under duty operations.

Looking at the past experience & proven performance of ProCoat coating systems, this steel manufacturing industry has decided to get these pipeline internals to be protected against devastating corrosion-abrasion-erosion. During the overhauling period these pipelines were demounted and made available in multiple pieces. Team ProCoat has carried out the surface preparation by means of copper slag blasting & hydro-jetting cleaning. Later the surface was blast cleaned again using chilled iron grit to Sa 2.5 surface profile using Elcometer Profile Gauge &, cross-checking the surface to ensure contamination free from any kind of salt precipitates.



Upon attaining the desired surface roughness, application of ProCoat coating system was carried out to the desired thickness levels as per the requirement. The thickness being deposited on the surface was examined using Elcometer WFT Gauge. Once the coating was cured the dry film thickness was measured using the Elcometer DFT Gauge.

Holiday Spark Testing was carried out on the entire surface of the applied coating system to make sure a flawlessness coating application & also to ensure complete coating integrity.

Pipelines of various lengths were coated following the above stringent procedure. On completion of the coating works these pipeline pieces were erected at their respective sites and welded together. On a stretch about 2 kilometre length of pipelines have been coated using ProCoat coating systems to offer durable protection to the metal surface falling prey to corrosion and punctures.



Chemical Corrosion Protection Of Pipeline Internal

Exposure Conditions: Hot Sulphur chemical solution along with abrasive particles causing erosion, corrosion and punctures


Seawater Induced Corrosion / Abrasion Protection Of Pipelines

Exposure Conditions: Seawater (Cooling Water) with suspended silt


Corrosion / Abrasion Protection Of Raw Water Handling Pipelines

Exposure Conditions: Raw Water with suspended silt


Abrasion / Corrosion Protection Of Pipe-bends

Exposure Conditions : Abrasive Slurry, Gaseous Slurry, Seawater / Raw Water

Pipeline Header Chemical Corrosion Protection

/0 Comments/in /by


External surface of these header pipelines are experiencing severe degree of corrosion as these are coming in contact with fumes of chemicals emanated from the nearby process vessels and presence of moisture in the atmosphere. On an account of the prevailing corrosion, heavy loss of metal is observed over the pipeline surface leading to pitting corrosion.

Chipping with hammer over the areas where heavy loss of metal flaking has taken place was carried out initially to remove lose rust deposits. Later, copper slag blasting was done on the entire header pipeline surface to remove further rust layer, followed up with water jet cleaning in order to neutralize the surface from adsorbed contaminants. Once the surface was dried up, second round of copper slag blasting was carried out to achieve the desired surface roughness essential for the application of coating.


Coating was applied all over the prepared surface using nylon rollers and brushes to the recommended thickness. Deposition of essential thickness was cross- checked using the Elcometer WFT Gauge.

Once the coating was cured, Dry Film Thickness was measured to make sure the applied coating is developed to the same that corresponds to Wet Film Coating Thickness.

These pipelines are mounted at various locations erected at different heights which ran through several lengths all across the plant. So in order to access entire surface of these pipelines, various scaffolding systems and safe accessing methods were incorporated to ensure quality application system. As per the requirements of the client, at few selected places over and top of the ProCoat Corrosion Resistant Coating System a colour coding top coat was applied that meets the industrial norms.

Gas Compressor Silencer Tank Chemical Corrosion Protection

/0 Comments/in /by


The internal surface of these silencers have been experiencing corrosion and abrasion due to gushing high pressure gases along with abrasive dust particles. At lot of places over the surface large number of pits have been observed alongside loss of metal in the form of metal flakes.

After disengaging the silencer from it’s operational position, the surface inside the silencer was examined thoroughly and surface preparation works were implemented. Initially the surface was scrubbed using cleaning agents & water washed to eliminate the presence of chemical containments. Once the surface has dried, a first round of copper slag blast cleaning was carried out followed up with detergent scrubbing & water washing again. The entire surface was blast cleaned again using chilled iron grit to attain the desired surface roughness, ensuring a surface profile of Sa 3 Swedish Standards.



Coating was applied all over the prepared surface using nylon rollers and brushes to the recommended thickness. Deposition of essential thickness was cross-checked using the Elcometer WFT Gauge. Once the coating was cured, Dry Film Thickness was measured to make sure the applied coating had been developed which corresponds to the Wet Film Coating Thickness. Holiday Spark Testing was performed to ensure complete coating integrity.

Adhering to all the quality standard methods the application of coating inside the silencer tank was completed. On completion of the application task inside the tank internal, similarly external surface of the silencer tank was also coated in the same way, to protect it from the external chemical exposure and moist working conditions.

Decomposition Boiler Chemical Corrosion Protection

/0 Comments/in /by

The external surface of this decomposition boiler being exposed to chemical fumes comprising of sulphur, ammonia along with moisture and high temperatures has lead to corrosion over this aluminized equipment. Owing to these working conditions the metal surface has tremendously corroded, although it has been covered up with the aluminized paint system. Underneath corrosion with heavy metal loss is observed over the surface.

Preliminary arrangement to access the complete surface of this huge equipment was made by erecting a tailor-made scaffolding system with safety requirements. First round of blast cleaning was carried out to remove the loose rust flakes and old paint from the surface. Surface was scrubbed thoroughly to foaming using cleaning agents and water washed using a high pressure water jet cleaning. This was performed to neutralize the surface and make it free from the entrapped electrolytic chemical molecules.

In order not to expose the prepared surface to the continuously liberated chemical fumes of this process plant, the boiler was wrapped up all over by using a tarpaulin to minimize the effect of chemical impregnation. The neutralized surface was thoroughly blast cleaned again using copper slag abrasive medium to SA3 surface profile to an average surface roughness of 100+ microns to near white metal finish ensuring the surface is also free from adsorbed contaminants.

Over the prepared surface, ProCoat coating was applied using synthetic rollers and tynex brushes to the recommended thickness levels not exposing the surface for longer times to the expelled chemicals and prevailing humid environmental conditions. Intermittent checks were made using Elcometer WFT gauge to ensure the desired thickness of coating as per the requirements.

On completion of coating works the cured coating surface was checked for Dry Film Thickness using the Elcometer DFT Gauge & examined with Holiday Spark Tester to ensure tough coating integrity. This decomposition boiler is being protected convincingly from the adverse corrosion affect caused due to the electrolytic chemicals since year 2013.

Concrete Soft Water Tank Corrosion Protection

/0 Comments/in /by

The water being stored in this concrete chamber is likely to be soft water which is utilized for various other plant operations. There is an ion-exchange process taking place between the water and the concrete surface of this storage tank, which is leading to change in ppm levels of the water. In order to maintain the desired ppm levels of water, isolation of the medium from concrete surface electrically and physically is necessary.

Looking at the past experience & proven performance of ProCoat coating systems, this steel manufacturing industry has decided to get essential protection to the concrete surfaces using ProCoat Coating System. During the overhauling the tank was emptied to get it coated. Team ProCoat has carried out the surface preparation by means of copper slag blasting & hydro- jetting cleaning. The surface was thoroughly scrubbed to foaming, water washed &, cross-checked to ensure contamination freeness from any kind of salt precipitates.
A plastic-sheet test method was performed to make sure the surface prepared is free from moisture prior to application of protective coating.



Upon attaining the desired surface roughness, application of ProCoat coating system was carried out to the desired thickness levels as per the requirement. The thickness being deposited on the surface was examined using Elcometer WFT Gauge.


Few of the critical applications carried out on concrete equipments, floors and structures which have been under the protection of ProCoat Coatings offering protection to spills, immersion, shock-resistant, acidic spillage conditions, etc..


Coke Dry Quenching Structure Corrosion Protection

/0 Comments/in /by


Coke at around 1050 °C is transported to the top side of this plant to cool it down using gases unlike the previous traditional water quenching process. Nevertheless, though this system is very effective and serves the purpose of an economizer in an industry yet the process has subtle affect on the mild steel structures of this Coke Dry Quenching (CDQ Plant) which are experiencing aggressive corrosion due to the working atmospheric conditions prevailing in this area. Being a hot working zone along side various gaseous exposure conditions has a an immense effect on the metallic structures which is leading to high corrosion.

In order to access all the structures of this CDQ Plant which stands tall to a height of 40 meters above ground level, a tailor made scaffolding system was erected abiding all the safety norms. In order to reduce the effect of heat transmission to some extent from the bucket carrying hot coke to it’s surrounding zone, a sheet metal wall was placed to cover the bucket, which also prevented the direct flame to the working men & also prevent the abrasive blast cleaning particles from getting deposited in the coke carrying bucket.


Keeping in view the safety factors, the structures have been blast cleaned using copper slag abrasive medium to remove the corrosion deposits from the surface.


After the first round of blast cleaning process, all the structures were thoroughly water washed and scrubbed to foaming using necessary cleaning agents. Once the surface got dried up, the copper slag blast cleaning process was repeated in order to prepare the surface to Sa 2.5 standards prior to coating application. Blasting was done to make sure the surface had a sheen of near white metal finish resembling the surface of the shade card.


Application of coating was carried out directly over the prepared surface using nylon rollers with an initial high hand pressure wetting coats, followed up with subsequent low hand pressure thickness deposition coats that met the desired recommended thickness levels.


During application process the coating thickness was measured using Elcometer WFT Gauge to ensure the required Wet Film Thickness. Once the coating was cured, Dry Film Thickness was measured using Elcometer DFT Gauge & Spark Testing was carried out to ensure flawlessness coating application and complete coating integrity. The structures being located at various elevations, the surface preparation and coating application process was carried out in a phased manner emphasizing on quality application methods and more importantly implementing safe working practices.


On completing the application of Corrosion & Temperature Resistant Coating system a Polyurethane weather resistant top coat was applied over and above ProCoat Coating that also served the colour coding purpose.

Chimney Internal Protection Coating

/0 Comments/in /by


This Chimney was to be replaced in view of reduction in metal thickness due to continuous reaction with acidic hot and wet steam alongside suspended abrasive particles released during the quenching of red hot iron slag.


Abrasive blast cleaning using copper slag as a medium was carried out to remove the rust scales and corrosion deposits. Repeating the blast cleaning for another time, on this occasion using chilled iron grit as the abrasive media to achieve the desired surface roughness over the surface. To access the entire internal surface, a tailor- made scaffolding system was arranged for ease of carrying out application works.


On preparing the surface using the entire surface was blown up with compressed air to make sure the surface is free from dust settlements. Application of coating was carried out using nylon rollers, intermittently checking up the wet film thickness of the coating using Elcometer WFT Gauge.


Dry film thickness was measured using the DFT Gauge followed up with Holiday Spark Testing to verify complete coating integrity.

Chemical Corrosion Protection Of Cooling Water Pipelines

/0 Comments/in /by

These cooling water pipelines running through harsh corrosive exposure conditions such as steam, water spills and chemical fumes in caster area is undergoing extreme chemical corrosion leading to severe metal loss. Repeated conventional painting methods have not been able to yield satisfactory results of protection.


After first round of copper slag blast cleaning to Sa2 standard, all vertical and horizontal channels are scrubbed with detergent to remove the chemical contamination and further rinsed with fresh water jet to ensure contamination freeness of structures surface. After surface got dry, aging second round of copper slag blasting was carried out to achieve Sa2.5 i.e., near white metal finish with an average surface profile of 85 microns.


Over this prepared surface, ProCoat chemical and corrosion resistant coating system was applied with heavy hand pressure to attain exceptional mechanical interlocking, polar-polar adhesion and chemical bonding of ProCoat system and followed with low pressure hand application with synthetic roller to build the recommended thickness on pipeline surface.


Carried out quality checks like wet film thickness during application, dry film thickness after curing, coating integrity check with Elcometers and ensured flawlessness.