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Surface Engineering Workshop

Budi Sulistyo Nugroho

April 15, 20162

Henkel at Glance

• Henkel is a global company serve for consumer and industrial business, headquartered in Dusseldorf, Germany

• 2011 revenue 15.61 billion Euro, spent 468 million Euro for R&D

April 15, 20163

Henkel at Glance

• Has 3 business area: home care; personal care; adhesive sealant and surface treatment for industrial

• Henkel Indonesien: Gedung Talavera, Jl. TB Simatupang, Jakarta• Website: www.henkel.com

April 15, 20164

The Industries we serve…• Power Generation

• Petrochemical

• Mining

• Mineral Processing

• Fertilizer

• Pulp & Paper

• Marine & Offshore

• Food & Beverage

• Water Utilities

• Steel Production

• Alumina, Cement

• OEMs

• Oil & Gas Plant

April 15, 2016 Title and author of presentationSlide 5 April 15, 2016Slide 5

Agenda

• Introduction.

• Composite Material to Equipment• MRO Special Products

• Presentation + Discussion time = 120 minutes.

April 15, 20166

Water Pump

April 15, 20167

• Causes Of Failure :

• Corrosion

• Abrasion

• Cavitation

• Scale formation

Water Pump Corrosion and Erosion

April 15, 20168

Product Recommended for Rebuilding:

Loctite Wear Resistant Putty / Loctite Superior Metal

• Ceramic Fibre Reinforced

• Machinable when still in semi cured state

• More wear resistant than metal filled putties


April 15, 20169

• Product Recommended to protect surfaces:

Nordbak Brushable Ceramic

• Smooth, glossy low coefficient of friction

• Corrosion and erosion resistant

• Temp. resistant up to 125* C Dry , 65 * C Wet

Technical Data Sheet


../../../../../sokhiaro/Documents/2010/SEW December 2010/SEW Best Practices/SEW Best Practice/SEW best practices files/TDS/Nordbak brushable ceramic.pdf

Cooling Water Pump PT Pertamina Plaju• Erosion & Corrosion of Outer & Inner

4/15/2016 Surface Engineering Workshop – Loctite Applications in Power Plant

• Causes of Failure• Abrasion and Flow of liquid particles leads to surfaces wearing

out



Solution • Surface preparation

• Cleaning with degreaser/solvent• Blasting SA 2.5-3• Blow with air compressor

• Apply Hold Coat of Loctite Superior Metal & Chemical Resistance Coating at the inner surface

• Rebuild the surface with Loctite Superior Metal & Chemical Resistance Coating to prevent further corrosion and abrasion



Product Recommended

Fixmaster Superior Metal • Two part ferro silicone based epoxy• Machinable • High compressive strength – 124 N/mm2

(18,000 psi)• Cure time 6 hrs.• Ideal for rebuilding shafts, bearing

housing • Pack size – 408 gm



Product Recommended

Chemical Resistant Coating• Polyurethane bisphenol system for

extreme Chemical resistance• Smooth glossy low friction surface• Light grey color• Temp. resistant 160 ℃ ( Dry ) 65 ℃ ( Wet) • Ideal for lining tanks and chutes, lining

chemical containment areas, pump bases



Benefits

Increase the life of the component

Salvaging worn out components thus reducing scrap

Reducing costly spares Reducing downtime

Increasein Profits


Application Case History • Customer / Country

• PT Pertamina Plaju (Oct 2013)/ Indonesia

• Problem / Application• Erosion & Corrosion of Outer & Inner

Cooling Water Pump• Corrosion Protection coating of inner &

Outer surface• Solution

• Loctite Superior Metal & Chemical Resistance Coating

• Benefits• Process cuts • Doubled the life of the asset


April 15, 201617

Chute & Hopper

April 15, 2016 Loctite Product SharingSlide 18


•Abrasion

•Impact

•Erosion

Chute and HopperCorrosion and Abrasion



Loctite Hi Impact Wearing Compound

• Ceramic filled Reinforced

• Outstanding Resistant to Abrasion

• Available for High Temp Wearing Compound

Chute and HopperCorrosion and Abrasion

Application Case History

• Customer / Country• Gold Mining at Nusa Tenggara

• Problem / Application• Abrasion to Hopper of Ball Mill & SAG

Mill• Protective coating of surfaces between

wear plate. • Solution

• Nordbak Wearing Compound

• Benefits• Longer life time of wear plate.


April 15, 201621

Shaft

April 15, 201622


• Friction

• Corrosion

• Over Load

ShaftWorn Out

April 15, 201623


Loctite Loctite Superior Metal

• Ceramic Fibre Reinforced

• Machinable when still in semi cured state

• More wear resistant than metal filled putties

Shaft Worn Out

April 15, 201624

Benefit:

a. No Heat means No Bending

b. Easy application

c. Cost Reduction & Faster Repair

Shaft Worn Out

C:/Users/nugrohob/Documents/Literatur/VIDEO_TS/Superior Metal.wmv

C:/Users/nugrohob/Documents/Literatur/VIDEO_TS/Superior Metal.wmv

April 15, 201625

Inlet & Outlet Condenser



•Abrasion

•Erosion

Inlet – Outlet CondenserCorrosion and Erosion



Loctite Wearing Compound




Inlet – Outlet CondenserCorrosion and Erosion

Inlet Outlet Condenser PT PJB Gersik

• Peel Off Rubber Lining as a Protection of Inlet Outlet Condenser


• Causes of Failure• Sea Water • Not good Adhesive (Rubber)



Solution

• Surface preparation• Blasting SA 2.5-3

• Apply Hold Coat of Nordbak Wearing compound on the surface

• Rebuild the surface with Nordbak Wearing Compound to prevent further corrosion and abrasion



Solution • Surface preparation

• Cleaning with degreaser/solvent• Blasting SA 2.5-3• Blow with air compressor

• Apply Hold Coat of Loctite Nordbak Wearing Compound at Carbon Steel Substrate

• Rebuild the surface with Loctite Nordbak Nordbak Wearing Compound at Carbon Steel Substrate



Benefits




Increasein Profits



• Customer / Country• PT PJB Gersik/ Indonesia

• Problem / Application• Peel Off & Corrosion rubber lining at

Inlet & Out let condenser• Solution

• Loctite Nordbak Wearing Compound• Benefits

• Process cuts • Doubled the life of the asset



Inlet Outlet Condenser PT PLTU Muara Karang (25 Nov 2015)• Inlet & Outlet Condenser


• Causes of Failure• Sea Water • Not good Adhesive (Rubber)


Inlet Outlet Condenser PT PLTU Muara Karang.

• Surface preparation• Cleaning with degreaser/solvent• Blasting SA 2.5-3• Blow with air compressor

• Apply Hold Coat of Loctite Fixmaster Superior Metal, Nordbak Wearing Compound & Loctite Nordbak Brushable Ceramic Grey at Carbon Steel Substrate

• Rebuild the surface with Loctite Fixmaster Superior Metal, Nordbak Wearing Compound & Loctite Nordbak Brushable Ceramic Grey at Carbon Steel Substrate


Inlet Outlet Condenser PT PLTU Muara Karang.

• Surface preparation• Blasting SA 2.5-3• Reinforcement by welding wire mesh

on surface if require• Anchoring the surface

• Apply Hold Coat of Loctite Fixmaster Superior Metal (Welding Join), Nordbak Wearing Compound & Loctite Nordbak Brushable Ceramic Grey the surface

• Rebuild the surface with Loctite Fixmaster Superior Metal, Nordbak Wearing Compound & Loctite Nordbak Brushable Ceramic Grey to prevent further corrosion and abrasion


Inlet Outlet Condenser PT PLTU Muara Karang

Benefits




Increasein Profits



• PT PLTU Muara Karang/ Indonesia• Problem / Application

• Peel Off & Corrosion rubber lining at Inlet & Out let condenser also prevent corrosion inside new pipe

• Solution• Loctite Loctite Fixmaster Superior

Metal, Nordbak Wearing Compound & Loctite Nordbak Brushable Ceramic Grey

• Benefits• Process cuts • Doubled the life of the asset



• Customer / Country• PLTU Labuhan Angin

• Problem / Application• Abrasion to Inlet & Outlet Condenser• Protective coating of surfaces.

• Solution• Nordbak Wearing Compound

• Benefits• Longer life time Elbow


Inlet Outlet Condenser PLTU Labuhan Angin• New Coating Lining at New Pipe Elbow & Pipe Streak


• Surface preparation• Cleaning with degreaser/solvent• Wire Grinding• Cleaning with degreaser/solvent• Blow with air compressor

• Apply Hold Coat of Loctite Fixmaster Superior Metal, Nordbak Wearing Compound & Loctite Nordbak Brushable Ceramic Grey at Carbon Steel Substrate

• Rebuild the surface with Loctite Fixmaster Superior Metal, Nordbak Wearing Compound & Loctite Nordbak Brushable Ceramic Grey at Carbon Steel Substrate


Inlet Outlet Condenser PLTU Labuhan Angin

April 15, 201643

Pulverizer & Classifier



•Abrasion

•Erosion

Pulverizer & ClassifierCorrosion and Erosion



Loctite Wearing Compound




PulverizerErosion and Abrasion


• Customer / Country• Semen Indonesia

• Problem / Application• Abrasion at Classifier Cone & Bar• Protective coating of surfaces.

• Solution• Nordbak Wearing Compound

• Benefits• Longer life time



• Customer / Country• Semen Indonesia


April 15, 201648

Conveyor Belt

April 15, 201649


• Abrasion

• Scratch Point

• Sharp material

Conveyor BeltDamage at Surface

April 15, 201650

Conveyor BeltDamage at Surface

Product Recommended:

Loctite Flex 80 Putty/ Rapid Rubber Repair (R3)

• Rubber – Urethane combination

• Strong Bonding and Flexible

• Emergency Repair – R3

April 15, 201651

Stop Lock



•Bad Coating Quality

•Chemical Attack (sea water)

Stop LockCorrosion and Material Failure




Loctite Superior Metal

• High Ferro Silicon Content

• Extremely resistant to corrosion, chemical attack and abrasion

• Machinable when fully cured



Loctite Chemical Resistant Coating


• Chemical and erosion resistant

• Also available for High Temperature Chemical Resistant Coating


April 15, 201655

ID Fan



•Abrasion

•Chemical and Temperature

•Erosion

ID FanCorrosion and Erosion



Loctite Superior Metal

• High Ferro Silicon Content

• Extremely resistant to corrosion, chemical attack and abrasion

• Machinable when fully cured




Nordbak High Temperature Brushable Ceramic


• Corrosion and erosion resistant

• Temperature Resistance up to 300oC


April 15, 201659

Heat Exchanger & Water Box

Turbine Maintenance – Condenser End Plate corrosion

• Coating End Plate and Water Boxes


Turbine Maintenance – Condenser End Plate corrosion• Causes of Failure

• Bimetallic Corrosion• Corrosion in Water Boxes • Leakages• Drop in efficiency


Solution

• Surface preparation • Cleaning for visible / non visible

contaminants • Put Taper Plugs on the tubes • Grit Blasting to prepare the surface SA

2.5 -3

• Apply Hold Coat of Nordbak compound on the surface to prevent flash rusting

• Rebuild the surface with Nordbak Compound to prevent further erosion / corrosion

• Final coating with Nordbak range of coating


Product Recommended

Wear Resistant Putty• Ceramic Fibre Reinforced• Machinable when still in semi cured state• Hardness – 85 Shore D • Temperature resistant 160 ℃• Excellent “Reprofiling” composite for

pump repairs and filling pitting corrosion. Over coat with Brushable Ceramic

• Pack size – 1.35 kg


Brushable Ceramic• Brushable, ceramic reinforced composite• Smooth, glossy low coefficient of friction• Corrosion and erosion resistant• Hardness – 85 Shore D• Temp. resistant up to 125℃ Dry, 65 ℃ Wet

.• Ideal for Pumps, valves, pipes, condenser

tube sheet and as a base coat prior to Nordbak Wearing range

• Pack size – 1 & 2 kg kit

• High Temp. version available

Product Recommended



• Customer / Country• Coal fired power plant

• Problem / Application• Bi-metallic corrosion on condenser end

plate and water box• Protective coating of surfaces

• Solution• Fixmaster Wear resistant putty and

Nrodbak Brushable ceramic• Benefits

• Power plant needed the coating once in 4/5 years thereby increasing MTBF

• Increased condenser efficiency



• PJB Muara Karang

• Problem / Application• Corrosion of Water Box • Replacing Rubber Lining

• Solution• Coating the surface with Brushable

Ceramic & Nordbak Wearing Compound

• Benefits• Increased life of condenser


Water Box PT PLTU Muara Karang

• Erosion & Corrosion of Inner


Water Box PLTU Muara Karang• Causes of Failure

• Sea Water


Solution


• Apply Hold Coat of Loctite Nordbak Brushable Ceramic Grey at Carbon Steel Substrate

• Rebuild the surface with Loctite Nordbak Nordbak Brushable Ceramic Grey at Carbon Steel Substrate


Water Box PLTU Muara Karang

Product Recommended

•


Water Box PLTU Muara Karang

Benefits




Increasein Profits



• PT PLTU Muara Karang (Dec 2012) /Indonesia

• Problem / Application• Erosion at Inner Water Box

• Solution• Loctite Brushable Ceramic Grey• Loctite Nordbak Wearing Compound

• Benefits• Process cuts


April 15, 201673

Tank and Vessel

April 15, 201674

Tanks and Vessels Internal / External Corrosion


• Uniform Corrosion

Corrosive attack over entire

surface of substrate

• Pitting Corrosion

Cavities or "holes" are

produced in the substrate

April 15, 201675

• Solution

• Surface preparation• Blasting SA 2.5-3

• Use composite material to protect the welded joints and to rebuild worn out areas.

• Protection coating using Composite two coat system.


April 15, 201676


April 15, 201677

Tanks and Vessels Application Case History

April 15, 201678

Concrete and Foundation

April 15, 201679


• Oil & Chemical Spillage

• Corrosion of Pump Base frame due to Sea Water or Chemical Attack

Concrete and FoundationDegradation

April 15, 201680

Concrete and FoundationDegradation

• Product Recommended :

• Loctite Fixmaster Concrete Sealer

Acts as a sealer and primer for

Chemical resistant coating

• Nordbak Chemical Resistant Coating

HCL Tank PT Dankos Farma

• New Substrate Chemical Concrete Cargo Tank


Solution


• Apply Hold Coat of Loctite NordbakChemical Resistance Coating at the surface Concrete

• Rebuild the surface with Loctite LoctiteNordbak Chemical Resistance Coating at the surface Concrete


Product Recommended

Chemical Resistant Coating• Polyurethane bisphenol system for

extreme Chemical resistance• Smooth glossy low friction surface• Light grey color• Temp. resistant 160 ℃ ( Dry ) 65 ℃ ( Wet) • Ideal for lining tanks and chutes, lining

chemical containment areas, pump bases


Surface Engineering WorkshopPC 7000 (High Temperature Abrasion Resistance)

April 15, 2016 Title and author of presentation

Loctite PC 7000 (High Temperature Abrasion Resistant Coating)


Coal-Fired Power Plants Current Situation

• Multiple styles of burner tips exist, each with different wear patterns

• Typical Burner Tip Life is 12 to 24 months• Burner nozzle wear negatively impacts boiler

performance• Wear is caused by pulverized coal blowing

over burner components


Coal-Fired Power Plants Boiler Efficiency

Burner Assemblies • Inclination angles change as tips wear• Combustion efficiency decreases• Coal usage increases

Downtime / Maintenance Costs• Burner repair can only be done when the

boiler is off and completely cooled • Scaffolding required to reach burners at

different elevations• Several days to conduct repairs


LOCTITE Solution Loctite PC 7000 High Temperature Abrasion Resistant Coating

FEATURES

•Unique three-component rapid setting silica-based composite coating.•Environmentally friendly water based system (resins and filler mixture).•High Abrasion resistance up to 1100 °C.•Bonds well to porous substrates like concrete, refractory bricks etc(metal substrates need metallic mesh reinforcement).

BENEFITS

•Up to 2 X Protection from wear•Lesser production loss•Cost effective –almost 29% cost saving over conventional methods•Laminar flow of coal-air mixture for optimum efficiency


LOCTITE Solution Loctite PC 7000 High Temperature Abrasion Resistant Coating


Application DetailBurner Tip Assembly


Application DetailBurner Tip Assembly

•Bonding to SS 310 & SS 316 Material•Failure Factor:

•Oxidation•Hot Erosion•Carburization

•Ignition Point on the tip•Temperature Resistant 11000C•Ash content 28 –30%•Flow velocity 28m/s•InsituRepair•Easy to cast in curved shape


Application DetailWhere to Apply

Coating of Loctite PC 7000


Application DetailWhere to Apply

SESA STERLITE •Part of Vedanta Group•1215 MW Captive Power Plant (CPP) at Jharsuguda(Orissa).•Largest CPP of India.•Commissioned in July 2008, the plant is configured with 9 nos. coal-fired sub-critical units of 135 MW.

APPLICATION DETAILS•Department : Boiler•Equipment: Coal Burner Nozzle Tip.•Burner Nozzle Tips are the most wear prone items affecting Boiler performance.•Frequent repair and replacement extends downtime and leads to higher production losses.

TYPICAL BOILER PARAMETERSSuperheated Steam Temperature: 540 °CFire Ball Temperature: 1100 °CCoal Firing Velocity: 28–30 m/sCoal Feed Rate:110-120 TPHCoal Fine Size > 5 Microns With Ash ( 40%)


Customer’s Current Practice


Summary


Coal Mill PT Semen Indonesia

AfterBeforeAPPLICATION DETAILS• Department : Coal Mill • Equipment: Pipe Cone Coal Mill.• Temperature : 200 – 300 DC.• Fluid : Ash Coal• Problem : Corrosion & Hole .


Product Packaging

April 15, 2016100

MRO Special Products

April 15, 2016Slide 101

Specialty Repair KitO-Ring Kit• Make replacement, high

performance O-rings in less than

a minute

• Contains 4 different diameter of

nitrile rubber (Buna-N) cord

• Contains 404 QuickSet CA,

O-ring fixture, blade, water

proofing solution, cleanup

solution

• This is for static flange sealing

only, not for dynamic flange use.


Corrosion can be everywhere

Protective CoatingTurco Rust Converter


Corrosion cause…

• Esthetic issue• Reduce parts / equipment life• Safety issue• Extra cost

• How to solve these……


What is Turco Rust Converter?

• Water base pre-treatment chemical to stop rust and prevent future corrosion.

• When applied to rusty metal, change the rust ( iron oxide ) to form iron phosphate. When dries, ready to paint.


Advantage :

Loctite ML-11

Clean grease, under dirt, and dissolves some adhesives

Quickly dries out if applied in electrical system

Protects Metal Surfaces from corrosion

Easy to use with special stainless steel straw


How to Remove Seizing Bolt / Nuts?

Penetrating Oil Localize heat Cutting the bolt / nut

Limitations:• Penetrating oil provide lubricate effect only• Space limitation / position• Special bolt, stud bolt (anchor) → can’t be cut• Flammable / explosive area

Common Method

Specialty Repair KitFreeze & Release


Why Bolt Assemble Seize?

• Galvanic corrosion happened on the threads assembly caused seize

• Loctite solution is “break the rust chain”


Spray Shock-freeze up to -43oC(Wait 1 – 2 minutes)

Cracks (disassembly)

How to Apply?

April 15, 2016109

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