Oil & Gas Offshore

8/9/2019 Oil & Gas Offshore

1/16

Belzona Protective Coatings and Repair Composites

MAINTAINING ASSET INTEGRITY IN THEOIL AND GAS INDUSTRY — UPSTREAM


2/16

Maintaining Asset Integrity in the Oil and Gas Industry — Upstream

1950 1960 1970 1980

Company established,offering zinc-richanticorrosive coatings

First cold curingMetallic Polymersintroduced

Began servicingthe Oil and Gasindustry

BELZONATIMELINE

First corrosionresistant steelalloy applied

NOVEL SOLUTIONS TO AGE-OLD PROBLEMSAggressive chemicals and erosion-corrosion can take their toll on equipment and structures, resulting inincreased capital and operating expenditure. Elevated temperature and pressure levels tend to exacerbatethe problem and necessitate the use of high performance protective and repair materials with a proventrack record. By utilising a Belzona solution, asset owners and engineering houses can incorporate suitableprotection into the design of a newly built piece of equipment. Components that have been damaged inservice can also be refurbished. Oil and Gas companies choose the Belzona solution because it helps them to:

• Reduce capital expenditure

• Lower maintenance costs• Improve efficiency and safety• Reduce downtime• Simplify maintenance procedures• Extend machinery and equipment life

Belzona offers a range of coatings and composites carefully formulated to address various issues faced bythe Oil and Gas industry. We take pride in the quality of our materials as well as the comprehensive trainingand eld support we provide to ensure the highest possible application standards.

OUR HISTORYEstablished in 1952, Belzona has pioneered innovative polymer technology that has revolutionised industrialrepair and maintenance procedures. Proven success has also led to a growing number of prominent clientsspecifying Belzona materials as a cost effective solution at the design stage of a project.

Today, Belzona is the world leader in the supply of polymer repair composites and industrial protectivecoatings and is continuously developing solutions to meet the ever increasing market demand.

100% solids epoxy protective linings forerosion-corrosion protection

High performance polyurethanes forflexible repairs

Composites for bonding, forming,shimming and rebuilding

Elastomers forexible repairsformulated

Ceramic metalsintroduced


3/16


GLOBAL PRESENCE - LOCAL SUPPORTBelzona have over 140 Distributors in more than 120 countries ensuring not only the availability of Belzonamaterials, but also specication support, project management, application and supervision services.Distributorships and their teams are supported by Belzona Corporate offices in Europe, North America andAsia.

Our expert Technical Consultants with years of eld experience and advanced training are available toassist you every step of the way to: discuss material selection options, diagnose the problem, recommend asolution and provide on-site application support.

1990 2000 2010

Erosion-corrosionresistant linings forhigh temperatureimmersion launched

Heat activated corrosionunder insulation repairproducts introduced

Introducedcompliant pipewrap technology

Next generationvessel liningsformulated

New peelablecoating conceptintroduced

Belzona Polymerics LtdHarrogate, UKt: +44 1423 567641f: +44 1423 505967

Belzona Asia PacicChonburi, Thailandt: +66 38 491031f: +66 38 491102

Belzona CanadaOntario, Canadat: +1 (905) 737-1515f: +1 (905) 737-1597

Belzona IncMiami, Fl, USAt: +1 (305) 594-4994f: +1 (305) 599-1140

CORPORATE OFFICES

Sprayable erosionresistant liningsdeveloped

To nd your local Belzonarepresentative visitbelzona.com/nd

http://belzona.com/en/about/disfinder.aspxhttp://belzona.com/en/about/disfinder.aspx


4/16


INTERNAL SURFACE PROTECTION FROMFLOWING CORROSIVE MEDIA

Prefabricated Belzona inserts bondedinto small bore nozzles

Belzona lining applied to a newly fabricated separator

Cold forming isolates ange facesfrom corrosive media

Process vessels - protection, reclamation and modication

Applied at ambient temperatures,VOC-free Belzona linings facilitatecorrosion prevention, repairs and vesselmodications.

Belzona liquid applied vessel liningswere rst specied in 1987 for separatorcorrosion repair and protection at a UKNorth Sea platform. Outstanding erosionresistance prevented wear during thesand jetting system operation and hasprompted the use of Belzona linings onhundreds of other vessels. We now offera complete solution for pressure vesselshandling liquid hydrocarbons, gas andprocess chemicals including separators,slug catchers, knock-out drums andmany more. Based on the experience ofcorrosion repair and prevention, spanningtwo decades, in the early 2000s assetowners and operators began to specifyBelzona linings at the design stage toprotect newbuild vessels.

Our linings can be spray or hand appliedand, once cured in service, form a barrierbetween the substrate and corrosivemedia, enabling the operator to implementa corrosion management plan. As well as

resisting erosion-corrosion, Belzona liningsare designed to withstand vast pressureand temperature uctuations, includingsteam-out and explosive decompression.

In addition to internal vessel lining, acomplete corrosion solution includes smallbore nozzle and ange face protection inorder to fully isolate the substrate from acorrosive environment. Belzona vessel liningsystems offer long-term corrosion protectionand are easier to maintain than alternativecorrosion protection technologies.


5/16


Touch up after 9 years Glass ake lining repair Full recoat

Corroded ange Forming technique Completed application

Deteriorated nozzle Pre-fabricated insert Nozzle protected

VESSEL LINING REPAIRSFailed coatings (or Belzona liningsdue for planned maintenance) can berepaired in situ with minimal disruptionto operations. Patch repair, partialrecoat or full recoat options reducedowntime, prolong vessel service lifeand extend maintenance-free periods.

FLANGE FACE FORMINGCrevice and galvanic corrosion can beprevented or repaired with a uniqueBelzona composite forming technology.Prefabricated formers are used toshape the specied Belzona materialthat bonds strongly to the ange face.The sealing face is then effectivelyisolated from corrosive media whilstmaintaining its shape and prole.

SMALL BORE NOZZLEPROTECTIONNarrow nozzles no longer need tobe considered “the Achilles’ heel” ofprocess vessels. Tailor made Belzonainserts can be bonded into the nozzleusing a uid grade material, eliminatingthe risk of pinholes or holidays.Excellent chemical and erosionresistance ensures long-term protectionof the nozzle, thus extendingmaintenance-free periods.

VESSEL MODIFICATIONWhere hot work is not permissibleor desirable, cold bonding of vesselinternals allows for modication andeliminates the need for post weld heattreatment. Tensile shear, tensile andcleavage adhesion tests performedshow that Belzona bonding can besuperior to welding.

For more information read In Focus:Process Vessels, belzona.com/vessels Separator modication Cold bonding technology 8 years later

Video: Process vesselcorrosion protection

http://belzona.com/assets/data/news/FOCUS-Process%20Vessels-en-online.pdfhttp://www.youtube.com/watch?v=HAjAeF7uenk&index=21&list=PL3D73C2529487608Fhttp://www.youtube.com/watch?v=HAjAeF7uenk&index=21&list=PL3D73C2529487608Fhttp://www.youtube.com/watch?v=HAjAeF7uenk&index=21&list=PL3D73C2529487608Fhttp://belzona.com/assets/data/news/FOCUS-Process%20Vessels-en-online.pdf


6/16


INTERNAL SURFACE PROTECTION FROMFLOWING CORROSIVE MEDIA

Spin spray application

Internal pipe lining

Girth weld covered in a single coat

Transfer pipe – erosion-corrosion protection lining

Sand entrainment and high ow ratescoupled with large quantities of CO 2, H 2Sand brine can lead to pipe corrosion ratesof several hundred mils per year. In 2012,Belzona pioneered a spray-friendly pipelining system that offers erosion-corrosionprotection. The substitution of hard-ceramic llers for a thermoplastic llerblend ensures there is very little wear tothe spray equipment.

Sprayable erosion-corrosion protectivelinings allow for the material to be spinspray applied in situ at wet lm thicknessup to 2000 microns without sagging,effectively covering girth welds and jointsin a single coat. The thermoplastic llerblend is formulated to achieve excellentimpact and sliding abrasion resistance, ahigh degree of toughness and chemicalresistance.

Next generation pipe linings are availablein medium and elevated temperaturevariations of up to 95°C (203°F).When comparing Belzona sprayablethermoplastic ller blend linings withceramic lled epoxies, abrasion testsrevealed reduced volume loss. Tests and

in-service performance conrm that thesenovel linings provide outstanding erosionresistance in extreme wear environments.

For more information download a whitepaper on belzona.com/1331

Video: Spin-sprayedpipe lining

http://belzona.com/en/products/1000/1331.aspxhttp://www.youtube.com/watch?v=EHVBvUwXNfA&index=20&list=PL3D73C2529487608Fhttp://www.youtube.com/watch?v=EHVBvUwXNfA&index=20&list=PL3D73C2529487608Fhttp://www.youtube.com/watch?v=EHVBvUwXNfA&index=20&list=PL3D73C2529487608Fhttp://belzona.com/en/products/1000/1331.aspx


7/16


Video: Pump repairand protection

Impeller protected with Belzona liningNew rewater pump lining

PUMPSPump deterioration leads to decreasedpumping efficiency and eventually costlypart replacement. Pitting, worn wearring clearances as well as casing thin andthrough wall defects can be rebuilt usingcomposites specically designed forpumping applications. Pumping efficiencyis restored and enhanced with the useof a hydrophobic smooth lining, whichalso protects from erosion-corrosionand cavitation. Once the pump has been

protected with Belzona, it can remainmaintenance-free for many years.

Due to over 30 years’ experience inrepairing and restoring upstream pumps,Belzona linings are now specied toprotect new pumps, thus signicantlyextending the lifetime of the assets andsubsequent maintenance-free periods.Belzona linings have become a rst choicein protecting rewater pumps in particular,offering long-term corrosion protectionand seizure prevention.

For more information on Belzona solutions

for pumps view a 3D map detailing variousapplication areas and case studies onbelzona.com/pumpmap

Protected with Belzona liningSeawater lift pump chambers

http://www.youtube.com/watch?v=G9sbWc1CFxQ&index=17&list=PL3D73C2529487608Fhttp://www.youtube.com/watch?v=G9sbWc1CFxQ&index=17&list=PL3D73C2529487608Fhttp://www.belzona.com/en/solution_maps/pumps/index.aspxhttp://www.belzona.com/en/solution_maps/pumps/index.aspxhttp://www.youtube.com/watch?v=G9sbWc1CFxQ&index=17&list=PL3D73C2529487608F


8/16


STRUCTURAL BONDINGApplied at ambient temperatures, 100% solids Belzona materials create a highperformance adhesive.

Video: Injectionbonding

Belzona plate bonding

Cable tray bonded on FPSO

Corroded deck on Buchan Platform

Design and maintenance scenarios thatwould historically involve hot work canbe completed with the use of polymericcold bonding composites. This technologyis applied and cures at ambienttemperatures, thus improving safety andreducing downtime.

Belzona bonding was rst used in the late1950s to attach equipment ID tags. Overthe years materials were enhanced toresist higher pressures and temperaturesas well as demonstrate comparably highadhesion and compressive strength.

COLD WELDING DECKEQUIPMENTCold bonding deck equipment eliminatesthe need for hot work and facilitates rapidinstallation. With tensile shear adhesionof up to 2,960 psi (20.4MPa), pull offadhesion of up to 3,240 psi (22.3MPa)and exural strength of up to 14,300 psi(98.6MPa) deck equipment, frameworkand supports can be bonded permanentlyand safely. Belzona cold bonding is equallyeffective at a fabrication stage, duringturnarounds or whilst the platform is inoperation. Belzona cold bonding materials

are also recommended to ll gaps arisingin tack welded elements, such as pipesaddles supports.

DECK MAINTENANCE- PLATE BONDINGCorroded equipment and structurescan be repaired in situ with Belzona’spioneering injection bonding technology.This technique has been successfullyutilised for deck renovation and otherstructural integrity repairs. Over a decadeof successful applications, which are stillin service today, attest to this method’seffectiveness and have promptedengineering houses to specify injectionbonding for greeneld applications.

To see Belzona Know-How in action,including bonding applications, visitkhia.belzona.com - our dedicated casestudy database

8 years later, Belzona plate bonding solution in excellent condition

http://www.youtube.com/watch?v=u4-RXie-ngkhttp://www.youtube.com/watch?v=u4-RXie-ngkhttp://khia.belzona.com/en/default.aspxhttp://khia.belzona.com/en/default.aspxhttp://www.youtube.com/watch?v=u4-RXie-ngk


9/16


Rudder bearing bonding – bottom view Rudder bearing bonding – top view

BEARING INSTALLATION/BONDINGBearings are susceptible to frictiondamage and galvanic corrosion. Since the1970s, Belzona has been used to preventbearing corrosion by seating rudder pintlebearings.

After a trial ship application in 1979,Belzona was accepted as a permanentinstallation and used from new on allGermanisher Lloyd classed vessels.

One of the rst and perhaps most notablebearing bonding applications in servicetoday was performed on a agship liner,Queen Elizabeth 2.

Bearing bonding is carried out by injectingthe Belzona material between the bearingand the housing. The Belzona shim takesup any ovality or housing wear, thuscreating a durable barrier with 100%surface contact, electrically isolating thebearing. This method has been applied tomultiple situations including riser bearingsand bushes amongst others.

Bush installation, North Sea Riser bearing bonding


10/16


PIPEWORK EXTERNAL CORROSIONREPAIR AND PROTECTION

Coating application

Corrosion under insulation

Pit lling

Heat activated solutions applied on-line

Video: Heat activatedapplication

CUI REPAIRSCorrosion under insulation occurs atan accelerated rate and can remainundetected for some time. Taking affectedparts of the pipework out of service forrepairs or replacement can in turn leadto high costs and lengthy downtime. Toaddress this problem, in the late 1990s,Belzona formulated heat activatedcomposites and coatings that facilitateon-line repairs. These materials adhereexceptionally well to hot contaminatedsurfaces and penetrate deep into thesubstrate eliminating the need for anangular blast prole prior to application.

Simple manual surface preparation andon-line brush application have inspired theuse of Belzona heat activated materialsto combat CUI globally, from the Gulfof Mexico to the North Sea. Typicalapplications in the range of -10°C to 150°C(50°F – 302°F) will resist salt spray andcommonly found inorganic acids andalkalis at concentrations up to 20%.

Insulation can then be sealed with abreathable membrane to prevent furtherliquid permeation. Belzona membrane canbe easily cut open for localised inspectionand resealed with little impact on theprocess.

For more information on CUI solutionsvisit belzona.com/cui

http://www.youtube.com/watch?v=6iRj8TPZZ7Q&list=PL3D73C2529487608Fhttp://www.youtube.com/watch?v=6iRj8TPZZ7Q&list=PL3D73C2529487608Fhttp://belzona.com/cui/http://belzona.com/cui/http://www.youtube.com/watch?v=6iRj8TPZZ7Q&list=PL3D73C2529487608F


11/16


Video: Application,peeling and resealing

PIPE WRAPS AND PLATEBONDINGThin and through wall defects causedby external and internal corrosion canbe repaired using composite wrapsystems. A wrap system is composedof a reinforcement sheet and a Belzonamaterial, tailored to the asset’s performancecriteria, such as presence of contaminants,operating temperatures and pressuresamongst others. A wrap system can also beapplied in conjunction with a bonded platewhere additional reinforcement is required.

Following almost ve decades of pipewrap installations, in 2007 we addedBelzona SuperWrap to the range, whichis compliant with ASME PCCC2 Article4.1 and ISO/TS 24817 and withstandspressures exceeding 250 bar. EveryBelzona SuperWrap system is individuallydesigned and is appli ed by validatedinstallers, carrying a warranty based onthe estimated design life. In 2014, threenext generation variations of BelzonaSuperWrap were released to betteraccommodate different climates andenvironments – winter, tropical and high

temperature grades.For more information read In Focus: PipeWraps on belzona.com/wraps

FLANGE PROTECTIONRepairing ange crevice corrosioncan be a very costly exercise, whereascommon preventative measures in mostcases are not ‘inspection friendly’. TheBelzona encapsulating membrane systemintroduced in 2014 seals bolted angeconnections preventing corrosion. Theliquid applied system includes a corrosioninhibitor and was designed to allowfor periodic inspection, where exibleprotection can be cut, peeled back andthen easily resealed. To maintain Healthand Safety standards, the system is handapplied, cures at ambient temperaturesand can resist common corrosive media.

For more information visit belzona.com/3411

PIPEWORK EXTERNAL CORROSIONREPAIR AND PROTECTIONCold applied 100% solids materials

T-piece wrap

Belzona SuperWrap applied Holed pipe

Peel to inspect, reseal to protect

Completed applicationSimple brush application

T-piece wrap

http://www.youtube.com/watch?v=Qti7a7vaM8Yhttp://www.youtube.com/watch?v=Qti7a7vaM8Yhttp://belzona.com/assets/data/news/FOCUS-Comprepairs-en-online.pdfhttp://belzona.com/en/products/3000/3411.aspxhttp://belzona.com/en/products/3000/3411.aspxhttp://belzona.com/assets/data/news/FOCUS-Comprepairs-en-online.pdfhttp://www.youtube.com/watch?v=Qti7a7vaM8Y


12/16


MARINE WORKSplash zones – applications above and below the water line

Coating applied Corroded platform leg

Constant salt spray and wave impactcreate perfect conditions for vast erosion-corrosion and necessitate in-situ repairsin order to avoid replacement costs. Toaddress these issues, Belzona formulateda surface-tolerant coating and compositein 2002. Applied and cured above orbelow the water line, these materials havethe ability to displace contaminants andbond strongly to the substrate. Thesesurface-tolerant materials are speciedwhere contact with water and othercontaminants is present during theirapplication on risers, platform legs andother splash zones.

RISERS Rubber cladding does not offer permanentprotection and tends to deteriorateafter a few years in service, with seawater corroding the steel underneaththe cladding. Belzona offers a completesystem, which restores corroded metaland repairs cladding in situ, sealing theneoprene boot topping of the ri ser, thuspreventing further water permeation.Due to proven longevity of cladding edgesealing, marine engineers specify Belzonaexible solution on new risers to preventwater ingress between the cladding andthe metal.

PLATFORM LEGSSea water movement with abrasiveresidues is capable of wearing awaysacricial protection and causing severedamage to the platform legs, particularlyaround the water line. Belzona surface-tolerant materials can be used to rapidlyrepair and prevent platform leg corrosion.Liquid-applied in situ and long lasting, thesystem forms a durable barrier betweenthe substrate and the sea water.

SUBSEA COATINGSFollowing over a decade of applicationson platform legs, FPSO operators specifyBelzona surface-tolerant materials for hullcoating repairs and other subsea coatingapplications.

For more information on Belzona solutions forsplash zones visit belzona.com/splashzones

Inspected ve years later

Corrosion repaired and cladding sealed Corroded riser

Video: Riser repair

http://belzona.com/en/focus/splash_zones.aspxhttp://www.youtube.com/watch?v=3o5tRKTaKGk&list=PL3D73C2529487608Fhttp://www.youtube.com/watch?v=3o5tRKTaKGk&list=PL3D73C2529487608Fhttp://belzona.com/en/focus/splash_zones.aspx


13/16


Auxiliary rubber equipment such asfenders, hoses and cables are prone to

in-service deterioration, where even minorrips and tears can lead to equipment beingdecommissioned. Belzona Elastomersare liquid-applied exible polyurethanes,which can reduce downtime and eliminatethe need for replacement. First introducedin 1985, Belzona Elastomers are commonlyused in situations where replacement istoo costly and alternative materials are notable to provide a durable repair.

FLOATING HOSES ANDFENDERSHoses can be damaged in service or in

transit and require a fast and durablerepair solution. Belzona Elastomersadhere strongly to any type of hoseand provide outstanding abrasion andimpact resistance once the hose is putback in service. Belzona Elastomers areendorsed by reputable oating hosemanufacturers as their recommendedrepair material. Corroded ange faces andinternal surfaces can also be repaired andprotected with the use of Belzona liningand ange face forming technology.

For more information on oating hoserepairs visit belzona.com/hoses

MARINE WORKFlexible repairs – liquid applied durable protection

Fender repaired in situDeteriorated fender

Belzona exible repair Hose damaged in transport

Video: Floating hoserepair

http://belzona.com/en/focus/floating_hose.aspxhttp://www.youtube.com/watch?v=kggkIQ8lIJY&list=PL3D73C2529487608Fhttp://www.youtube.com/watch?v=kggkIQ8lIJY&list=PL3D73C2529487608Fhttp://www.youtube.com/watch?v=kggkIQ8lIJY&list=PL3D73C2529487608Fhttp://belzona.com/en/focus/floating_hose.aspx


14/16


GLOBAL APPLICATION STANDARDS

PREQUALIFICATIONBelzona materials are subject to stringent independent andin-house testing, documented in the product specicationsheets and chemical resistance charts. Testing is performedin our ISO 9001 audited laboratory to recognised standards,including NACE, ASTM, ISO, Lloyds and many more. Numeroushigh prole Oil and Gas companies prequalify the useof Belzona materials at the design stage and for assetmaintenance.

Data collected from the eld inuences improved formulationsand application methodology to ensure increasingly efficientin-service performance.

SPECIFICATIONOptimum materials and application procedures are selectedto meet specic design and operating conditions of the asset.Dedicated project engineers coupled with round the clockhead office technical support allow for the correct materialand application procedure to be specied.

We also maintain a comprehensive database accessible by theGlobal Belzona Distributor network, which facilitates sharingof information and experience, improving specication andapplication standards.

APPLICATIONApplication standards, including surface preparation, areintegral to the success of solution implementation. Belzonarecognises the need to set and monitor global applicationstandards.

Applications are carried out by experienced and trainedpersonnel. Belzona runs training programmes with theoreticaland practical courses, including validated training. Combinedwith method statements, quality control procedures and dailyinspection reports we strive to ensure application standardsare maintained.

INSPECTIONInspection is carried out by certied inspectors (e.g.NACE, FROSIO) prior to, during and upon completion ofthe application to ensure Belzona systems are applied inaccordance with our standards and client’s requirements.

Upon nearing the end of the system’s expected servicelife, the asset is inspected again and appropriate actionrecommended, which may involve minor repair work or noaction, as Belzona systems tend to outlast projected servicelife.


15/16


BELZONA SOLUTIONS FOR THEOIL AND GAS INDUSTRY — UPSTREAM

HIGH PERFORMANCE LININGSresistant to high pressures and temperatures

COLD BONDINGto replace hot work

WRAPSfor pressurised pipework repairs

HEAT ACTIVATED COATINGSfor hot surface repairs on-line

SURFACE-TOLERANT PROTECTIONfor applications above and below the waterline

ELASTOMERSfor exible repairs


16/16

ISO 9001:2008Q 09335ISO 14001:2004EMS 509612

Belzona products are manufacturedunder an ISO 9000 Registered QualityManagement System UK • USA • Canada • Thailand

Documents

Oil & Gas Offshore