Worldwide repairs carried out with PolymerMetal

Transcription

1 REP-# 006 Repair of several bilge pumps and fire pumps (type Loew VZLG 65/1/2, power 60 m3/h) with Ceramium pasty and Ceramium liquid. An inspection 3 years after the repair did not show any faults or objections at the repaired object.

2 REP-# 007 Repair of heat exchangers using Ceramium and Hardener CE.

3 REP-# 012 Elimination of damages at two vessel s propeller caused by cavitation with Ceramium and Hardener CE.

4 REP-# 013 Deep groves at the surface were filled out with Ceramium and Hardener CE.

5 REP-# 034 Repair of a three-way valve housing for sea water. Material: grey cast iron. Damage: considerable wash-outs as well as a gaping hole in the valve housing. The repair was carried out with MM-metal SS-steelceramic and Hardener yellow and Ceramium, liquid with Hardener CE.

6 REP-# 035 The upper part of an impeller of a pump for filling up the ready cement in sacks was exposed to very strong wear and tear. In the meantime it was tried to restore by build-up welding. The final repair has been carried out with Ceramium and Hardener CE.

7 Worldwide repairs carried out with PolymerMetal REP-# 048 Repair of an automatic glass machine at a channel for broken glass and water. The coating procedure was affected in two steps - first application with Ceramium, pasty, followed by a second application with Ceramium, liquid. The previous reconstruction procedure was buildup welding.

8 REP-# 057 Repair of a corroded gas pipe due to throat gas from blast furnace carried out with Ceramium and Hardener CE.

9 REP-# 063 Reconstruction of the sealing surface of the cover at a turbine. The repair was carried out with Ceramium, liquid and Hardener CE at an electric generating station.

10 REP-# 064 A crack at an enamel coated chemical plant for the production of solvents was filled with Ceramium and Hardener CE.

11 REP-# 065 Ceramium with hardener CE was used to repair cracks and damages caused by erosion between cast segments at a gas washer (Venturi) of a blast furnace cleaning facility. Due to this the life of the device was doubled.

12 REP-# 066 Repair of two turbine rotors. Damages were present at all areas of the blades where the water leaves the blades. First large holes have been welded. Then the erosive areas have been filled up with Ceramium, pasty. Finally a supplementary layer of VP has been applied as protection against cavitation.

13 REP-# 067 Cavitation damages on a flange were repaired by using Ceramium pasty and Hardener CE.

14 REP-# 068 Because of bad maintenance during the resting period the covers of 3 auxiliary capacitors, each 6 m2 were affected by erosion of up to 3 cm depth. The volume for filling was obtained by applying 200 kg Ceramium and Hardener CE.

15 REP-# 069 Repair of 160 cylinder liners using Ceramium, pasty and Hardener CE. Afterwards a layer of Ceramium, liquid and Hardener CE was applied.

16 REP-# 070 Repair of a bucket wheel excavator for the field of open-cast mining by applying Ceramium liquid. The main drive shaft of the bucket wheel rim, which was damaged due to abrasion, was reconstructed at a length of 400 mm with a diameter of 360 mm. The diameter has been reduced to 350 mm before the rebuilding.

17 REP-# 071 Repair of the bottom part of a coal mill. The repair has been carried out both with Ceramium pasty and Ceramium liquid.

18 REP-# 072 Coating of the inner respectively outer diameter of a penstock pipe with diameter appr. 1,5 m, length appr. 900 m. Damages were caused by erosion and abrasion due to water and sand. The coating was affected with Ceramium pasty with Hardener CE.

19 REP-# 073 Repair of a Kort nozzle using Ceramium with Hardener CE.

20 REP-# 075 Elimination of cavitation damages at a bronze propeller and a steel propeller with Ceramium and Hardener CE.

21 REP-# 083 Repair of heat exchangers using Ceramium and Hardener CE.

22 REP-# 089 Repair of the soot blower compressor at a heat station by coating the additional cooler with Ceramium. The coating was affected in two steps: a first application of Ceramium pasty type, afterwards a second application with Ceramium liquid type.

23 REP-# 090 A cover with Ceramium was reconstructed. The coating was affected in two working procedures: First a surface reconstruction with Ceramium, pasty and Hardener CE. Second an application with Ceramium, liquid with Hardener CE.

24 REP-# 093 Repair of a ship propeller shaft made of bronze in the zone of the stuffing box packing with Ceramium pasty and Hardener CE. The original shaft diameter of 630 mm was machined down to 615 mm over a length of 60 cm. After the application of Ceramium the diameter was 632 mm. Finally the applied Ceramium was turned down to the requested diameter. For the complete repair 39 units of Ceramium / Hardener CE were used for applying 4 layers. Additionally 3 layers of glass fibre fabric tape were processed.

25 REP-# 094 Blocking valves have been reconstructed by using Ceramium. Responsible was serious wear and tear on the steel alloy caused by the clay loam.

26 REP-# 095 Repair of an undersized bronze propeller shaft: diameter appr. 380 mm, length appr mm due to friction in the stuffing box. Material used: Ceramium with Hardener CE. After curing the propeller shaft was machined.

27 REP-# 096 Repair of a propeller shaft near the stuffing box packing by using Ceramium pasty with Hardener CE.

28 REP-# 097 Maintenance of a shaft of a paint coating machine at a paper mill in the zone of the stuffing box packing with Ceramium pasty and Hardener CE. The formerly common company repair solution by metal spraying was not considered because the machine would have been too long out of order.

29 REP-# 104 An additional water-centrifugal pump being damaged by erosion and cavitation was rebuilt using Ceramium. Housing and flanged socket were coated inside with VP

30 REP-# 105 Coating of a turbine impeller due to cavitation damages. Here the materials Ceramium and Hardener CE were used.

31 REP-# 108 Repair of worn piston rods caused by the exhausts of a blast furnace. The piston rods were brought to nominal diameter again using Ceramium. After the repair has been completed the piston rods are in operation again over 3 years.

32 REP-# 112 Corrosion and abrasion damages on high pressure fan casings in a paper-mill have been removed using Ceramium pasty and Hardener CE.

33 REP-# 113 Repair of gas drilling surge valves. Abrasion due to escaping gas (2800 psi) and carrying contaminations such as e.g. sand. The repair has been carried out using Ceramium. A later inspection did not reveal any damages.

34 REP-# 117 A damaged shaft of a conveyer worm was rebuilt using Ceramium. An inspection after 6 months did not reveal any damages on the conveyer worm.

35 REP-# 126 Repair of a pump housing. Damage: erosion and corrosion had reduced the wall thickness to a minimum. The resulting damage was a hole in the housing. For deep wash-outs Ceramium, pasty with MM-Fabric mats (steel) were used. For the purpose of wear-and-tear resistance the pump was coated with Ceramium, liquid.

36 REP-# 129 Durable protection against wear and corrosion on welded constructions i.e. receivers and covers can be achieved by using Ceramium together with an application of VP afterwards.

37 Worldwide repairs carried out with PolymerMetal REP-# 132 In a granulation plant several pumps (2 granulation pumps, 2 condense pumps, 2 cooling circuit pumps, 1 submerged pump) material loss caused by wear. All pump casings and running wheels consist of hard cast. Pumping medium is circuit water with a slag sand content of appr. 10 mg/l at a average corn size of 0,3 mm. The water temperature is 90 C (194 F) at the cooling circuit pumps and 40 C (104 F) at the condense pumps. The pumps have been repaired with a coating of Ceramium.

38 REP-# 136 A worn pump casing was coated with Ceramium liquid for demonstration purposes. Depending on the application consistency, Ceramium can be applied with a brush, a spatula or any other suitable tool or by pouring or injecting. Before coating, the surface must be roughened i.e. by sand blasting and then cleaned with MM-Degreaser Z or Acetone.

39 REP-#143 Several valves of a line system on an oil platform were damaged. The problem was abrasion caused by the transportation of sand and sea water. The damages were repaired with the help of Ceramium, pasty.

40 REP-#144 A turbine paddle was worn out caused by a water-sand-mixture. The pasty variant of the PolymerMetal Ceramium was used to rebuild the worn-out areas.

41 REP-#146 At a steelwork, heavy erosion caused damage of a blast furnace. Several areas of the conveyer cone were severely damaged due to the continuous loading with coke. Some plates were welded on the cone and then coated with Ceramium as well as some other damaged parts and the machine was put into operation successfully again.

42 REP-#148 Several holes and damaged spots respectively in the roof of a big tank at an oil refinery were first grinded and cleaned to prepare the surface and then coated with Ceramium. Then the Ceramium was grinded to rough up the surface. Finally a layer of MM-Elastomer was applied to compensate any bigger tensions.

43 TEC-# 001 Wear behaviour of polymer materials Used products Ceramium, VP , MM-Elastomer Technical Report PolymerMetal Description Mechanical and chemical stress acting on surfaces lead to wear and corrosion. If a high wear resistance is required, usually a very high hardness is needed, too. The hardness Vickers, Brinell or Rockwell hardness of polymer materials, like PolymerMetals or polymer ceramics, is meaningless for nearly all wear mechanisms of wear stressed machine parts. Mixtures of ceramic, metallic and polymer materials as well as elastomers show, that wear resistance and hardness do not correspond. Nowadays, erosive-abrasive wear stress is simulated with the help of a slurry pot or an abrasive wheel. The test in the slurry pot is very meaningful when the metals are exposed to sandy streamings. The water-sand mixing ratio determines the degree of wear. The adhesion between the sand grains is rising when the water content is very low. As a result wear is increasing as well. However, the influencing factors in praxis should not be underestimated. Tests carried out in model experiments help to determine the material s quality and to choose the right material. A guarantee for the durability cannot be given by these tests. Ceramium is a reliable material to protect metals against abrasion and surface destruction provided that the size of the particles is not more than 500 µm. In the following test a medium grain size of a very strong hardness was chosen: SiC ca 60 µm. Water and SiC were mixed in ratio 1 : 2 by volume. It is quite obvious that Ceramium was exposed to a very high stress. The used materials showed the following results: Material Hardness (Vickers) Wear (after 30 days) Ceramium HV 28 2,93 ccm Tool steel HV 840 3,60 ccm Steel St-52 HV 120 7,20 ccm In case that the particle size is higher than 500 µm the wear of Ceramium increases progressively. MM-Elastomer and VP show a better wear resistance, because they are plastically deformable. On the other hand, it has to be considered that the bonding on water-stressed metal surfaces of all elastomer materials is diminishing with advancing time.

44 TEC-# 002 Wearing due to sea water and sand Used products Ceramium Technical Report PolymerMetal Description Wear and tear is the progressive loss of material from the surface of a solid body. The causes are solid, liquid or gaseous antibodies. Ceramium offers a maximum of wear resistance. Metal surfaces damaged or worn by corrosion, erosion, abrasion or cavitation are restored by means of Ceramium. This type of surface restoration is quick, reliable and efficient. Bonding with the metal structure, one of the stress-relevant criteria, is ensured by the MM-technology.

45 Technical Report PolymerMetal TEC-# 007 The corrosion-chemical behaviour of PolymerMetals in combination with casting material (contact corrosion) Used products MM-metal SS-steelceramic / MM-metal SQ / MM-metal SS-steel 382 / MM-metal SS-steel / MM-metal ol-steelceramic / MM-metal UW / Ceramium / MM-metal S-steel Introduction PolymerMetals are used for repairs of metallic constructions which were damaged by physical loads like tear, impact, erosion, abrasion, corrosion and cavitation or by chemical load. Questions of customers concerning the contact corrosion of our PolymerMetals lead us to do tests. The following report shows how the test has been carried out and what results have been obtained. Tests have been made with seven different PolymerMetals in artificial sea water (laboratory test) as well as in aggressive marshy soil. The PolymerMetals used were potentially equivalent or potentially superior to the base material (cast iron). Place of repair Moorland in the North of Germany and laboratory Preparation of test samples 56 plates measuring 150 x 95 x 25 mm and 95 x 47 mm have been cut off cast iron. The surface of 23 plates has been treated mechanically. 2-3 bore holes of different diameters were installed in order to create different proportions between cast iron and PolymerMetals. General information An ordinary salt spray test proved insufficient. As the tested PolymerMetals are non-electrical conductive products it was decided not to measure the current density potential curves. The contact resistance in the Meg-Ohm-sphere was too high. Test in moorland Marshy soil is to be said very aggressive (DVGW rating no. -15 up to -19) Reasons are: -very low soil resistance (appr Ohm x cm) -very high salt content (chloride mg/kg / sulphate mg/kg) -very high moisture contents (appr %) -anaerobic conditions, proved by hydrogen-sulphide The cast iron plates and PolymerMetals, machined and non-machined, were stored in a considerable depth of marshy soil for more than one year. Test in artificial see water (laboratory test) The cast iron plates and PolymerMetals - machined and non-machined - were stored in a laboratory in considerable depth of artificial sea water (DIN ) for more than one year.

46 Samples The following photographs show the different PolymerMetals applied to cast iron which have been partly machined after full curing. After they have been stored for 12 months in aggressive moorland or artificial sea water the samples have been examined. The following four photographs concern machined samples which have been exposed to artificial sea water: Sample MM-metal SS-steelceramic Sample MM-metal SS-steel Sample MM-metal ol-steelceramic Sample MM-metal UW Result The results of both tests were nearly the same. Due to the strong reaction caused by the aggressive soil or by the sea water the cast iron plates were coated with ferric hydroxide. While the surface of the cast iron plates were differently affected, the PolymerMetals still remained unchanged after storage of more than 12 months. They were only covered with rust deposit. Even peak-to-valley heights from previous treatments could clearly be recognised. There was no contact corrosion, not even at the transitional point of the PolymerMetal and the cast iron. It was proved that PolymerMetals are not electrically conductive and cannot constitute any local element with cast iron. Tested PolymerMetals MM-metal SS-steelceramic MM-metal SS-steel 382 MM-metal SS-steel MM-metal SQ MM-metal ol-steelceramic MM-metal UW Ceramium MM-metal S-steel

47 TEC-# 008 Repair of a shaft with PolymerMetals Technical Report PolymerMetal Used products MM-metal SS-steelceramic / MM-metal SS-steel 382 / MM-metal SS-steel / MM-metal SSaluminium / MM-metal SS-copper / MM-metal SS-bronze / Ceramium / Molymetall Introduction The high quality PolymerMetals from can be used to repair worn shafts by restoring material. This report is supposed to assist the applicator during the repair. Because of the different sizes of wear length areas and diameters of the shaft to be repaired and the available processing time of the PolymerMetals (pot life appr min at 20 C) the application of the PolymerMetals was divided into four variants. Preparation shaft has to be turned off in the area of the damaged part to at least 1 mm undersize from target diameter, the surface quality should be appr. Rz 100 afterwards clean shaft from oil, grease, coolant etc with MM-Degreaser Z or MM-Degreaser C adhere to Technical data sheet of used PolymerMetal especially consider the available processing time (pot life) Application of PolymerMetal Variant 1: Shaft length of wear area < 150 mm and diameter < 200 mm Shaft hold by lathe has to run with a low turning speed during all following repair steps Apply a thin layer (max 0,5 mm) of PolymerMetal with a spatula with pressure on the complete wear area of the shaft to avoid air bubbles in the interface between metal and PolymerMetal Apply PolymerMetal on complete wear length of shaft in a layer of appr. 2 mm oversize against target diameter By using a metal rule which is long enough (and therefore reaching over the complete wear length) the surface of the PolymerMetal should be smoothened so that an oversize of only 1-2 mm remains

48 Variant 2: Shaft length of wear area < 150 mm and diameter > 200 mm Shaft hold by lathe has to be turned by hand during all following repair steps Apply a thin layer (max 0,5 mm) of PolymerMetal with a spatula with pressure on the first part of the wear area ( 1 on sketch) of the shaft to avoid air bubbles in the interface between metal and PolymerMetal; then apply PolymerMetal on the same part of the wear area in oversize of appr. 2 mm against the target diameter Apply a thin layer (max 0,5 mm) of PolymerMetal with a spatula with pressure on the second part of the wear area ( 2 on sketch) of the shaft to avoid air bubbles in the interface between metal and PolymerMetal; then apply PolymerMetal on the same part of the wear area in oversize of appr. 2 mm against the target diameter Go on applying PolymerMetal in the same way on all other parts of the wear area till the complete wear area is coated If possibly there is enough pot life, use a metal rule which is long enough (and therefore reaching over the complete wear length) to smoothen the surface of the PolymerMetal so that an oversize of only 1-2 mm remains Hint: the transitions shown in the sketch i.e. between part area 1 and part area 2 are fluid and do not have to be kept strictly

49 Variant 3: Shaft length of wear area > 150 mm and diameter < 200 mm Shaft hold by lathe has to run with a low turning speed during all following repair steps Apply a thin layer (max 0,5 mm) of PolymerMetal with a spatula with pressure on the first part of the wear area on the length of appr. 150 mm on the complete shaft perimeter to avoid air bubbles in the interface between metal and PolymerMetal; then apply PolymerMetal on the same part of the wear area in oversize of appr. 2 mm against the target diameter; use a metal rule which is long enough (and therefore reaching over the complete wear length) to smoothen the surface of the PolymerMetal so that an oversize of only 1-2 mm remains Apply a thin layer (max 0,5 mm) of PolymerMetal with a spatula with pressure on the second part of the wear area on the length of appr. 150 mm on the complete shaft perimeter; then apply PolymerMetal on the same part of the wear area in oversize of appr. 2 mm against the target diameter; use a metal rule which is long enough (and therefore reaching over the complete wear length) to smoothen the surface of the PolymerMetal so that an oversize of only 1-2 mm remains Go on applying PolymerMetal in the same way on all other parts and smoothen the surface of the PolymerMetal till the complete wear area is coated and pulled Variant 4: Shaft length of wear area > 150 mm and diameter > 200 mm Shaft hold by lathe has to be turned by hand during all following repair steps Divide the shaft into several max appr. 150 mm long areas Apply a thin layer (max 0,5 mm) of PolymerMetal with a spatula with pressure on the first shaft section of the wear area ( A on sketch) on the length of appr. 150 mm of the first part of the wear area to avoid air bubbles in the interface between metal and PolymerMetal; then apply PolymerMetal on the same part of the wear area in oversize of appr. 2 mm against the target diameter Apply a thin layer (max 0,5 mm) of PolymerMetal with a spatula with pressure on the first shaft section of the wear area ( A on sketch) on the length of appr. 150 mm of the second part of the wear area; then apply PolymerMetal on the same part of the wear area in oversize of appr. 2 mm against the target diameter Go on applying PolymerMetal in the same way on all other shaft sections and parts till the complete wear area is coated If possibly there is enough pot life, use a metal rule which is long enough (and therefore reaching over the complete wear length) to smoothen the surface of the PolymerMetal so that an oversize of only 1-2 mm remains

50 Further processing Wait till PolymerMetal has been totally cured (adhere to Technical data sheet) Further processing of the shaft without cooling/greasing agent Depending on used PolymerMetal machine the coated surface with Diamond or standard tools Material MM-metal SS-steel 382 MM-metal SS-steel MM-metal SS-aluminium MM-metal SS-copper MM-metal SS-bronze each with Hardener yellow MM-metal SS-steelceramic with Hardener yellow Ceramium with Hardener CE Molymetall with Hardener Molymetall Type of machining standard tools diamond tools General machining data Cutting speed v c Cutting depth a p Feed f Recommended machining data at rough turning Cutting speed v c Cutting depth a p Feed f Recommended machining data at finish turning Cutting speed v c Cutting depth a p Feed f m/min 0,5...1 mm 0,1...0,2 mm/u m/min 0,5...1 mm 0,1...0,2 mm/u 80 m/min 2 mm 0,125 mm/u 125 m/min 0,5 mm 0,125 mm/u * For machining we recommend to use Syndite (trademark of the De Beers Industrial Diamond Division ) PKD tools grade 010 respectively 025. After machining with PKD tools the surface quality of the coating has a medium peak-tovalley value of Ra 3,4 µm.

51 Technical Report PolymerMetal TEC-# 013 Wear tests Used products MM-metal SS-steelceramic / Ceramium / Ceramium DW Dry wear test linear amount of wear 400 Ceramium MM-metal SS-steelceramic tool steel HRC 65 construction steel St 37 The type of wear phenomena occurring at the tests corresponds with the sliding abrasion (three body abrasion) according to DIN Wet wear test Ceramium Ceramium DW tool steel HV 840 construction steel St volume wear in mm3 The type of wear phenomena occurring at the tests corresponds with the particle erosion (erosion water) according to DIN

52 Technical Report PolymerMetal TEC-# 014 Wear resistance Used products Ceramium Description Ceramium and Ceramium DW offer maximum wear resistance against continuing material loss on metallic surfaces.

53 TEC-# 019 Injection of PolymerMetal Technical Report PolymerMetal Used products MM-metal SS-steel 382, liquid / MM-metal SS-steel, liquid / Ceramium, liquid Description Next to a pasty or brushable application consistency many PolymerMetals are available in a liquid application consistency, too. An essential advantage of these liquid PolymerMetals is that they can be injected at i.e. difficult accessible repair sites to fill up hollow spaces or gaps in devices. Air bubbles embedded in the PolymerMetal do have a bad influence on the bonding between PolymerMetal and device. Therefore it is important, that the air can escape from the area which is supposed to be filled with PolymerMetal. We recommend drilling a channel, so the PolymerMetal can be injected. The channel should be constructed in a way that through the injection hole the PolymerMetal fills the space or gap from the bottom to the top so that the trapped air can escape.

54 Technical Report PolymerMetal TEC-# 020 Repair of a propeller shaft with PolymerMetals (short version) Used products MM-metal SS-steelceramic / MM-metal SS-steel 382 / MM-metal SSsteel/aluminium/copper/bronze / Ceramium / Molymetall Description PolymerMetals can be used to repair worn shafts by restoring material. Here the PolymerMetal can be applied during running shaft followed by turning down to nominal diameter. For this repair should be used one of the above mentioned PolymerMetals. Further information concerning the repair of a shaft with PolymerMetals can be found in the Technical Report TEC-# 008.

55 Technical Report PolymerMetal TEC-# 030 High stress due to temperature, chemicals (aggressive lye) and erosion affecting at the same time Used products Ceramium Experience report of a producer of aluminium oxide The favourable properties of the producer of the material Ceramium prompted us to check if the technical data are valid also for the present operating conditions. For a realistic evaluation it is important to record the operating times. Subject: examination concerning the removal of erosion damages with Ceramium Objekt/work piece: structural part of steel casting Brinell hardness 300 Medium: suspension consisting of - natrium aluminate lye Na 2 O 200 g/l - aluminium oxide Al 2 O g/l - ore remains (The aggressiveness of the Natrium aluminate lye more or less corresponds to natrium hydroxide NaOH of a concentration of 15%) Operating temp.: 135 C volume flow ~ 150 m 3 /h velocity 10 m/s Operating pressure: ~ 2 bar

56 Description: The standpipe to the C14B07 has a structural part made of steel casting of Brinell hardness 300. Damages were caused by erosion due to burbling and formation of whirls. According to the drawing on the right side the eroded areas were refilled with Ceramium pasty. Therefore the original wall thickness was restored. The surfaces were sand blasted, made dust free and degreased before. After appr. 4 months a revision was carried out. No visible erosion damages at the surfaces coated with Ceramium were found. The areas of the steel casting which were not coated with Ceramium showed very severe erosion damages. Result: The test showed that Ceramium fulfils the conditions for the repair of damaged metal surfaces. At the same time the wear resistance will be improved. Note: The original text of the customer was summarised.