CoatingsPro Magazine

JUL 2018

CoatingsPro offers an in-depth look at coatings based on case studies, successful business operation, new products, industry news, and the safe and profitable use of coatings and equipment.

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COATINGSPRO JULY 2018 51 Prior to blasting, the crew installed Werner extendable work platforms inside the tanks. "We always start at the back so the blasting doesn't blow abrasives toward the surface we want to blast next," said Hartgraves. "We do the bottom first so later we're not trying to blast through spent abrasives on the floor." e crew worked their blast nozzles efficiently, but the tightly adhered Munkadur Latiglas wasn't cooperating. With 40,000 square feet (3,716.1 m²) of steel to be prepped, any delay now might affect Enerfab PC&L's ability to meet the deadline. Someone had to figure out a way around this bottleneck! "One hiccup at the beginning involved the distance from the laydown yard to the floors we were working on," said Enerfab PC&L Project Manager Rachel Ritter. "Some of the hose runs were hundreds of feet, so you can only imagine how much air pressure was being lost. Once we figured out the problem, we rented a 375-cfm [10.6 m³/min.] compressor from Sunbelt to add to the 1600-cfm [45.3 m³/min.] rig. at gave us sufficient air pressure. Vacuuming was slow at first, too, so we rerouted suction hoses to shorten up runs and to take advan- tage of the vertical drops to the BlastMaster Vacuload IV in the laydown yard." To prep, the crew blasted the steel and then swept, vacuumed, and repeated until they removed all dust and other contaminants. They ran long hoses between the equipment, staging area, and tanks throughout the job. Using a confined space permit, manway monitors, and full-body harnesses, the crew spray applied a single coat of epoxy from Munk + Schmitz. In total, they covered approximately 40,000 square feet (3,716.1 m²). JOB AT A GLANCE PROJECT: Abrasive blast and spray apply new interior coating system on 24 beer tanks at a major brewery COATINGS CONTRACTOR: Enerfab, Inc. 4955 Spring Grove Ave. Cincinnati, OH 45232 (513) 641-0500 www.enerfab.com SIZE OF CONTRACTOR: The Protective Coatings & Linings (PC&L) division typically has a full-time staff of 8 to 10 SIZE OF CREW: Up to 20 crew members with local labor helped PRIME CLIENT: An internationally known brewer that requested to remain nameless SUBSTRATE: Carbon steel CONDITION OF SUBSTRATE: Excellent condition SIZE OF JOB: ~40,000 sq. ft. (3,716.1 m²) DURATION: 4½ months UNUSUAL FACTORS/CHALLENGES: » The tanks were situated on four floors in a functioning brewery. » Ambient air temperature in cellar was 38 °F (3.3 °C) on average. » Long hoses had to be run between equipment, the staging area, and the tanks. MATERIALS/PROCESSES: » Insulated tanks and preheated to 58 °F to 62 °F (14.4—16.7 °C) » Abrasive blasted with coal slag to achieve NACE No. 2/Society for Protective Coatings (SSPC) Surface Preparation 10: Near-White Metal Blast to a 4-mil (101.6 microns) average anchor profile » Swept, vacuumed, and repeated until tank interiors were free of dust and contaminants » Spray applied one coat of Munk + Schmitz Munkadur GL epoxy to achieve approximately 20 mils (508.0 microns) dry film thickness (DFT) SAFETY CONSIDERATIONS: » Wore hard hats, steel-toed boots, safety glasses, and high-visibility clothing » Used confined space permits and manway monitors and wore full-body harnesses while inside the tanks » Utilized LOTOs (lockout/tag out locks) to prevent accidental opening of pressurized pipes that might result in injury » Wore air-supplied blast hoods and breather boxes when blasting, and Tyvek suits when spraying

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