INTERNAL REPORT ESSO PETROLEUM COMPANY FAWLEY REFINERY DUPLEX 18 STRAINER REFURBISHMENT

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INTRODUCTION INTERNAL REPORT ESSO PETROLEUM COMPANY FAWLEY REFINERY DUPLEX 18 STRAINER REFURBISHMENT This

Refinery. The strainer was severely corroded and in need of repair (see pictures 1-3).

baskets and the landings for the baskets.

1 INTRODUCTION INTERNAL REPORT ESSO PETROLEUM COMPANY FAWLEY REFINERY DUPLEX 18 STRAINER REFURBISHMENT This report details the coating work carried out on a Duplex 18 firewater strainer, one of three, for Fawley Refinery. The strainer was severely corroded and in need of repair (see pictures 1-3). The mechanical repairs were undertaken by Sulzer Bootham Engineering and included the replacement of the baskets and the landings for the baskets. It also required a full overhaul of the mechanical mechanism for operating the isolation of the two chambers in the strainer. PICTURE 1. PICTURE 2. ESSO FAWLEY PLENTY STRAINER REFURBISHMENT Page1 of 11

This was followed by the following coating applications: -!

2 PICTURE 3. The internal and eternal corrosion protection of the strainer casings required the removal of all mill scale, mud, debris, corrosion products and salt contamination before grit blasting all surfaces. This was followed by the following coating applications: -! EXTERNAL SURFACES (DFT 300µ ± 50µ) Coat 1 CHEMCO Epo-chem RS 500P Primer, DFT µ Coat 2 CHEMCO Epo-chem RA 500M glass filled epoxy, DFT µ Coat 3 CHEMCO Epo-chem RC 500GTC epoxy acrylic, DFT µ (Coat 3 to be Poppy red BS4800 colour code 04 E53)! INTERNAL SURFACES (DFT 1000µ ± 175µ Coat 1 CHEMCO Epo-chem RS 500P Primer, DFT of µ Coat 2 CHEMCO Ceram-chem RP 500 Ceramic epoxy blue, DFT µ Coat 3 CHEMCO Ceram-chem RP 500 Ceramic epoxy green, DFT µ Coat 4 CHEMCO Ceram-chem RP 500 Ceramic epoxy Blue, DFT µ (Deep holes and pitting to be filled, where possible with CHEMCO Ceram-chem RH 500 Ceramic putty) CLEANING & SALT REMOVAL Initial cleaning was achieved by UHP blasting, carried out by DF Coatings. This involved the blasting of the casing to remove the mud and mill scale. The casing was then left to dry followed by grit blasting to remove hard to remove mill scale and surface embedded salts. The casing was then left outside in the rain for a week to leach out further salts (see pictures 4-9) PICTURE 4. PICTURE 5. The main covers and ancillary equipment were then dried and blasted on the external surfaces to carry out the first two coats for the external surfaces to SA 2.5(see pictures 10-12). Whilst these items were being ESSO FAWLEY PLENTY STRAINER REFURBISHMENT Page2 of 11

3 coated with a RS 500P primer coat read, (See pictures 13 & 14), the external main body was also grit blasted to SA 2.5. (See Picture 15) PICTURE 6. PICTURE 7. PICTURE 8. PICTURE 9. PICTURE 10. PICTURE 11. PICTURE 12. ESSO FAWLEY PLENTY STRAINER REFURBISHMENT Page3 of 11

4 PICTURE 13. PICTURE 14. EXTERNAL COATING The ancillary parts were primed with RS 500P Red, the main body with RS 500P grey (See picture 16). The RA 500M was then applied over the primed surfaces after curing overnight. (See pictures 17 & 18) Picture 15. Picture 16. ESSO FAWLEY PLENTY STRAINER REFURBISHMENT Page4 of 11

Picture 17. Picture 18. The external coatings were left to cure over a weekend.

INTERNAL BLASTING & COATING The internal surfaces of the ancillary equipment and main body were blasted to an SA2.

The blasted surfaces were checked using Testex tape and the results showed the blasted surfaces to be between 114µ -156µ (See

After blasting the internal surfaces were vacuumed and wiped down with acetone.

5 Picture 17. Picture 18. The external coatings were left to cure over a weekend. The final topcoat, Epo-chem RC 500GTC Poppy Red, was left till the internal blasting and coating was completed. INTERNAL BLASTING & COATING The internal surfaces of the ancillary equipment and main body were blasted to an SA2.5 standard and minimum 75µ profile. The blasted surfaces were checked using Testex tape and the results showed the blasted surfaces to be between 114µ -156µ (See Pictures 19-22) Picture 19. Picture 20. Picture 21. Picture 22. After blasting the internal surfaces were vacuumed and wiped down with acetone. The right hand side outlet chamber, in particular, was badly pitted from corrosion damage (See picture 19 above). These pitted areas were largely filled with CHEMCO Ceram-chem RH 500 Ceramic Putty. The access to these pitted areas was very difficult, with a result that proper fairing could not be accomplished to our normal standards (See Pictures 23-25). ESSO FAWLEY PLENTY STRAINER REFURBISHMENT Page5 of 11

with acetone before applying the Epo-chem RS

internal surfaces (See pictures 28-30 below).

pitting on the faces (See pictures 26&27

6 Picture 23. Picture 24. Picture 25. The Ceram-chem RH 500 Ceramic putty was allowed to cure and then, as best as possible, faired using wheel flaps to remove the high points. The chamber was vacuumed again and wiped with acetone before applying the Epo-chem RS 500P grey epoxy primer to all the prepared internal surfaces (See pictures below). The inlet and outlet faces were also filled with Ceram-chem RH 500 ceramic putty to protect the faces from further corrosion pitting on the faces (See pictures 26&27 below). Picture 26. Picture 27. Picture 28. Picture 29. ESSO FAWLEY PLENTY STRAINER REFURBISHMENT Page6 of 11

7 Picture 30. The Primer coating was left overnight and was then over-coated with the first coat of Ceram-chem RP 500 Ceramic epoxy blue (See pictures 31-34). Picture 31. Picture 32. Picture 33. Picture 34. ESSO FAWLEY PLENTY STRAINER REFURBISHMENT Page7 of 11

The first coat RP 500 blue was left overnight to cure before application of the

The second coat RP 500 green was allowed to cure over night before the third and

second coat RP500 green (See pictures 39-42 below).

After completing the final blue coat of RP 500 the final coat of Epo-chem RC

8 The first coat RP 500 blue was left overnight to cure before application of the second coat RP 500 green (See pictures below). Picture 35. Picture 36. The second coat RP 500 green was allowed to cure over night before the third and final coat Ceram-chem RP 500 Ceramic filled epoxy blue was applied over the second coat RP500 green (See pictures below). FINAL EXTERNAL COAT Picture 37. Picture 38. After completing the final blue coat of RP 500 the final coat of Epo-chem RC 500GTC acrylic epoxy Poppy Red coat was applied to all external surfaces (See pictures below). ESSO FAWLEY PLENTY STRAINER REFURBISHMENT Page8 of 11

Picture 39. Picture 40. Picture 41. Picture 42.

surfaces were left to cure over a weekend prior to loading

Sulzer Bootham Engineering to re-assemble the strainer

47). Prior to loading the surfaces were measured for their

analysis and confirming that the recommended specifications

A separate report deals with the recording of the various

9 Picture 39. Picture 40. Picture 41. Picture 42. After completion if applying the final exterior coat the surfaces were left to cure over a weekend prior to loading the refurbished equipment on a truck for transport to Sulzer Bootham Engineering to re-assemble the strainer before returning it to Esso Petroleum Company (See picture 47). Prior to loading the surfaces were measured for their final DFT and the results captured on a computer for analysis and confirming that the recommended specifications mentioned above had been met. A separate report deals with the recording of the various readings of temperatures, profiles and DFT s. Picture 43. Picture 44. ESSO FAWLEY PLENTY STRAINER REFURBISHMENT Page9 of 11

Picture 45. Picture 46. TOUCH-UP AFTER REBUILD Picture 47.

touching up from handling and all the bolts, used to put the covers back onto the main body,

The bolts were rubbed down with a course emery cloth and then coated with Epo-chem RS 500P and left

10 Picture 45. Picture 46. TOUCH-UP AFTER REBUILD Picture 47. Once the strainer had been rebuilt, by Sulzer Bootham Engineering, the external body required touching up from handling and all the bolts, used to put the covers back onto the main body, required coating. The bolts were rubbed down with a course emery cloth and then coated with Epo-chem RS 500P and left to cure overnight before applying a coating of RC 500GTC Poppy Red over the bolts and other areas that had either been missed or damaged during the rebuild (See pictures 48-53). ESSO FAWLEY PLENTY STRAINER REFURBISHMENT Page10 of 11

11 Picture 48. Picture 49. Picture 50. Picture 51. Picture 52. Picture 53. ESSO FAWLEY PLENTY STRAINER REFURBISHMENT Page11 of 11

End Covers for coolers

APPLICATION REPORT End Covers for coolers Application: Place: Corrosion protection of end covers for coolers SUIM Workshop, Gran Canaria Date: October 2010 Job and report done by: Wencon products used: