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African Petrochemicals Quarterly Edition 15_6

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THERMASPRAY BOOSTS PETROCHEMICAL INDUSTRY PORTFOLIO WITH NEW LASER CLADDING TECHNOLOGY Thermaspray, a powerhouse in the delivery of turnkey coating service solutions to southern African industry, recently extended its impressive offering with the introduction of innovative laser cladding technology. 10 “As one of South Africa’s leading surface engineering specialists, we boast an extensive range of coating and welding solutions including thermal spray coatings, polymerbased coatings, and Plasma Transferred Arc (PTA) cladding as well as machine shop capabilities,” states Thermaspray’s Managing Director, Dr. Jan Lourens. “The addition of laser cladding technology has further enhanced our capabilities to meet the petrochemical industry’s refurbishment and surface engineering needs.” According to Laser Cladding Technician, Jordaan Lourens, who will oversee the new product portfolio, the petrochemical industry is of substantial significance in the South African market, making up approximately 5% of Gross Domestic Product. “This industry boasts a number of key blue-chip companies who conduct large scale operations, giving rise to extensive scope for laser cladding refurbishment in this space.” Laser cladding, a coating process akin to welding, has been developed for aggressive environments typically found in the petrochemical industry. Compared to thermal spray methods which are mechanically bonded to the substrate material, laser cladding forms a metallurgical bond with the substrate material making laser clad coatings far less prone to cracking under point loading or impact and far more forgiving to impacts and bumps. Laser cladding enables accurate localised application of weld beads and thus presents the perfect solution for applications where localised refurbishment and sensitivity to distortion are key. Compared to similar refurbishment and/or surface engineering methods that increase service life and/or restore components to better-than-new condition, laser cladding technology is known worldwide to offer coatings that exhibit notably low heat input into the component substrate, exceptionally low porosities and low dilution with substrate material. Jordaan points out that because of the very low heat input from the process, distortion of a component is far easier to manage. “These superior properties put laser cladding into a league of its own. Due to laser cladding’s impressively high resistance to wear and abrasion, corrosive environments and erosive applications, these coatings are easier to apply to a variety of components. In short, when the surface of a component is enhanced with a laser clad coating, it will significantly extend the service life of that component before refurbishment is once again needed. The fact that the components remain in service longer, leads to improved uptime and productivity and ultimately reduces total cost of ownership for customers and end-users.” This technology is perfectly suited for both component refurbishment to OEM specifications as well as surface enhancement of new components, ensuring that components remain in service for longer. Typical components in the petrochemical industry that will benefit from laser clad coatings include offshore rig tension shafts, hydraulic shafts, drive components, drill bit components, stabilisers, reamers, wear bands and bearing- or seal-journals on shafts in general. Alongside the petrochemical industry, power generation, automotive, mining, oil and gas, pumps and agriculture sectors also successfully make use of this proven laser cladding technology on components such as industrial gas turbine blade tips and turbine rotors, down-the-hole (DTH) drilling equipment, gearbox housings, crankshafts, guides and rollers, boiler tubes and logging equipment. Jordaan notes that while they are looking forward to presenting laser cladding to the local petrochemical industry, they are also cognisant of the challenges. He explains, “The petrochemical industry is saturated with offshore companies that will readily use highly cost-effective refurbishment services or replacement of parts from their OEMs situated in other countries. Thermaspray, as one of only a very few companies in South Africa to offer laser cladding technology that is compliant to international standards, combined with our more than two decades of experience in surface engineering and coating technologies, is uniquely positioned to offer these companies a financially beneficial solution.“ Laser cladding will be done at Thermaspray’s well-equipped, custom-built facility in Olifantsfontein, Johannesburg, with production commencing in January 2019. “Working closely with an international welding engineer who does consultative work for us, we successfully combine extensive global knowledge and experience with local expertise to offer the surface engineering market a turnkey solution,” concludes Jordaan. Thermaspray is a ISO 9001:2015 certified company and is in the process of obtaining ISO 3834 certification which is the quality standard for welding applications. /ends About Thermaspray Thermaspray, headquartered in Olifantsfontein, Johannesburg, has 23 years’ experience in wear- and corrosionresistant thermal spray coatings. In addition to providing a comprehensive range of support coating finishing technologies in the bespoke finishing shop, Thermaspray also refurbishes industrial components damaged by wear and corrosion. The company’s in-house, metallurgical laboratory is the only dedicated facility of its kind in Africa’s thermal spray industry and is equipped to undertake world-class developments and quality control. Thermaspray is a DQS ISO 9001 Quality Management and Eskom level 1 certified company. About Surcotec Surcotec is the oldest established thermal spray coating company in the Western Cape. The company has a wealth of experience in thermal spray coatings and mechanical component refurbishing. Surcotec’s coating services are supported by a fully equipped engineering workshop and an on-site machining division. A level 1 B-BBEE company, Surcotec is TNV ISO 9001 Quality Management certified and is certified as a level 2 nuclear supplier to Eskom. Contact: Tel: +27 (0) 11 316 6520/8/9 Fax: +27 (0) 11 316 7527 Website: Blog: / YouTube:

MINEARC SYSTEMS: PROVIDING LIFE-SUPPORT SOLUTIONS TO THE PETROCHEMICAL INDUSTRY It is not uncommon to find shelter-in-place or safe haven locations designated within chemical facilities across the globe. What varies is the level of protection. Functionality can range from merely a muster point (shelter-in-place) to an external positively pressurized room (safe haven). MineARC has been providing ChemSAFE Safe Haven and Shelter-in-Place solutions to the petrochemical, refining and power generation industries for almost 10 years. Understanding that emergency response requirements differ greatly between sites depending on their processing conditions, the location of personnel and dangerous goods inventory, MineARC has a team of experienced engineers and industry professionals to assist in the consultation and design process; resulting in a safe haven solution to best suit each individual petrochemical facility. ChemSAFE Exterior. MineARC’s ChemSAFE solutions offer a safe and secure ‘go-to’ area for multiple personnel in the event of a toxic chemical release, fire, explosion or other hazardous emergency response scenarios. The range includes fully transportable Safe Havens as well as ‘Shelter-in-Place’ Room Conversions with purpose-built life support systems. ChemSAFE Safe Havens provide a unique and cost-effective alternative to shelter-in-place; allowing flexibility as site requirements shift over time. MineARC’s Safe Havens are meticulously engineered to ensure complete protection from the outside environment, including a robust shell with up to 12psi blast rating, a fully pressurised vestibule and 0% ACH (External Air Change per Hour). The ChemSAFE Safe Haven boasts a range of unique life-support features that have been engineered specifically for sustaining life in an enclosed environment. Systems include; a proprietary CO/CO2 ‘scrubbing’ system with digital control and voice prompts, breathable oxygen supply, air conditioning, an advanced digital gas monitoring system, and UPS battery backup. Select safe havens also feature the GuardIAN Remote Monitoring and Diagnostics System; allowing shelters to be monitored and observed from anywhere within the facility or even off-site. Alternatively, MineARC’s ChemSAFE Shelter-in-Place Rooms Conversions are intended for petrochemical facilities that wish to use an existing room, or do not have the physical space for a portable Safe Haven. These modular constructed rooms are designed to have minimal Air Changes per Hour (ACH). By incorporating a range of MineARC’s life support systems such as the AirGEN, AirBANK and AirMAX, facilities can be confident that occupants will remain safe for the entire duration of the emergency. In the case of conducting a Shelter-in-Place Room Conversion, MineARC petrochemical industry specialists work closely with each site to develop a turnkey solution that suits their requirements. The process starts with a site assessment to determine the suitability of any shelter-in-place location for conversion. This may also include a blower door or tracer gas test to generate a baseline for the room’s leakage and ultimately its potential infiltration concentration rate. Conventional manual sealing of the room is then undertaken and generally includes the installation of a clean room-style roof and lighting. The removal of windows and installation of purposedesigned doors and/or door sweeps provide further air-tightness. This ChemSAFE Interior. type of conventional sealing can improve the tightness of a typical room by at least twofold. If further sealing is necessary, aerosol-based envelope sealing has been used effectively to seal orifices that cannot be sealed by manual means. One of MineARC’s clients has shown this type of sealing to improve the air-tightness of its safe haven rooms by up to 90 percent. A final post-sealing blower door or tracer gas test is then needed to determine the safe haven’s final leakage rate. Infiltration concentration rates are once again calculated by MineARC engineers. With manufacturing facilities in South Africa, Australia and North America, MineARC Systems provides safe haven equipment to Nutrien, INVISTA, Chemours, Duke Energy, BP Castrol, IOWA Fertilizer, Yara, PetroChina, Vopak and many other global petrochemical customers. For more information contact our South African office: Tel: +27 (0) 11 796-5162 Website: 11


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