A condenser unit in service at a fertilizer plant required surface preparation work and a protective coating. On arrival at Corroserve’s workshop corrosion was evident on the internals of the water boxes and on the condenser tube face as evidenced in the image to the left.

The unit was abrasive blasted to Sa21⁄2 to provide a minimum surface profile of 50μm. Corroglass 600 series was then applied to the internals to achieve a minimum dft of 1500μm. During the blasting /coating procedure the ends of the condenser tubes were protected by inserting rubber plugs into the tube ends. This was done not only to protect the tube ends from the abrasive but also to ensure that no abrasive or debris could enter the tubes themselves.

When cured thickness and spark testing was completed to ensure the correct DFT was achieved in all areas and to identify any holidays and ensure the quality of the coating. The external surfaces were blasted to Sa2 and given two coats of Plasmet ZF followed by a final coat of industrial enamel.