ENECON solution to protect rudders against cavitation ... · corrosion, erosion and cavitation. The...

ENECON solution to protectrudders against cavitation,erosion and corrosion

ENECON solution to protectrudders against cavitation,erosion and corrosion

POLIMERI ITALIA

PROTECTION OF NAVAL RUDDERS AGAINST «CAVITATION», «CORROSION», «EROSION» WITH ENECON COMPOSITE POLYMER

In this documentr we will show an application of Enecon polymers for the solution of problems such as marine corrosion, erosion and cavitation.

The use of Enecon polymers guarantees the possibility to restore and protect metal surfaces in a quick and economic solution.

The Project "RUDDER NAVAL" was performed on the rudders of a cruise ship during dry dock.

One of the problems highlighted was a strong cavitation in some specific points of the rudders.

The entire project was to protect two rudders for a total area of about 120 square meters of a cruise ship. The project duration was 4 days.

NAVAL RUDDERS PROJECT

POLIMERI ITALIA

PRESENTATION

Introduction to ENECON Solution

REFERENCES

Similar application Worldwide with ENECON polymers

PRODUCT

Description and Techinical data of ENECON product used in this project

«RUDDERS PROJECT»

Description of the project step by step

Summary

POLIMERI ITALIA

ENECON POLIMERI ITALIA SRL Via Luigi Masotti,16

48100 Ravenna - Italia tel. e fax 0544.200.541

www.enecon.it - [email protected]

Recognized world leader in the development of the technology of polymer composites, Enecon organization has opened the way for a revolutionary coating system for the Marine Industry, Petrochemical and Power.

ENECON ITALIA operate mainly in the field of maintenance with range of products and solutions that reduce operating costs and solve problems such as:

Corrosion - Erosion - Cavitation - Abrasion - Chemical atack - Calcification

Our engineers have developed the first non-slip coating approved by the American Navy and the first product approved by the Department of Defense Specification C-24176 for hull protection

Our polymer composites, ceramic and urethane, are the basic products for the maintenance of:

naval rudders, keels, heat exchangers, condensers, pumps, protection of landing bridges, repairs of plants, containment areas, etc...

We extended the "Pot Life" (time of application) to facilitate the application. All carcinogens have been kept out of our formulations.

The polymers are on the approved list Enecon ABS, Lloyd's Register, Korean Shipping, IMPA.

Enecon is the organization you can contact when the problems in flow systems are costing you time and money

POLIMERI ITALIA

American Bureau of Shipping

Lloyd’s Register

Specifiche militari

Korean Register

INTERNATION CERTIFICATION

In 20 years activities,Enecon organization was able to obtain certifications and awards in all industries, from shipbuilding, to industrial, governments to power plants.

All product are included in the IMPA codes with reference to marine product used on ship

Below are some of the certificates of the most important institutions that have issued their certification attesting polymers Enecon as suitable for the repair of equipment from erosion, corrosion, cavitation.

Copyright © 2013 ENECON POLIMERI ITALIA

POLIMERI ITALIA

ENECON POLYMERS

USED TO PROTECT

RUDDERS IN KOREA

Photo of an application in a Korean shipyard

POLIMERI ITALIA

FLEXICLAD

PROTECTS RUDDERS

FOR US NAVY SINCE 1995

DURATOUGH

POLIMERI ITALIA


FLEXICLAD

DURATOUGH

AND

CERAMALLOY

PROTECTS

RUDDERS

PHOTO OF AN APPLICATION ON RUDDERS ON A SHIP OF HANSA SHIPPING

POLIMERI ITALIA

THE MINISTRY OF DEFENCE OF CANADA SELECT ENECON PRODUCT TO SOLVE CAVITATION, CORROSION PROBLEM ON THEIR VESSEL

POLIMERI ITALIA

THE US COAST GUARD SELECT FLEXICLAD TO SOLVE CAVITATION PROBLEMS ON THEIR VESSEL


POLIMERI ITALIA

ITALIAN SHIPPINGCOMPANY SELECTCERAMALLOY ANDFLEXICLAD TO PROTECT EQUIPMENTSAGAINST CAVITATIONAND CORROSION

REBUILDING SURFACEWITH CERAMALLOY

BEFORE BLASTING

PROTECTION WITH FLEXICLAD

POLIMERI ITALIA


SINGAPORE SHIPPINGCOMPANY SELECT

FLEXICLAD TO PROTECT AGAINST

CAVITATIONAND CORROSION

POLIMERI ITALIA

CeramAlloy CL+AC is a two component, 100% solids, liquid polymer composite used for repairing, resurfacing and coating both damaged and new components to provide outstanding fluid flow erosion and corrosion resistance. When mixed, is a viscous liquid. cures to a hard, ceramic-like material with an extremely smooth surface finish.

Repairs & Protects... Heat Exchanger ,Tube Sheets &

Water Boxes, Pumps, Valves & Pipework, Housings & Tanks, Cooling Towers

...and more

Physical properties

Tensile Shear AdhesionSteel 3700 psi 259 kg/cmqAlluminio 2700 psi 189 kg/cmq

Chemical ResistenceGasolio: EccellenteAcido solforico (10-20%): Eccellente Acido cloridrico (10-20%): Eccellente

Densità dopo la polimerizzazione 1,28 gr/cc

FLEXICLAD® DuraTough™ DP is a two component, 100% solids elasto-ceramic polymer composite specifically formulated to rebuild equipment prone to cavitation attack and subsequent damage. DuraTough™ combines the superior strength, durability and adhesion of an epoxy with the exceptional flexibility, abrasion resistance and shock-absorbency of an elastomeric urethane.

Rudders, pumps, gaskets, flexible equipment, ect.. Proprietà Fisiche

Resistenza al taglioAcciao 3700 psi 259 kg/cmqAlluminio 2700 psi 189 kg/cmqRame 3000 psi 210 kg/cmq

Resistenza chimicaGasolio: EccellenteAcido solforico (10-20%): Eccellente Acido cloridrico (10-20%): Eccellente


FLEXICLAD DuraTough DL is a two component, 100% solids, fluid consistency elasto-ceramic polymer composite specifically formulated to protect equipment subject to cavitation accelerated erosion / corrosion.

FLEXICLAD DuraTough™ DL combines the superior strength, durability and adhesion of an epoxy with the exceptional flexibility, abrasion resistance and shock-absorbancy of an elastomeric urethane.

Rudders, pumps, gaskets, flexible equipment, ect..

Proprietà Fisiche

Resistenza al taglioAcciao 3700 psi 259 kg/cmqAlluminio 2700 psi 189 kg/cmqRame 3000 psi 210 kg/cmq

Resistenza chimicaGasolio: EccellenteAcido solforico (10-20%): Eccellente Acido cloridrico (10-20%): Eccellente


PRODUCT


Rebuilds equipment damaged by cavitation.

POLIMERI ITALIA

COMPARATIVE TEST FOR RESISTANCE TO CAVITATION

“Cumulative Mean Depth Loss” [CMDL]

Duration: 24 hours

Frequence: 20 KHz

Amplitude: 0.001 pollici

Test carried out according to the standard: ASTM G-32

FLEXICLAD DuraTough DL

Material

DuraTough DL

Carbon Steel

316 Stainless Steel

3M 2216 B/A Gray

Loss

50

240

60

207

Du

raTo

ug

h D

L

3M

22

16

B/A

Gra

y

300

200

100

0

MATERIAL

PERDITA

Ca

rbo

n S

tee

l

31

6 S

tain

less S

tee

l

PRODUCT

POLIMERI ITALIA

Analysis of the Problem

The inspectors of the shipowner found on the rudders of the cruise ship the progress of cavitation in some areas.

The inspectors contacted the tEnecon ITALY in order to obtain a solution to their problems.

The technicians of Enecon ITALY suggested to protect the rudders with their polymer composites to control cavitation, erosion and corrosion

Enecon solution

With reference to past experience and thanks to the success achieved by the system FLEXICLAD and CERAMALLOY, Enecon Italia engineers have proposed the following treatment:

A) Surface preparation by sandblasting to white metal to remove traces of oxidation or previous coating.

B) coating with CeramAlloy, to block the propagation of corrosion

providing a coating on the metal surface with a strong resistance to erosion.

C) Complete the treatment with Flexiclad Duratough to protect areas subject to cavitation

initial test

During the month of October 2012 was carried out, at Fincantieri in Trieste, treatment as shown in the following pages

TREATMENT

POLIMERI ITALIA

With reference to product data sheet, pot life and our specimen, we have prepared a graphic realization of the procedure performed on the rudder naval

After surface preparation, we applied the first layer of CeramAlloy CL

We then reconstructed the cavitated area with the paste-like polymer DuraTough DP

Applied a first coat of liquid DL DuraTough in cavitation area

Applied a second coat of liquid DL DuraTough in cavitaion area

Application over the rest of the surface of the liquid CeramAlloy CL+AC

The overlap of 50 mm of the CeramAlloy on DuraTough is necessary to ensure the maximum adhesion of the Anticavitation treatment

Treatment description

Metal surface

DuraTough DL( f i r s t coa t )

50mm

CeramAlloy CL (first coat)

CeramAlloy CL (second coat)

DuraTough DL(second coat)

DuraTough DP

Cavitation

TREATMENT

POLIMERI ITALIA

Treatment Description

Surface Preparation

In order to get the best results, surfaces must be sandblasted to remove old coatings, traces of oil and moisture.

Through a specialized company, we proceeded to carry out blasting with aluminum oxide or equivalent to the degree NACE1 or SA3, white metal, with angular profile of 76 microns.

After blasting and machining, the surface has been cleaned with solvents that leave no residue.

Once the step of surface preparation is passed to the subsequent stages of the treatment

The application of protective systems Enecon require a working cycle as follows:

- Surface Preparation

- Repair damaged metal parts

- Surface Treatment against corrosion

- Surface Treatment against cavitation


TREATMENT

POLIMERI ITALIA

Repair damaged metal parts

After surface preparation, we proceeded to repair most of the surfaces damaged by cavitation.

We used CeramAlloy CL + AC as a primer and CeramAlloy CP + AC, in paste form, to reconstruct missing or thicknesses as in the photos illustrate to uniform the surface after the welding operations. (photo 1)

After the reconstruction phase, we applied the system Flexiclad through the use of his Primer (photo 2) and the polymer paste DuraTough DP (photo 3).


TREATMENT

POLIMERI ITALIA

Surface Treatment against corrosion

For parts of the rudder not subject to cavitation was decided to perform a treatment with the system Metalclad CeramAlloy CL + AC, two-component ceramic ideal to give maximum protection from erosion and corrosion.

The application of the polymer CeramAlloy CL + AC has required the preparation of two layers for final thickness of about 600 microns.


TREATMENT

POLIMERI ITALIA

Surface Treatment against cavitation

For parts of the rudder subject to cavitation, the treatment performed included the application of the system Flexiclad DuraTough DL.

We applied a first coat of CeramAlloy CL + AC as primer and then completed the treatment with two layers of different color of DuraTough DL for a final thickness of about 1.6 mm.


TREATMENT

POLIMERI ITALIA

0544.200.541

24 ore - 7 giorni su 7

POLIMERIITALIA

TREATMENT

POLIMERI ITALIA

ENECON POLIMERI ITALIA SRL Via Luigi Masotti,16 48100 Ravenna - Italia tel. e fax 0544.200.541www.enecon.it - [email protected]

POLIMERI ITALIA

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