How to Repair and Protect High-Temperature Process Vessels | PART 2

Part 2: Long-Term Protection for High-Temperature Process Vessels with Belzona 1593

This blog post is part two of a two-step guide for the protection of high-temperature vessels. First, part one details how to mend pitting damage using Belzona 1511 (Super HT-Metal). This second section offers a step-by-step guide of how to apply an overcoat of Belzona 1593 to ensure lasting protection against corrosion and chemicals. 

Click Here to Read Part 1 of the Article

Why Should Belzona Be Used to Protect High-Temperature Process Vessels? 

Once pitting damage has been repaired, Belzona recommends protecting the vessel using a high-temperature epoxy coating, such as Belzona 1593. This product was designed to provide long-term protection for process vessels operating in harsh conditions, including elevated temperatures up to 320°F (160°C) under continuous immersion in aqueous/hydrocarbon conditions.

How to Protect a Protect Vessel with a High-Temperature Lining  

Step 1: Surface Preparation 

The Belzona 1511 (Super HT-Metal) repair has a 24-hour overcoat window, during this time the Belzona 1593 can be applied with no additional surface preparation. If applying the coating outside of this window, the surface will need frost blasting to achieve a surface profile of 1.6 mils (40 microns) prior to the epoxy coating being applied. 

Step 2: Mixing the Product 

Next, transfer the entire contents of the Belzona 1593 Solidifier container into the Base container (or measure out a ratio of 11:1). The two components should then be mixed thoroughly to achieve a uniform colour, free of any streaks. 

Mix the base and solidifier until a uniform colour is achieved 

Step 3: First Coat of Belzona 1593 

Using a brush or Belzona applicator, apply the product directly onto the prepared surface, ensuring a consistent coating. More detailed areas, such as brackets and welds, may need to be stripe-coated before the main application area. Once a uniform thickness is achieved, take regular wet film thickness readings and adjust accordingly. Make sure to evenly coat the entire prepared surface, as well as any nearby surfaces that need protection.

Apply the first coat of Belzona 1593 

Step 4: Applying the Second Coat 

As soon as the initial coat is sufficiently firm, a second coat should be applied for greater corrosion and chemical protection. Whilst this is usually six to eight hours after the application of the first coat, the timeframes vary depending on application temperature, so please refer to the IFU for more specific overcoat information.   

Apply a Second Coat of Belzona 1593

Step 5: Leave to Cure 

Once the second coat has cured, a DFT test should be performed to ensure the final target thickness has been achieved. Any areas that do not meet this target can be marked up and a local repair coat can be applied. 

The fast-curing time of Belzona 1593 will allow a quick return to service, and once cured this product forms a robust, chemical-resistant lining. Additionally, the system withstands the steam-out process up to 482°F (250°C) and rapid depressurisation. 

Once cured, perform a DFT test to ensure target thickness has been achieved 

Using Belzona 1511 (Super HT-Metal) for pit filling followed by Belzona 1593 for internal lining effectively repairs and protects process vessels from hydrocarbons, process chemicals, and aqueous solutions for the long term. With Belzona solutions, process vessels and other equipment can extend their service life, reducing downtime and maximising productivity. 

Watch This Video to See the Application in its Entirety: 


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