Problem Statement

At the VRA Thermal Plant, pipelines transporting natural gas and light crude oil faced severe corrosion issues due to the coastal location and corrosive substances including moisture, humidity, and acid/sulphur content in the transported fuel. This corrosion led to frequent maintenance and repairs, escalating operational costs and causing significant downtime, which disrupted power generation. Additionally, the risk of leaks from corroded pipelines raised safety and environmental concerns. Existing corrosion control measures were insufficient, necessitating a more effective and durable solution.

Solution

To tackle the corrosion issues, VHL offered a comprehensive solution with our specialized 3-coat system from Sherwin Williams. We started the process with a thorough surface preparation of the pipelines to remove rust, dirt, and old coatings. Macropoxy C402V2, a high-build epoxy primer, was then applied for excellent adhesion and corrosion resistance. Macropoxy 400, a high-performance epoxy midcoat that added durability and enhanced barrier properties, followed this. Finally, Acrolon 7300, a polyurethane topcoat, was applied for UV resistance, colour retention, and a durable, glossy finish, improving both functionality and appearance.

Outcome

The Sherwin Williams coating system we implemented significantly improved corrosion protection for the VRA Thermal Plant. The multi-layered system extended the pipelines’ lifespan, reduced maintenance costs, and minimized operational downtime due to corrosion. The enhanced pipeline integrity and the coating’s durable properties also improved plant safety by reducing leak risks and potential hazards

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