Surface Preparation in an ATEX Zone for Leaking Tank Repair
Surface preparation in an ATEX zone was a key part of repairing a leaking, insulated storage tank. Gas leaks had developed in the rear plate of a metal enclosure around a flange connection. Restricted access and the hazardous environment required a carefully planned approach. Using Allmet tools, the team prepared the surface for a Belzona repair. All work was completed during a one-day shutdown.
Leaks Beneath the Insulation
A metal enclosure had been installed around the flange connection to make it easier to fit the insulation. Several small leaks had developed in the enclosure’s rear plate, on the tank side. The damage extended into areas beneath the insulation that were difficult to reach.
Before carrying out the repair, the team needed to expose the leaking area and prepare the surface. Both the ATEX environment and the limited working space around the flange influenced the approach.
Surface Preparation with Allmet
The team used the A-0155 Surface Grinder with the A-0500 Grinding Disc for Paint. This combination is designed for cold work surface preparation, including coating removal and the preparation of metal substrates. The pneumatic A-0155 is certified for use in ATEX gas zones 1 and 2.
Using Allmet tools, the team exposed and ground the area around the flange, providing access to the damaged substrate. This was an important stage of the project, as the surrounding structure restricted access to the leaking areas.
This method of surface preparation in ATEX zones allowed the team to prepare the substrate without hot work, subject to the applicable site safety requirements.
Belzona Repair for Elevated Operating Temperatures
Following surface preparation, the team filled the damaged areas with Belzona 1511 (Super HT-Metal). This repair composite is designed for rebuilding metal equipment operating at elevated temperatures.
The team then applied Belzona SuperWrap II with Belzona 1983, the resin grade designed for higher operating temperatures. The composite repair was applied in two layers with a 50% overlap.
Allmet surface preparation provided the starting point for the repair: exposing the damaged area and preparing the substrate for the subsequent Belzona application.
All Work Completed in One Day
Surface preparation and the Belzona repair were completed during the same one-day shutdown. Following the repair, no further leakage was observed and the insulation could be reinstated.
By responding quickly and using cold work methods for both preparation and repair, the team completed the work within the available shutdown.
Preparing a repair in an ATEX zone? Contact us to discuss which Allmet tools suit your substrate and access requirements.