Surface Engineering Workshop - ranadityo.co.idranadityo.co.id/wp-content/uploads/2018/10/1A.-LOCTITE-SEW-General.pdf · • Chemical Content 8/9/2016 Surface Engineering Workshop

Surface Engineering Workshop

Budi Sulistyo Nugroho

August 9, 20162

Henkel at Glance

• Henkel is a global company serve for consumer and industrial business, headquartered in Dusseldorf, Germany

• 2011 revenue 15.61 billion Euro, spent 468 million Euro for R&D

August 9, 20163

Henkel at Glance

• Has 3 business area: home care; personal care; adhesive sealant and surface treatment for industrial

• Henkel Indonesien: Gedung Talavera, Jl. TB Simatupang, Jakarta• Website: www.henkel.com

August 9, 20164

The Industries we serve…• Power Generation

• Petrochemical

• Mining

• Mineral Processing

• Fertilizer

• Pulp & Paper

• Marine & Offshore

• Food & Beverage

• Water Utilities

• Steel Production

• Alumina, Cement

• OEMs

• Oil & Gas Plant

August 9, 2016 Title and author of presentationSlide 5 August 9, 2016Slide 5

Agenda

• Introduction.

• Composite Material• MRO Special Products• Materi Optional: • Anaerobic:

a. Threadlockerb. Threadsealantc. Retainingd. Gasketing

• Presentation time = 60 - 90 minutes.

August 9, 20166

Water Pump

August 9, 20167

• Causes Of Failure :

• Corrosion

• Abrasion

• Cavitation

• Scale formation

Water Pump and Vacuum PumpCorrosion and Erosion

August 9, 20168

Product Recommended for Rebuilding:

Loctite Wear Resistant Putty / Loctite Superior Metal

• Ceramic Fibre Reinforced

• Machinable when still in semi cured state

• More wear resistant than metal filled putties

Water Pump Corrosion and Erosion

August 9, 2016 Title and author of presentationSlide 9

• Product Recommended to protect surfaces:

Nordbak Brushable Ceramic

• Smooth, glossy low coefficient of friction

• Corrosion and erosion resistant

• Also available for High Temperature Brushable Ceramic

Water Pump and Vacuum PumpCorrosion and Erosion

Cooling Water Pump PT Pertamina Plaju• Erosion & Corrosion of Outer & Inner

8/9/2016 Surface Engineering Workshop – Loctite Applications in Power Plant

• Causes of Failure• Abrasion and Flow of liquid particles leads to surfaces wearing

out



Solution • Surface preparation

• Cleaning with degreaser/solvent• Blasting SA 2.5-3• Blow with air compressor

• Apply Hold Coat of Loctite Superior Metal & Chemical Resistance Coating at the inner surface

• Rebuild the surface with Loctite Superior Metal & Chemical Resistance Coating to prevent further corrosion and abrasion



Product Recommended

Fixmaster Superior Metal • Two part ferro silicone based epoxy• Machinable • High compressive strength – 124 N/mm2

(18,000 psi)• Cure time 6 hrs.• Ideal for rebuilding shafts, bearing

housing • Pack size – 408 gm



Product Recommended

Chemical Resistant Coating• Polyurethane bisphenol system for

extreme Chemical resistance• Smooth glossy low friction surface• Light grey color• Temp. resistant 160 ℃ ( Dry ) 65 ℃ ( Wet) • Ideal for lining tanks and chutes, lining

chemical containment areas, pump bases



Application Case History • Customer / Country

• PT Pertamina Plaju (Oct 2013)/ Indonesia

• Problem / Application• Erosion & Corrosion of Outer & Inner

Cooling Water Pump• Corrosion Protection coating of inner &

Outer surface• Solution

• Loctite Superior Metal & Chemical Resistance Coating

• Benefits• Process cuts • Doubled the life of the asset


August 9, 201616

Shaft

August 9, 201617


• Friction with Bearing

• Corrosion

• Over Load

ShaftWorn Out

August 9, 201618


Loctite Loctite Superior Metal

• Ceramic Fibre Reinforced

• Machinable when still in semi cured state

• More wear resistant than metal filled putties

Shaft Worn Out

August 9, 201619

Benefit:

a. No Heat means No Bending

b. Easy application

c. Cost Reduction

Shaft Worn Out

C:/Users/nugrohob/Documents/Literatur/VIDEO_TS/Superior Metal.wmv

C:/Users/nugrohob/Documents/Literatur/VIDEO_TS/Superior Metal.wmv

August 9, 201620

Concrete and Foundation

August 9, 201621


• Oil & Chemical Spillage

• Corrosion of Pump Base frame due to Sea Water or Chemical Attack

Concrete and FoundationDegradation

August 9, 201622

Concrete and FoundationDegradation

• Product Recommended :

• Loctite Fixmaster Concrete Sealer

Acts as a sealer and primer for

Chemical resistant coating

• Nordbak Chemical Resistant Coating

Cooling Water Pump PT Pertamina Plaju• Concrete Foundation & Degradation


Waste Water Tank Pipe Pertamina Plaju• Causes of Failure

• Chemical Content


Solution

• Surface preparation• Cleaning with degreaser/solvent• Blasting SA 2.5-3• Blow with air compressor

• Apply Hold Coat of Loctite Nordbak Chemical Resistance Coating at the surface Concrete

• Rebuild the surface with Loctite Nordbak Chemical Resistance Coating at the surface Concrete


Product Recommended






• PT Pertamina Plaju (Jan 2007)/ Indonesia

• Problem / Application• Erosion at Inner Concrete Foundation

Tank Neutralization• Solution

• Loctite Chemical Resistance Coating• Benefits

• Process cuts • Doubled the life of the asset


HCL Tank PT Dankos Farma

• New Substrate Chemical Concrete Cargo Tank


Solution


• Apply Hold Coat of Loctite Nordbak Chemical Resistance Coating at the surface Concrete

• Rebuild the surface with Loctite LoctiteNordbak Chemical Resistance Coating at the surface Concrete


Product Recommended





August 9, 201631

Cleaner & Degreaser

August 9, 2016

Water Base Cleaner & Degreaser

• Background: • Strong requirement for environment friendly and non-flammable

cleaner• Introduce Loctite Natural Blue• Feature & Benefits:

• Water base cleaner & degreaser• Excellent penetration and dissolution of all kind of soils• Provides temporary rust protection• Low dermatological hazard

August 9, 2016

Application Example

August 9, 201634

Tank and Vessel

August 9, 201635

Tanks and Vessels Internal / External Corrosion


• Uniform Corrosion

Corrosive attack over entire

surface of substrate

• Pitting Corrosion

Cavities or "holes" are

produced in the substrate

August 9, 201636

• Solution

• Surface preparation• Blasting SA 2.5-3

• Use composite material to protect the welded joints and to rebuild worn out areas.

• Protection coating using Composite two coat system.


August 9, 201637


August 9, 201638

Tanks and Vessels Internal/ External Corrosion

Water Tank PT Kaltim Prima Coal

• New Substrate Coal Water Tank


Solution


• Apply Hold Coat of Loctite 290, Loctite Fixmaster Superior Metal & Loctite Nordbak Chemical Resistance Coating at the surface Metal Tank

• Rebuild the surface with Loctite 290, Loctite Fixmaster Superior Metal & Loctite Nordbak Chemical Resistance Coating at the surface Metal Tank


Metal Repair

• 2 Component metal filled epoxy, cured at room temperature• Once cured, product can be drill / machining process • Available at liquid form, paste form and semi-solid stick

Product Recommended






• PT Kaltim Prima Coal(Nov 2014) / Indonesia

• Problem / Application• Corrotion because of acid Water Coal

• Solution• Loctite 290, Loctite Fixmaster Superior

Metal &Nordbak Chemical Resistance Coating

• Benefits• Process cuts • Doubled the life of the asset


Raw Material Tank – Nippon Shokubai

• Leakage at Base Tank


Solution

• Surface preparation• Cleaning with degreaser/solvent• Water Jet Cleaning with Alkali Cleaner• Rinse with clean water

• Apply Hold Nordbak Wearing Compound• Nordbak Chemical Resistance Coating for

Top Coat.

• Rebuild the surface with Loctite 290, Loctite Fixmaster Superior Metal & Loctite Nordbak Chemical Resistance Coating at the surface Metal Tank



• PT Nippon Shokubai (Aug 2015) / Indonesia• Problem / Application

• Leakage at Bottom Tank• Solution

• Loctite Nordbak Wearing Compound. Nordbak Chemical Resistance Coating

• Benefits• Process cuts • Extend Tank Life.


August 9, 201647

Chute & Hopper

August 9, 2016 Loctite Product SharingSlide 48


•Abrasion

•Impact

•Erosion

Chute and HopperCorrosion and Abrasion

August 9, 2016 Loctite Product SharingSlide 49


Loctite Hi Impact Wearing Compound

• Ceramic filled Reinforced

• Outstanding Resistant to Abrasion

• Available for High Temp Wearing Compound

Chute and HopperCorrosion and Abrasion

Application Case History

• Customer / Country• Gold Mining at Nusa Tenggara

• Problem / Application• Abrasion to Hopper of Ball Mill & SAG

Mill• Protective coating of surfaces between

wear plate. • Solution

• Nordbak Wearing Compound

• Benefits• Longer life time of wear plate.



• Customer / Country• PT Krakatau Posco

• Problem / Application• Abrasion to Slurry Pipe Blast Furnace• Protective coating of Inside of Pipe

• Solution• Nordbak Wearing Compound

• Benefits• Longer life time of Slurry Pipe.



• Customer / Country• PT Powerblock

• Problem / Application• Abrasion to Mixing Blade• Protective coating of Mixing Blade Plate

• Solution• Nordbak Wearing Compound

• Benefits• Longer life time of Mixing Blade.



• Customer / Country• PT Indoferro

• Problem / Application• Abrasion to Dust Pump• Protective coating of Inside Component.

• Solution• Nordbak Pneu Wear + Brushable

Ceramic

• Benefits• Longer life time of Dust Pump


August 9, 201654

MRO Special Products

August 9, 2016Slide 55

Specialty Repair KitO-Ring Kit• Make replacement, high

performance O-rings in less than

a minute

• Contains 4 different diameter of

nitrile rubber (Buna-N) cord

• Contains 404 QuickSet CA,

O-ring fixture, blade, water

proofing solution, cleanup

solution

• This is for static flange sealing

only, not for dynamic flange use.


Corrosion can be everywhere

Protective CoatingTurco Rust Converter


Corrosion cause…

• Esthetic issue• Reduce parts / equipment life• Safety issue• Extra cost

• How to solve these……


What is Turco Rust Converter?

• Water base pre-treatment chemical to stop rust and prevent future corrosion.

• When applied to rusty metal, change the rust ( iron oxide ) to form iron phosphate. When dries, ready to paint.


How to Remove Seizing Bolt / Nuts?

Penetrating Oil Localize heat Cutting the bolt / nut

Limitations:• Penetrating oil provide lubricate effect only• Space limitation / position• Special bolt, stud bolt (anchor) → can’t be cut• Flammable / explosive area

Common Method

Specialty Repair KitFreeze & Release


Why Bolt Assemble Seize?

• Galvanic corrosion happened on the threads assembly caused seize

• Loctite solution is “break the rust chain”


Spray Shock-freeze up to -43oC(Wait 1 – 2 minutes)

Cracks (disassembly)

How to Apply?

August 9, 201662


Threadlocker



Background

• 30% of total production time is spent for assembly parts. • The simplest way to cut assembly cost is to make sure that once

installed, the fasteners will stays tight.


Basic Principal

• How does a nut & bolt work?• Application of on-torque.• Bolt is stretched like a spring.• Clamp load effect.

• Clamp load is retained by :a) Bolt head friction.b) Thread friction.

ab


What Factors Makes Threaded Assemblies Fail?


Failure Factors

steel

copper

Different Thermal Expansion

Gasket RelaxationSelf-loosening because vibration

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../Traverse shock loosening fastener.wmv

../Traverse shock loosening fastener.wmv


Mechanical Locking Devices

Spring washer Nut with nylon Castellated nut Tooth flanged bolt

Star washer Tab washer Lock nut


Loctite Solution – Loctite Threadlocker

• Anaerobic adhesive to lock and seal threaded fasteners which filling the gap between interfacing threads.


How Loctite Threadlocker Cured?

oxygenFe

CuCu

CuCu

Cu

CuCu

Cu CuCu CuCu

Cu

CuCu

CuCu

Cu

Fe Fe

Fe

Fe

Fe

Fe

Fe

Fe

Fe

Fe

Fe

Fe

Fe

Fe

Stays liquid in contact with oxygen (air)

Cures to a solid thermosetwith condition:1. No oxygen (air)2. Metal contact.

What Metal ?

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../../../../New Presentation Thread Locker/Sales Modules/TSI_ETS_Transfer/Fischer/Von Georg/Vorträge/Premium Partner Schulungen/Grundlagen_PPP/Filme/Anaerober Klebstoff Funktion.mov

../Anaerobic cure mech.wmv

../Anaerobic cure mech.wmv


Mudah Berkarat

• Active metals• Aluminum • Kuningan• Perunggu • Tembaga• Mangan• Besi

• Inactive metals• Anodized aluminum• Stainless steel• Zinc dichromate• Zinc galvanized

Anaerobic Category


Primer Loctite 7649 • Inactive metals

• Anodized aluminum• Stainless steel• Zinc dichromate• Zinc galvanized• Gold • Silver• Tin

Metal Substrates and Primers


How to Apply Loctite Threadlocker?

Through Holes Blind Holes Post Assembly


Loctite Threadlocker Types

• Low Strength –Purple color, removable, good for adjustment screws. Fasteners up to M6.

• Medium Strength –Blue color, removable with hand tools, fasteners up to M20.

• High Strength –Red color, removable with higher strength.

• Wicking –Green color, removable with hand tools for pre-assembled fasteners.


Application Example

../Threadlocker(Agco-270).wmv

../Threadlocker(Agco-270).wmv

../Threadlocker(Lotus-243).wmv

../Threadlocker(Lotus-243).wmv


Loctite Threadlocker 222, 243, 242, 262, 271, 272, 277, 290

Threadlocker

242, 243

262, 271, 272, 277

290Post Assembly

High Strength

Low Strength

Medium Strength

222


Any Question ?


Threadsealant


Background

Damage in the thread

Weak tightening torque

Thermal cycle

Not efficient sealant

Excessive Internal pressure

Why it leaks


General Type of Pipe Sealant

Teflon Tape

Available anywhere Fair instant sealing Cheap

Advantage :

Require extensive manual wrapping

Internal contamination

Adjustment not possible

Low heat resistance

Disadvantage :


Loctite Anaerobic Pipe Sealant

High wet-ability makes 100% fill on all surface irregularity. Doesn’t lose seal-ability when adjusting location. Not loosened by exteRnal vibration. Unlike teflon tape, no contamination to system. Assembly area looks clean. Easy disassembly by simple tool when necessary.

Advantage :






Any Question ?


Retaining Compound


Mechanical MethodPins, Screws, Key and Splines

Pins: high stress concentrationstime consuming

Grub Screws: low strength,high cost

Keys and Splines:costly machining,liable to fretting


Mechanical MethodProblem

• Fretting Corrosion• Backlash

• Shaft Wear/ Damage • Crack


Mechanical MethodOther Problem

• Empty space (only 20% metal to metal contact) causing leak

• Environment penetration• Extra heat treatment is required


Retaining with AdhesiveBonded Fit

• No Fretting Corrosion• No Backlash• Low Machining Cost• Environment difficult to penetrate no

corrosion• Even stress distribution, so no crack


Retaining Compound Product Selector


Retaining Compound Product Selector


Any Question ?


Gasketing


Traditional Method vs Loctite

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http://1.bp.blogspot.com/_RdzjAhiMuyk/Sw8dvY_2iII/AAAAAAAAARg/78W8EOC1J7g/s1600/P1030687.JPG


GasketingProduct Selection


Loctite GasketingApplication