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How to urgently repair corrosion-induced perforations in acid water tanks

2026-07-18View Original

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Given the high risk of corrosion in the acidic water tanks of refining units mentioned earlier, emergency repairs for corrosion-induced perforations must prioritize safety before following standard procedures: 1. Pre-repair safety measures: Personal protection is essential; workers must wear acid-resistant suits, goggles, gas masks, acid-resistant gloves, and rubber boots to avoid contact with toxic and harmful substances. Risk isolation: Immediately close the inlet/outlet valves upstream and downstream of the tank area to cut off the source of the medium, and simultaneously activate the on-site ventilation system to reduce the concentrations of hydrogen sulfide and acid mist. Medium neutralization: Use alkaline substances such as sodium bicarbonate or lime to cover the area where there is a leak, thereby neutralizing the spilled acidic liquid and preventing the spread of corrosion. II. Emergency repair under pressure without interrupting flow – Clamping device sealing process: Custom clamping devices are designed to fit the area where leakage occurs; special sealant is injected to create a new sealing layer, allowing for rapid sealing at pressures up to 5 MPa. This method can be applied to various areas such as tanks and pipelines. Temporary emergency sealing: For small holes, wooden wedges/lead sheets can be inserted and sealed using adhesive; this method allows the system to continue operating with ongoing monitoring, and it is suitable for situations where welding repairs cannot be carried out immediately. Wrapping reinforcement method: Steel strips/wires soaked in adhesive are used to wrap around the leaking area; this method is suitable for thin-walled sections of tanks that are severely corroded and have a loose structure. III. Thorough repair after shutdown: Surface pretreatment – Perform sandblasting and grinding on the perforation and surrounding areas to achieve a Sa2.5 standard; clean them with anhydrous ethanol to ensure the surface is dry and free of oil. Repair of pitting defects: Mix the 2211F polymer composite in the appropriate proportions, apply it evenly over the pits to level them with the substrate, and then polish the area until it is smooth after curing. Complete restoration of the anti-corrosion layer: Apply the 418 series of corrosion-resistant high-temperature coatings in sequence; use carbon fiber composite materials to reinforce the areas around gaps, and conduct pressure testing for acceptance after full curing.

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