Process Vessels

• Internal pitting and general thinning in chemical, water, and process service.
• Erosion of internal surfaces at inlet nozzles, distributors, and impingement plates.
• External shell corrosion from atmospheric exposure and corrosion under insulation.
• Bottom-head and weld-seam pitting from settled water or chemistry.
• Manway and nozzle flange-face corrosion, blocking gasket seating.
• Lining breakdown in older glass-flake or rubber-lined vessels.

Vessel work fits the inspection cycle

Process-vessel scope is set by the vessel's integrity record. The inspector identifies wall-loss locations, the engineer specifies the repair tolerance, and the applicator restores wall thickness and lining integrity inside the planned outage. The selected system has to cure cold, accept the inspector's NDE expectations, and survive until the next inspection.

Belzona product families used on process vessels

Wall-loss rebuild

Belzona 1111 (Super Metal) and Belzona 1311 (Ceramic R-Metal) rebuild internal pitting and general wall loss back to the original profile. Selection follows service temperature and erosion class; 1311 carries the heavier-erosion duty.

Internal lining

For continuous immersion in moderate chemistry, Belzona 5811 (Immersion Grade) is the baseline lining. For elevated-temperature water and process duty, Belzona 1391T extends the immersion envelope. For aggressive chemistry (acid, alkali, solvent at elevated temperature), Belzona 4311 (Magma CR1) and Belzona 4341 (Magma CR4) provide chemical-resistant linings rated above the temperature ceiling of standard epoxy.

External shell and CUI

External corrosion, including corrosion under insulation, is handled with the same family that covers piping CUI: rebuild with 1111 / 1311, topcoat with 5811 or a temperature-rated CUI system, reinstall insulation. The boundary between internal-lining work and external-corrosion work is documented separately.

Nozzle and manway flange faces

Vessel nozzles and manway flanges are repaired with the same Belzona 1111 / Flange Face Forming Kit approach used elsewhere on the plant. The reformed face accepts a standard gasket on reassembly, which avoids custom flange machining or replacement.

Inspection compatibility

The repair file (PSS, IFU, application record, dry film thickness check) is filed with the vessel's integrity record so the next inspector reads the actual coating layer rather than guessing. Belzona Baton Rouge plans the recoat boundary so that the polymer life aligns with the next inspection interval, not the calendar.