Project Overview
In October 2020, a wear protection project for the coal conveying pipelines was carried out at Vinh Tan 2 Thermal Power Plant. EVNGENCO 3 Power Service Company was responsible for the installation work, while GAC and Kalenborn provided technical consultancy, guidance, and supervision.
After being pulverized and passing through the separator system, the coal is conveyed to the combustion chamber through a pipeline system. During this process, the coal continuously abrades the internal surfaces, causing pipeline wear. Within the entire system, the three-way pipe section was the most severely worn area and therefore required priority treatment.
GAC, EVNGENCO 3, and Kalenborn jointly conducted an on-site inspection and subsequently selected a solution to replace the three-way pipe assembly. The pipe shell was fabricated from Hardox 500 wear-resistant steel and combined with an internal KALCRET hard compound lining for wear protection.
The KALCRET installation process included surface preparation, steel mesh welding, compound mixing, and lining application. All stages were carried out in accordance with the manufacturer’s recommendations under the supervision of GAC and a Kalenborn representative before final completion and handover to the customer.
Customer challenges
Internal pipeline wear
During conveying to the combustion chamber, coal abrades the internal surfaces, causing progressive pipeline wear over time
Severe deterioration of the three-way pipe
Within the coal conveying system, the three-way pipe was the most severely worn section and required priority repair
Risk of pipeline failure
If wear continued to progress, the pipeline could fail, resulting in coal leakage into the surrounding environment
Coal leakage into the environment
In the event of pipeline failure, coal could leak into the environment during conveying
CURRENT CONDITION OF THE COAL CONVEYING THREE-WAY PIPE
The inner surface of the three-way pipe is severely worn
Project Objectives
PROTECT THE INTERNAL PIPE
Install an internal wear-resistant lining to protect the pipe surface against abrasion caused by the coal flow
REPLACE THE THREE-WAY PIPE ASSEMBLY
Replace the three-way pipe assembly, which was identified as the most severely worn section of the coal conveying system
MINIMIZE PIPE FAILURE AND COAL LEAKAGE
Improve the pipeline’s wear resistance to minimize the risk of pipe failure and coal leakage into the surrounding environment
Project execution process
Site inspection
GAC, EVNGENCO 3, and Kalenborn jointly inspected the coal conveying pipeline, focusing on the severely worn three-way pipe section
Select the treatment solution
Based on the site inspection, the parties selected a solution to replace the three-way pipe assembly using wear-resistant materials combined with an internal KALCRET lining
Fabricate the Hardox 500 shell
Fabricate the steel shell of the three-way pipe assembly from Hardox 500 wear-resistant steel according to the project specifications
Prepare the surface and weld steel mesh
Clean and prepare the internal pipe surface, then weld the steel mesh in preparation for the KALCRET lining application
Mix and apply KALCRET
Mix the compound and apply KALCRET to the internal pipe surface in accordance with the manufacturer’s recommendations
Supervision, completion and handover
The installation process was supervised by GAC and a Kalenborn representative before final completion and handover to the customer
Project results
COMPLETED THREE-WAY PIPE ASSEMBLY
The severely worn three-way pipe assembly was replaced using wear-resistant materials in accordance with the project specifications
COMBINATION OF HARDOX 500 AND KALCRET
The steel shell was fabricated from Hardox 500 and combined with an internal KALCRET lining to improve piping wear resistance
COMPLETION AND HANDOVER
The KALCRET installation stages were carried out in accordance with the manufacturer’s recommendations under GAC and Kalenborn supervision before final completion and handover to the customer
“We highly appreciate Gia Anh’s professionalism and ability to meet the project schedule. The KALCRET cast lining solution has helped improve the operational reliability of the ore conveying pipeline system at Dung Quat while significantly reducing annual maintenance costs. Completing the delivery 20 days ahead of schedule was a highly commendable achievement.”
Mr. Tran Van Hoa
Project Management Board - VINH TAN 2
What Makes Gia Anh Different?
One-Stop Solutions
From inspection and material selection to fabrication and on-site installation, Gia Anh supports customers throughout the entire process, eliminating the need to work with multiple providers
GAC 3D Map Material Selection Process
More than material grade, GAC 3D Map helps select the right material type and mechanical properties for each application, ensuring performance and operational safety
Global Experience Library
As the exclusive representative of three world-leading material manufacturers, Gia Anh has access to proven global case studies, enabling us to deliver the most suitable solution for each customer's application
Request Solution Consultation
Speak directly with our experienced engineers for a free site assessment and consultation on the most suitable solution
Key Clients
More from this category
