PERIOD! - GPI FACING 8–16 Hours Shop Time ... Ceramic tiles are brittle Difficult to “patch” repair often need to remove all tiles before repairing

ARC™ PHOTO CASE HISTORIES PRESENTER – SECTION 1.1Private & Confidential

© A.W.CHESTERTON CO., 1993. All rights reserved. REV.1

DIVISION OF CHESTERTON ®TM

In 1992 the A.W. Chesterton Company

established a separate division under the trade name

The ARC Division, through its separation and specialization

will provide customers with the highest level of service

and technical support.


representing their Polymer Composite Products.

Your exclusive ARC Distributor is:




QUALITY

Awarded the ISO 9001 Quality Standard

February 25,1993

NATIONAL STANDARDS AUTHORITY OF IRELANDGLASNEVIN, DUBLIN 9, IRELAND

Certificate of Registrationof Quality System to

I.S./ISO 9001 / EN 29001:1989The National Standards Authority of Ireland and certifies that

A.W. Chesterton CompanyStoneham, Massachusetts, U.S.A.

has been assessed for compliance with the provisions of the aboveIrish Standard in respect of the scope of operation given

hereunder and is hereby registered in theNSAI Register of Certified Products and Registered Companies

Scope of Registration

design, and manufacture of mechanical seals, components, spare parts, repairsand exchange; pimps and pump related products, components, spare parts

and repairs; industrial maintenance products and polymer comosites;hydraulic & pneumatic sealing devices and affiliated products at

Groveland, MA USAdesign and manufacture of mechanical packing, gasketing and

affiliated live loading products at Woburn, MA, USA

Signed: AUTHORIZED OFFICER

Date of Issue: February 25, 1993 Registration No.: M608 / M801

The technical requirements of the standard referred to above are identical to the following nationalstandards harmonized with EN 29001: France NF-EN 29001, Germany DIN ISO 9001,

United Kingdom BS 5750: 1987: Pt 1, USA ANSI/ASQC Q91 and also national standardsimplementing the ISO 9000 (EN 29000) series in the other countries of the EC,EFTA and worldwide.




COMPOSITES:The most Advanced Material Technology today.

PERIOD!




COMPOSITE:A substance composed of two or more

materials in separate phasesREINFORCINGPHASE

MATRIX PHASE(Stress Transfer)

COMPOSITE

FIBERS

BEADS & PARTICLES POLYMER

+

+

=

=

ARC:Incorporating this same Composite Technology

to solve Industrial Surfacing Problems




OUR PRODUCTS ARE SPECIFIED BY VIRTUALLY EVERY

MAJOR INDUSTRIAL PLANT IN THE WORLD.

We are the only manufacturer in our field to be awarded the ISO 9001 Quality Award.

WHATEVER YOUR INDUSTRY...We have proven results!

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PETRO-CHEMICAL

UTILITIES

MINING

PULP & PAPER

MARINE

BUILDINGS& FACILITIES

REPAIR MACHINERYAND EQUIPMENT

Bearing HousingsScored ShaftsValvesPumpsScored Hydraulic RamsLeaking Pipes and TanksHeat ExchangersCracked Castings and MoldsElevator EquipmentFlange FacesPress FitsKey Ways

CORROSION/EROSIONAND CHEMICAL ATTACK

Water TreatmentPumpsValvesBottle WashersChillersMotor HousingsCooling Water SystemsAtmospheric Corrosion Reaction VesselsStorage TanksSmoke StacksTube Sheets

CONCRETEPump BasesSumpsConcrete Spall RepairDrainsStairsTrenchesConcrete PadsSecondary Containment Sea WallsPiers, BridgesTunnels

ABRASIONDeflector PlatesSlurry PumpsElbowsPulverizersCyclonesWear PlatesFans Hydro PulpersHoppers and ChutesTurbo SeparatorsNi-hard, Ceramic and Rubber




IN WHICH AREA ARE YOU

LOOKING TO LOWER COSTS?







HOW DO YOU REPAIR LEAKS?

Do you weld?Do you replace? How long does it take?How much does it cost you?

WHY?

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HOLED TANKS

LINED VESSELS

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PIPES

HYDRAULICS

SWITCH GEARTRANSFORMERS

NORMAL REPAIRShut down lineDrain line pressureGas free line – 1 HourGet hot work permit –1 HourPrepare pipe – 30 MinutesWeld up crack –30 MinutesLet cool/Pressure up –1 Hour

ARC REPAIRShut down lineDrain line pressureClean around crack – 30 MinutesMix and apply ARC 5 –10 MinutesMix and apply ARC 10 –20 MinutesAllow to cure – 30 MinutesReturn line to service




LEAK REPAIRLeaking pipe in a chemical plant, low pressure.

Problem – A crack one inch in length.

Material Cost ....................$50.00

TOTAL TIME............4 Hours

Material Cost ....................$50.00

TOTAL TIME.........11/2 Hours

HOW MUCH MONEY COULD YOU SAVE?

What are your labor costs?

What are your lost production costs?

What are your downtime costs?

How many leaks per year do you repair?

PROBLEMS WITH:Cracking?Warping?Shrinking?Disbonding?

DO YOU:Weld?Metalize?Fuse?Sleeve?




DO YOU FIXWORN OR DAMAGED SHAFTS?

WHY?

TOTAL TIME: 13 Hours 15 Minutes

Shop Rate: $35.00/Hour

Labor .............................$463.75Material Cost .................$ 50.00

TOTAL .....................$513.75

ARC REPAIRChuck up shaft in lathe –1 HourUndercut shaft3 mm (1/8 inch) – 1 HourDegrease – 10 MinutesMix and apply ARC 10 –45 MinutesAllow to cure – 1 HourMachine to size – 1 HourPolish – 15 Minutes

NORMAL REPAIRChuck up shaft in lathe – 1 HourUndercut shaft 3 mm (1/8 inch) – 1 HourRemove to weld shop – 1 HourPlace in fixture – 1 HourWeld up – 3 HoursAllow to cool – 2 HoursRechuck in lathe – 1 HourMachine to size – 2 HoursPolish – 15 Minutes




SHAFT REPAIRWorn bearing journal on a 100 mm (4 inch) diameter shaft.

The journal is 150 mm (6 inches) in length, and wear is approximately 2,5 mm (0.10 inch) in depth.

Total shaft length is 7 meters (24 feet).

TOTAL TIME: 5 Hours 10 Minutes

Shop Rate: $35.00/Hour

Labor ............................$183.75Material Cost .................$ 30.00

TOTAL.....................$213.75

HOW MUCH MONEY COULD YOU SAVE?

What if shaft cannot be removed from equipment?

What if shaft cannot be welded?

What about welding fumes and gases?




WELDING METHODPrepare surface Preheat rods and substrateLay 1/4 inch x 1/8 inch bead 81/2 inches long CleanOverlap beads by 50% Normally two passes required to achieve 1/4 inchStress relieve periodicallyTotal 176 passes20 – 30% loss




COST OF WELDINGExample: To surface an area 81/2 x 11 x 1/4 inches (600 cm2).

FILL WELDING

2 – 4 Hours Shop Time ..........................$1057 lb at $5/lb ........................$ 35

TOTAL .........................$140

HARD FACING

8 – 16 Hours Shop Time..........................$4007 lb at $35/lb .....................$245

TOTAL .........................$645

WHAT ABOUT:Overhead costs?

Electric and power consumption?

Warping?

Cracking?

Safety?




ARC METHODPrepare surface Mix ARC CompositeApply to 1/4 inch thickness Allow to cure




COST OF ARC COMPOSITEExample: To surface an area 81/2 x 11 x 1/4 inches (600 cm2).

ARC REPAIR

11/2 Hours Shop Time .......................$52.5013/4 lb ARC .......................$39.64

TOTAL .......................$91.14

IN ADDITION NO PROBLEM WITH:

Warping

Cracking

Stress relieving

Safety

ARC: 35% less expensive than fill welding

86% less expensive than hard face welding

And ARC out performs both!




WHAT DO YOU DO FOR:

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VALVES

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BEARINGHOUSINGS

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COUPLINGS

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CRACKS INCAST IRON

▼FLANGE FACES

▼KEYWAYS




WHY?




HOW DO YOU FIX WORN OR ABRADED PARTS?

Do you use:

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WELDING

CERAMIC TILES

▼RUBBER LININGS

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NI-HARD/SPECIAL ALLOYS




PART REPLACEMENTCOST FACTORS

TECHNICAL ALTERNATIVE: A high performance, multi-use composite

A long term repair technique offering versatility to do many types of repairs

Off the shelf availability

Quick repair – Reduction in downtime

Low cost

STAINLESS STEEL IMPELLERReplacement Cost: $48,000 ARC Composites: $3,000

SAVINGS:$45,000

■ Large inventoriesHow many different size shafts, impellers, pumps, etc. in your warehouse?

■ Long lead times■ Down time –

loss of production■ Higher cost – for spare parts■ Re-occuring problem/cost




RUBBER LINING REPAIRSCOST FACTORS

TECHNICAL ALTERNATIVE: A high performance, durable composite

Easy to install on site

Quick return to production

Repairability

Tenacious bond to the surface

Consistent performance – allows predictive maintenance

Non-hazardous, ambient curing system

■ Liners are hard to patch■ Cuts or peels off the surface■ Time to failure is

unpredictable and often catastrophic

■ Undetected failures lead toextensive substrate damage

■ Age embrittlement and cracking

■ Some require heat, vulcanization or hazardous curatives

■ Difficult to install on site■ Thick linings reduce

volume capacity

ARC consistently outperforms rubber linings!




CERAMIC TILESCOST FACTORS

TECHNICAL ALTERNATIVE: A toughened, moldable ceramic

Resilient matrix provides anon-brittle, wear-resistant surface

Easy to install, if required easy to repair

Tenacious bond to the substrate

Easily controlled Thicknesses/Tolerances

■ Ceramic tiles are brittle■ Difficult to “patch” repair

often need to remove all tiles before repairing

■ Fall off the surface (Impact, Vibration, Thermal Shock, Poor Adhesion

■ Tiles add excessive weight

ARC ceramic composites withreinforcements of diamond-like hardness:

9.2 Moh; Outperform ceramic tiles




ABRASION RESISTANT ALLOYSCOST FACTORS

TECHNICAL ALTERNATIVE: A repairable ceramic composite

Lower material costs

No material waste, mix and apply what you need

Easy to repair,moldable for intricate applications

In stock availability

Reduce downtime

■ Very expensive■ Minor damage

leads to total replacement ■ Difficult to weld ■ Some are brittle■ Spare parts have

long lead times

ARC ceramic composites withreinforcements of diamond-like hardness:

9.2 Moh; Outperform abrasion resistant alloys







DOES EROSION OR CORROSION DAMAGE YOUR EQUIPMENT?

DO YOU PAINT MORE THAN ONCE?

WHY?




WHAT DO YOU DO FOR:CORROSION

EROSION




TRADITIONAL COATINGS CAN’T COMPETE

WITH AN ADVANCED COMPOSITE SURFACE

TECHNICAL ALTERNATIVE:■ An advanced

composite surface■ Adhesion of

140 – 280 kg/cm2

(2,000 – 5,000 psi)

■ Unprecedentedchemical resistance

RESULT:No underfilm corrosionNo chemical attack

TRADITIONALCOATING FAILURE:Underfilm corrosion■ Iron expands 2.2 times

it’s volume when it oxidizes, creating a force of 150 kg/cm2

(2,200 psi)

■ Industrial coatings have an adhesion of 15 – 35 kg/cm2

(200 – 500 psi)

RESULT:Underfilm corrosion

IRON OXIDE

IRON OXIDE

METAL

METAL

PAINT

ARC COMPOSITE

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TYPICAL INDUSTRIAL COATINGSvs ARC COMPOSITES

RESISTANCE TO UNDERFILM CORROSIONASTM B117 scored salt fog test

2400

2200

2000

1800

1600

1400

1200

1000

800

600

400

200

0

2400

2200

2000

1800

1600

1400

1200

1000

800

600

400

200

0

AD

HES

ION

(psi

)R

ESIS

TAN

CE

TO U

ND

ERFI

LM C

OR

RO

SIO

N (H

ours

)

TraditionalIndustrialPaint Coatings

TraditionalIndustrialPaint Coatings

ZincRichPrimers

ZincRichPrimers

Todays High SolidsCoatings

Todays High SolidsCoatings

ARC Composite

ARC Composite

400

100

300

500

900

2300

10,000+

50

ADHESION

CORROSION RESISTANCE

FORCE OF OXIDATION




ARC COMPOSITESARE ENGINEERED TO RESIST

OSMOTIC BLISTERINGTRADITIONALCOATING FAILURE:Over time permeation occurs.The rate depends on the degree of osmotic drive andthe materials permeability.Any one of the followingcan create osmotic drive.■ Differences in electrical

potential (Voltage)

■ Dissimilar chemical concentrations (Solutions seek equilibrium)

■ Temperature differences(Hot permeates towards cold)

■ Unbalanced pressures

ARC PERFORMSWHERE OTHERS FAIL:■ Adhesion which exceeds

typical osmotic forces:120 kg/cm2 (1,800 psi)

■ Surface engineeredceramic reinforcementsare impregnated undervacuum to virtually eliminate permeability

H2O

OSMOTIC DRIVE

HOT COLD

TANK WALLOR SUBSTRATE

PURE WATER SOLUABLE SALTSHIGH PRESSURE LOW PRESSURE

H2O

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DIVISION OF CHESTERTON®TM

ARC COMPOSITESAn ISO 9000 Company.

Over 100 years helping maintenance engineersaround the globe

ARC COMPOSITES ARE SAVING MONEY!

Are you ready to benefit from todays technology?

WHETHER ITS ACRITICAL APPLICATION

IN A USA NUCLEAR PLANT

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A 1000 ft TALL CHIMNEYIN EASTERN EUROPE

OR A SMALL PUMPAT A LOCAL AMUSEMENT PARK

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PERIOD! - GPI FACING 8–16 Hours Shop Time ... Ceramic tiles are brittle Difficult to “patch” repair often need to remove all tiles before repairing