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Galvanized Steel | Heater Core Repair

February 28, 2018

THE CUSTOMER

Double G Coatings Company, L.P., a steel processing company, is a valued customer for Hydradyne. Double G Coatings, which operates a hot dip galvanizing and Galvalume facility, is located in Jackson, Mississippi and processes steel supplied by U.S. Steel and ArcelorMittal, the company’s joint owners. Double G Coatings primarily serves the prepainted construction market and has an annual production capability of approximately 315,000 tons.

GALVANIZATION

Used to prevent rusting, galvanization is the process of applying a protective zinc coating to steel or iron. The most common method is hot-dip galvanizing, in which parts are submerged in a bath of molten zinc. Galvanizing protects in three ways:

  • The zinc coating prevents corrosive substances from reaching the underlying steel or iron.
  • The zinc serves as a sacrificial anode so that even if the coating is scratched, the exposed steel will still be protected by the remaining zinc.
  • The zinc protects iron by corroding first.

THE CHALLENGE

Hydradyne’s Brookhaven branch was asked by Double G Coatings to remove a corroded heating core from the furnace at their galvanizing and Galvalume facility and replace it with a new unit that they had purchased from the equipment manufacturer.

Hydradyne’s lead supervisor on the job was familiar enough with this customer’s facility that as soon as he saw the new heating core he knew that it had been manufactured incorrectly. The customer’s connections were exactly opposite of what they should have been. Since this is an extremely critical piece to their operation, Double G Coatings could not afford to send it back to the manufacturer – they needed it immediately.

So the Hydradyne team loaded up the heating core and brought it back to the Brookhaven branch.

THE SOLUTION

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Once unloaded at the Hydradyne shop in Brookhaven, supports were tack welded in place to maintain the integrity of the unit. The management team as well as two Hydradyne technicians stayed late to assure that this critical task was done correctly.

The ends were torched off, ground clean, and then welded back together properly. One piece was too hot to reattach that evening, so after staying until 8:30 PM, the technicians came back to the shop at 5:00 AM to finish the job.

THE RESULT

Hydradyne was back on-site by 7:00 AM the next day to install the new reassembled heating core for the customer.

What would have been a minor disaster and significant downtime for the customer was avoided due to the ingenuity and flexibility of the Hydradyne technicians.

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