Case Study: From Failure to Full Recovery

A power and water station in Western Australia engaged REMA TIP TOP to restore a critical pressure vessel used in its water treatment process. The vessel had failed a routine inspection and could not be repaired by multiple providers.

As an essential asset for ongoing plant operations, any prolonged downtime posed significant operational and financial risk. Through advanced material engineering, global technical collaboration and precise execution, our team completed a full strip and reline, returning the vessel to service faster and more cost-effectively than replacement.

The challenge

The carbon steel pressure vessel (1100mm diameter x 4000mm length) was used to contain dilute sulphuric acid (H₂SO₄) and had failed inspection due to lining deterioration. This presented several critical challenges:

• The existing lining system was unknown, making it difficult to determine a suitable repair approach
• Previous repair attempts had failed, with no viable solution offered by other contractors
• If the compromised lining was left untreated, there was a risk of permanent damage to the shell and costly capital expenditure
• Potential for contamination and hazardous leaks, impacting both safety and process integrity
• Operational exposure, as the plant relied on parallel systems

The client required a solution that would restore asset integrity quickly and reliably, without the long lead times and high costs associated with fabricating a new vessel.

The solution

REMA TIP TOP delivered a comprehensive, engineered relining solution that combined in-house expertise, global technical support and high-performance materials. Our Australian team collaborated with REMA TIP TOP’s in-house chemists in Germany to assess the operating conditions and verify the optimal material specification.

Chemonit 31 ebonite rubber was selected as it is specifically engineered for sulphuric acid environments. The material was air freighted from Germany to minimise project delays.

The vessel was completely stripped of the failed lining, followed by detailed surface preparation to ensure optimal adhesion. REMA TIP TOP primers and adhesives, designed specifically for compatibility with Chemonit systems, were then applied. Everything was completed at our Welshpool rubber lining workshop by our team of expert rubber liners, under strict confined space HSE protocols.

The new lining was hot vulcanised to 80 Shore D hardness, creating a dense, highly corrosion-resistant barrier. To ensure long-term performance and compliance, the project included full QA/QC processes, including hardness, adhesion and spark testing. Our Bunbury branch is now also fully equipped with a new autoclave that can handle jobs at this capacity.

The outcome

REMA TIP TOP restored the vessel to full operational condition, delivering clear value through improved performance, reduced costs and minimised risk:

• Back in service in 10 weeks: The entire project, including material procurement, air freight, stripping and relining, was completed in just 10 weeks. That is significantly faster than the approximate 16 weeks required for an offshore replacement.
• Repair instead of replacement: By relining the existing vessel rather than manufacturing a new one, the client achieved notable cost savings.
• Reduced risk: The solution reduced the risk of corrosion damage to the steel shell, eliminated the potential for chemical leaks and process contamination, and improved overall asset reliability.
• Full handover: REMA TIP TOP provided comprehensive documentation of the installed lining system, along with guidance on inspection, maintenance and future repair strategies, giving the client full visibility and confidence in managing the asset moving forward.