corrosion protection offshore installations
TRANSCRIPT
12
CORROSION PROTECTIONOffshore installations
Introduction 3
Typical offshore specifications 5
Key offshore products 6
Documentation 7
Crucial performance indicators 8
Problems and solutions 9
Offshore product range 10
2
Contents
CORROSION PROTECTIONOffshore installations
3
For almost a century, Hempel has been providing high-quality
protective coating systems for stationary and floating steel
structures of all kinds. Today, some of the world’s longest
bridges, tallest cranes and largest ships rely on Hempel
quality to keep them working and looking their best. Not
surprisingly, Hempel also provides protection for a vast
number of offshore structures in some of the harshest
environments in the world.
High return on investmentOwners and operators know that each floating production
system – from full-scale platforms to FPSOs and barges
– represents a valuable asset as both a capital investment
and a source of ongoing revenue. They also know that
high-performance protective coatings from Hempel provide
an extremely beneficial return on investment, dramatically
increasing the useful lifetime of all individual components
and keeping downtime to a minimum. And for anyone looking
for a protection specification that will last up to 30 years,
second best is simply not good enough.
Technical expertiseOur FROSIO/NACE-certified technical staff and coating
advisers have in-depth knowledge and understanding of
on-site working procedures and the conditions under which
paint contractors must operate. In fact, we’re one of the few
companies authorised to conduct in-house FROSIO training.
A lifetime protecting offshore structures
4
1
2
3
4
6
5
7
4
4 5
1 Main exterior surfaces
Generic type Dry film thicknessPolyurethane or 50 µm / 2 mils or Polysiloxane 100 µm / 4 mils Epoxy 125 µm / 5 mils Epoxy 125 µm / 5 mils Inorganic or organic zinc-rich 50 µm / 2 mils
2 Main exterior decks, escape routes, heavy traffic and helidecks
Generic type Dry film thicknessHeavy-duty epoxy 3000 µm / 120 mils
3 Hot surfaces
Generic type Dry film thicknessSilicone aluminium 25 µm / 1 mil Silicone aluminium 25 µm / 1 mil Thermal sprayed aluminium 200 µm / 8 mils
4 Tank lining
Generic type Dry film thicknessEpoxy phenolic 100 µm / 4 milsEpoxy phenolic 100 µm / 4 milsEpoxy phenolic 100 µm / 4 mils
5 Splash zone and submerged surfaces
Generic type Dry film thicknessGlass flake epoxy 500 µm / 20 milsGlass flake epoxy 500 µm / 20 mils
6 Interior surfaces
Generic type Dry film thicknessEpoxy 100 µm / 4 mils Epoxy 100 µm / 4 mils
7 Exterior production equipment
Generic type Dry film thickness Polyurethane or 50 µm / 2 mils or Polysiloxane 100 µm / 4 mils Epoxy 125 µm / 5 mils Epoxy 125 µm / 5 mils Inorganic or organic zinc-rich 50 µm / 2 mils
Typical offshore specifications
Inorganic or organic zinc-richEpoxyEpoxyPolyurethane or Polysiloxane
Steel
Inorganic or organic zinc-richEpoxyEpoxyPolyurethane or Polysiloxane
Steel
EpoxyEpoxy
Steel
Glass flake epoxyGlass flake epoxy
Steel
Thermal sprayed aluminiumSilicone aluminiumSilicone aluminium
Steel
Epoxy phenolicEpoxy phenolicEpoxy phenolic
Steel
Heavy-duty epoxy
Steel
Inorganic or organic zinc-richEpoxyEpoxyPolyurethane or Polysiloxane
Steel
Inorganic or organic zinc-richEpoxyEpoxyPolyurethane or Polysiloxane
Steel
EpoxyEpoxy
Steel
Glass flake epoxyGlass flake epoxy
Steel
Thermal sprayed aluminiumSilicone aluminiumSilicone aluminium
Steel
Epoxy phenolicEpoxy phenolicEpoxy phenolic
Steel
Heavy-duty epoxy
Steel
Inorganic or organic zinc-richEpoxyEpoxyPolyurethane or Polysiloxane
Steel
Inorganic or organic zinc-richEpoxyEpoxyPolyurethane or Polysiloxane
Steel
EpoxyEpoxy
Steel
Glass flake epoxyGlass flake epoxy
Steel
Thermal sprayed aluminiumSilicone aluminiumSilicone aluminium
Steel
Epoxy phenolicEpoxy phenolicEpoxy phenolic
Steel
Heavy-duty epoxy
Steel
Inorganic or organic zinc-richEpoxyEpoxyPolyurethane or Polysiloxane
Steel
Inorganic or organic zinc-richEpoxyEpoxyPolyurethane or Polysiloxane
Steel
EpoxyEpoxy
Steel
Glass flake epoxyGlass flake epoxy
Steel
Thermal sprayed aluminiumSilicone aluminiumSilicone aluminium
Steel
Epoxy phenolicEpoxy phenolicEpoxy phenolic
Steel
Heavy-duty epoxy
Steel
Inorganic or organic zinc-richEpoxyEpoxyPolyurethane or Polysiloxane
Steel
Inorganic or organic zinc-richEpoxyEpoxyPolyurethane or Polysiloxane
Steel
EpoxyEpoxy
Steel
Glass flake epoxyGlass flake epoxy
Steel
Thermal sprayed aluminiumSilicone aluminiumSilicone aluminium
Steel
Epoxy phenolicEpoxy phenolicEpoxy phenolic
Steel
Heavy-duty epoxy
Steel
Inorganic or organic zinc-richEpoxyEpoxyPolyurethane or Polysiloxane
Steel
Inorganic or organic zinc-richEpoxyEpoxyPolyurethane or Polysiloxane
Steel
EpoxyEpoxy
Steel
Glass flake epoxyGlass flake epoxy
Steel
Thermal sprayed aluminiumSilicone aluminiumSilicone aluminium
Steel
Epoxy phenolicEpoxy phenolicEpoxy phenolic
Steel
Heavy-duty epoxy
Steel
Inorganic or organic zinc-richEpoxyEpoxyPolyurethane or Polysiloxane
Steel
Inorganic or organic zinc-richEpoxyEpoxyPolyurethane or Polysiloxane
Steel
EpoxyEpoxy
Steel
Glass flake epoxyGlass flake epoxy
Steel
Thermal sprayed aluminiumSilicone aluminiumSilicone aluminium
Steel
Epoxy phenolicEpoxy phenolicEpoxy phenolic
Steel
Heavy-duty epoxy
Steel
For specific products, see the offshore product range (page 10). Several of Hempel’s coating systems have been tested and pre-qualified for NORSOK M-501.
6
Tough, tougher...HEMPADUR MULTI-STRENGTH GF 35870 – glass flake epoxyProvides excellent corrosion protection as well as high resistance to both impact
and abrasion. This product is tailor-made for the severely corrosive atmospheric
conditions faced by offshore oil and gas constructions.
New thinking in topcoat solutionsHEMPAXANE 55000 – polysiloxaneProvides exceptional gloss and colour retention along with excellent resistance to abrasion, spillage of chemicals, stains and
UV-light. HEMPAXANE 55000 is not just a topcoat – it is also an integrated part of your corrosion protection.
Key offshore products
Features Benefits
Reinforcement with high content of lamellar glass flakes Provides excellent corrosion protection through superior barrier effect. (more than 25% by weight of pigments and extenders).
Immersible just 6 hours after application (20°C/68°F), as Facilitates repair of structures in tidal zones. curing proceeds under water.
Rain-resistant just 4 hours after application. Structures can be coated indoors and stored outdoors in wet or humid conditions shortly after application.
High volume solids content (87%). High-build properties ensure greater dry film thickness in just one or two coats.
Low volatile organic compound content (180 g/litre). Healthier and safer for applicators, particularly when applied indoors.
NORSOK M-501-approved
A breakthrough in tank liningsHEMPADUR 85671 – epoxy phenolic (Novolac)A two-component, amine adduct
cured phenolic epoxy (Novolac)
coating with excellent resistance
to high temperature, water and
chemicals. Suitable as an interior
lining in tanks, pipelines, etc. for
hot water, brine, crude oil and
potable water.
Features Benefits
Excellent resistance to hydrocarbons. Excellent/safe choice for cargo tanks and all fuel oil Also approved for jet fuel. tanks.
Excellent resistance to water at high temperatures Excellent/safe choice for process water and slop tanks. – also water contaminated with oil.
Very good resistance to high pressure and Excellent choice for separators and other pressure decompression. vessels.
Approved by WRAS/UK and NSF/USA for contact Excellent/safe choice for drinking water tanks. with potable water.
NORSOK M-501-approved
Features Benefits
Excellent colour and gloss retention. Far superior performance compared to other generic types of topcoats.
High volume solids content (84%). Complies with VOC regulations all over the world.
Excellent resistance to spillage from Greater durability and less risk of damage to a wide range of chemicals. steel surfaces.
Excellent barrier effect against Longer working life, lower maintenance costs and diffusion of water and ions. less risk of premature refurbishment.
NORS
OK M
-501
-app
rove
d
0
20
40
60
80
100
120
Solv
ent
emis
sion
inde
x
Solvent emission to the atmosphere
Acrylic Polyurethane55000
The specifier, engineer, owner or any other decision-maker
responsible for selecting the right coating system to protect
offshore installations is very aware of the fact that making
the wrong choice can be costly.
Documentation is therefore normally required for major projects
in order to corroborate the performance of the coating system.
Two types of documentation are often required:1) Documentation concerning practical performance, to
confirm that the coating system has worked satisfactorily
under similar conditions.
This documentation is the best possible proof that the system
is efficient under real-life conditions. The main disadvantage
of this type of documentation is that many of the coatings
used 10–15 years ago are no longer on the market today.
2) To a certain extent, documentation concerning
performance can also be obtained through accelerated
testing. Several standards currently list accelerated test
methods that should be performed for the qualification
testing of coating systems for offshore use.
Such standards include NORSOK M-501, ISO 12944 and ISO
20340, as well as different NACE standards. Hempel’s internal
test package is in fact on a par with or tougher and usually much
more comprehensive than the above external test requirements.
The above standards specify very extensive requirements
and should therefore be suitable for coating systems used
in tough offshore conditions.
Unfortunately, no accelerated test method used today
correlates with real-life performance. It is therefore very
important to understand that even an excellent test result
does not automatically guarantee excellent performance in
practice. There are simply too many variables that give rise
to important differences between laboratory application and
testing on the one hand, and real-life situations on the other.
ExperienceHempel has vast experience in the use of coating systems in
marine and offshore environments. This accumulated know-
how makes Hempel an extremely reliable supplier, and the
company can deliver extensive documentation on the use of
coating systems in practice.
Hempel also carries out comprehensive accelerated tests,
both internally at its modern Test and Innovation Centre in
Denmark, and externally at different recognised independent
laboratories.
At the end of the day, optimum corrosion protection is only obtained
when the coating system is properly applied on-site. In many
cases this can only be ensured by a good QAS system, backed
up by one of Hempel’s many experienced coating engineers.
Documentation
7
Hempel’s internal test:
Most of the tests are according to accredited standards such as, ASTM, NORSOK, NACE and ISO.
• Surface preparation • Temperature gradient • Abrasion resistance • Application • Cathodic disbondment • Aging stability • Water immersion • Rust creepage resistance • Cyclic testing • Chemical resistance • Thermal cycling resistance • Blister box • Pull off • Colour/gloss retention • Salt spray • Impact strength • Edge build • Physical constants • Flexibility • Thick fi lm crack resistance
8
Offshore installations require optimum coating systems
A balance between crucial
performance indicators
Recoatingintervals
Application properties
Impact and abrasion
resistance
Gloss and colour retention
Anticorrosive performance
Flexibility
Chemical resistance
Gloss and colour retentionA good coating system is resistant to the environmental
stresses to which it is exposed, and maintains good gloss
and colour retention.
Anticorrosive performanceA good coating system provides good corrosion protection
– even in areas that are mechanically damaged.
Chemical resistanceA good coating system provides optimum resistance to a
wide range of chemicals.
FlexibilityA good coating system has sufficient flexibility to withstand
steel expansions and contractions at varying temperatures.
Recoating intervalsA good coating system provides workable overcoating
intervals that ensure better than adequate intercoat
adhesion.
Application propertiesA good coating system has good application properties
that match the environmental conditions under which it is
applied.
Impact and abrasion resistanceA good coating has mechanical properties that match the
kind of service for which it is intended (flexibility, impact and
abrasion resistance).
9
Problems and solutionsProblems encountered with offshore maintenanceThe cost of coating maintenance is increasing – both when
carried out on-site and when done during shutdowns or a
docking.
Labour, equipment, downtime and even paint are also
becoming more and more expensive.
Many of our customers are well aware of this and they fully
understand that maintenance costs can be significantly
reduced if the right coating system is chosen and applied
correctly – the first time.
But how does a customer choose between good and bad
coating systems? And how can the customer make sure that
the system will provide the best possible lifetime protection?
Without a large laboratory consisting of vast test facilities,
it is difficult to distinguish between good and bad coating
systems – the customer must therefore rely on the supplier’s
recommendations.
Another concern for many owners during maintenance is how
to ensure that even the best coating system in the world is
applied properly – and how to do so without a large staff of
qualified coating inspectors.
Hempel solutions• Reliable supplier with almost a century of worldwide
experience.
• Supplier with a proven quality assurance system that ensures
products of a uniform, high quality, anywhere in the world.
• Supplier that can provide coating systems with documented
performance (both in the laboratory and in service).
• Supplier that not only ensures the supply of products, but
also provides expert assistance during the application
– ensuring the best possible result.
All these benefits are recognised by most global companies
working in the oil and gas industry.
Hempel is a recognised supplier to well-known companies including:
• Shell • ENI Group • BP • ConocoPhillips • Statoil • ExxonMobil • ChevronTexaco
• Total • Saudi Aramco • Petronas • Maersk Oil & Gas • ADNOC • Repsol YPF • Kuwait Oil Company
10
Generic type Product name Description Vol. Solids Normal DFT Range Epoxy HEMPADUR PRO 45601/3 A universal primer and intermediate for high- 66% 125 µ – 200 µ performance coating systems for atmospheric 5 mils – 8 mils or submersed service.
HEMPADUR UNIQ 47741/3 A unique universal newbuilding primer that 80% 125 µ – 200 µ provides excellent corrosion protection and 5 mils – 8 mils abrasion resistance for all areas.
HEMPADUR MASTIC Multi-purpose coating for maintenance 77% 125 µ – 200 µ 45880/1 including ballast tanks and new steel. 5 mils – 8 mils
High-strength epoxy HEMPADUR A high-strength coating for areas exposed to 79% 150 µ – 250 µ MULTI-STRENGTH 45751/3 abrasion and aggressively corrosive climates, 6 mils – 10 mils such as ramps and drilling decks.
HEMPADUR SPRAY-GUARD A heavy-duty coating for steel and concrete 100% 2.5 mm – 3 mm 35490/3 exposed to severely corrosive conditions and/or 100 mils – 120 mils impact such as splash zones and decks. Glass flake epoxy HEMPADUR A self-primed, high-build coating mainly for 87% 350 µ – 500 µ MULTI-STRENGTH GF 35870 areas subject to abrasion and/or a highly 14 mils – 20 mils corrosive environment, such as splash zones, jetty pilings and work decks. Glass flake polyester HEMPEL’S POLYESTER A rust-preventive coating for areas exposed to 90% 650 µ – 750 µ GF 35920 high abrasion and impact. 26 mils – 30 mils
Epoxy phenolic HEMPADUR 85671 An interior lining in tanks, pipelines, etc. for 68% 100 µ – 125 µ hot water, brine, crude oil and potable water. 4 mils – 5 mils
Inorganic zinc silicate HEMPEL’S GALVOSIL 15700 An inorganic zinc silicate as a single, complete 64% 50 µ – 100 µ coating for long-term protection of steel 2 mils – 4 mils exposed to severely corrosive environments. HEMPEL’S GALVOSIL 15680 An inorganic zinc silicate as a single, complete 90% 50 µ – 75 µ
coating for long-term protection of steel 2 mils – 3 mils exposed to severely corrosive environments.
Zinc-rich epoxy HEMPADUR ZINC 17360 A versatile, VOC-compliant, long-term primer on 65% 50 µ – 75 µ steel for epoxy, polyurethane and polysiloxane 2 mils – 3 mils coating systems in severely corrosive environments.
Polyurethane topcoats HEMPATHANE TOPCOAT A two-component, acrylic polyurethane coating 52% 40 µ – 60 µ 55210 with excellent gloss and colour retention. 1.6 mils – 2.4 mils Good resistance to water, impact and abrasion. HEMPATHANE TOPCOAT A VOC-compliant, high-build finishing coat for 66% 75 µ – 125 µ 55910 protection of structural steel in corrosive 3 mils – 5 mils environments, especially for maintenance.
HEMPEL’S URETHANE A deluxe finishing coat for protection of structural 63% 40 µ – 60 µ 5595U steel in severely corrosive environments. 1.6 mils – 2.4 mils
Polysiloxane topcoat HEMPAXANE 55000 An isocyanate-free glossy protective finishing 84% 100 µ – 125 µ coat for new steel structures in severely 4 mils – 5 mils corrosive environments.
Modified acrylic – HEMPEL’S PRO ACRYLIC An isocyanate-free finishing coat in severe 56% 50 µ – 100 µ isocyanate-free topcoat 55880 atmospheric environments where safety rules 2 mils – 4 mils preclude the use of isocyanate-cured paints.
Heat-resistant HEMPEL’S SILICONE For long-term protection of hot pipelines, 35% 25 µ ALUMINIUM 56910 exhaust pipes, smoke stacks and other hot 1 mil surfaces.
Self-polishing antifouling HEMPEL’S ANTIFOULING Self-polishing antifouling. 58% 50 µ – 100 µ GLOBIC RANGE 2 mils – 4 mils
Hempel’s offshore product rangeAvailability
Hempel worldwideMost major construction projects today involve companies
from many nations, with different sections being
constructed in different countries before final assembly
on site. Delays in the construction of any of these
sections mean costly delays for the entire project.
This is why the rapid, efficient supply of paint is an
important key to our customers’ success.
Hempel’s worldwide presence is perfectly suited to
the multinational construction business, regardless
of whether this involves petrochemical plants, tank
farms, bridges, power plants or offshore platforms.
The Hempel Group of companies currently comprises 22
manufacturing plants, 5 R&D centres, 46 sales and service
offices and more than 120 stock points around the world.
We operate with a worldwide product assortment, which
means our products are readily available wherever and
whenever required. For operators within the maritime
industry, Hempel paints are readily available at all major
ports of call.
Contact your local Hempel office for further information
and answers to any questions.
Comprehensive information about Hempel products and services is always available at www.hempel.com
12
12
11/2
00
4
Hempel offices in main offshore markets
Buenos Aires Office Hempel (Argentina) S.R.L. Libertad 1213, 2nd floor (C1012AAY) Capital Federal, Buenos Aires Argentina Phone: +54 11 4816 3137 Fax: +54 11 4812 7450 E-mail: [email protected] Dammam Office Hempel Paints (Saudi Arabia) W.L.L. P. O. Box 1077, Dammam 31431 Saudi Arabia Phone: +966 3 847 1616 Fax: +966 3 847 1816 E-mail: [email protected] Houston Office Hempel (USA) Inc. 600 Conroe Park North Drive Conroe, Texas 77303 USA Phone: +1 936 523 6000 Fax: +1 936 523 6073 E-mail: [email protected] Singapore Office Hempel (Singapore) Pte. Ltd. 25, Tuas Avenue 11, Singapore 639088 Singapore Phone: +65 6 799 8383 Fax: +65 6 799 8400 E-mail: [email protected]
Bergen Office Hempel (Norway) A/S Liavegen 12, P. O. Box 163, Nyborg N-5871 Bergen Norway Phone: +47 55 95 80 00 Fax: +47 55 95 80 50 E-mail: [email protected] Hong Kong and China Office Hempel-Hai Hong (China) Ltd. Room 1408, South Tower China Merchants Plaza 333 Chengdu Road North Shanghai 200041 The People’s Republic of China Phone: +86 21 5298 1258 Fax: +86 21 5298 1088 Doha Office Hempel Paints (Qatar) W.L.L. P. O. Box 3484 Doha Qatar Phone: +974 460 0881 Fax: +974 460 0901 E-mail: [email protected]
The Hempel Group Head OfficeHempel A/S Lundtoftevej 150DK-2800 Kgs. Lyngby DenmarkPhone: +45 45 93 38 00 Main fax: +45 45 88 55 18 E-mail: [email protected]
For other Hempel offices visit our website www.hempel.com