corrosion protection offshore installations

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CORROSION PROTECTION Offshore installations

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Page 1: Corrosion Protection Offshore Installations

12

CORROSION PROTECTIONOffshore installations

Page 2: Corrosion Protection Offshore 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

Page 3: Corrosion Protection Offshore Installations

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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

Page 4: Corrosion Protection Offshore Installations

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Page 5: Corrosion Protection Offshore Installations

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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.

Page 6: Corrosion Protection Offshore Installations

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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

Page 7: Corrosion Protection Offshore Installations

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

Page 8: Corrosion Protection Offshore Installations

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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).

Page 9: Corrosion Protection Offshore Installations

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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

Page 10: Corrosion Protection Offshore Installations

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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

Page 11: Corrosion Protection Offshore Installations

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

Page 12: Corrosion Protection Offshore Installations

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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