Corrosion Protection Offshore Installations [PDF]

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CORROSION PROTECTION Offshore installations

CORROSION PROTECTION Offshore installations

Contents

2

Introduction

3

Typical offshore specifications

5

Key offshore products

6

Documentation

7

Crucial performance indicators

8

Problems and solutions

9

Offshore product range

10

A lifetime protecting offshore structures For almost a century, Hempel has been providing high-quality

an extremely beneficial return on investment, dramatically

protective coating systems for stationary and floating steel

increasing the useful lifetime of all individual components

structures of all kinds. Today, some of the world’s longest

and keeping downtime to a minimum. And for anyone looking

bridges, tallest cranes and largest ships rely on Hempel

for a protection specification that will last up to 30 years,

quality to keep them working and looking their best. Not

second best is simply not good enough.

surprisingly, Hempel also provides protection for a vast number of offshore structures in some of the harshest

Technical expertise

environments in the world.

Our FROSIO/NACE-certified technical staff and coating advisers have in-depth knowledge and understanding of

High return on investment

on-site working procedures and the conditions under which

Owners and operators know that each floating production

paint contractors must operate. In fact, we’re one of the few

system – from full-scale platforms to FPSOs and barges

companies authorised to conduct in-house FROSIO training.

– 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

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Typical offshore specifications 1

Main exterior surfaces

Generic type Polyurethane or Polysiloxane Epoxy Epoxy Inorganic or organic zinc-rich

2

Main exterior decks, escape routes, heavy traffic and helidecks

Generic type Heavy-duty epoxy

3

Dry film thickness 25 µm / 1 mil 25 µm / 1 mil 200 µm / 8 mils

Tank lining

Generic type Epoxy phenolic Epoxy phenolic Epoxy phenolic

5

Dry film thickness 3000 µm / 120 mils

Hot surfaces

Generic type Silicone aluminium Silicone aluminium Thermal sprayed aluminium

4

Dry film thickness 50 µm / 2 mils or 100 µm / 4 mils 125 µm / 5 mils 125 µm / 5 mils 50 µm / 2 mils

Dry film thickness 100 µm / 4 mils 100 µm / 4 mils 100 µm / 4 mils

Splash zone and submerged surfaces

Generic type Glass flake epoxy Glass flake epoxy

Dry film thickness 500 µm / 20 mils 500 µm / 20 mils

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Interior surfaces

Generic type Epoxy Epoxy

Dry film thickness 100 µm / 4 mils 100 µm / 4 mils

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te l SStee l SStteeeel

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Exterior production equipment

Generic type Polyurethane or Polysiloxane Epoxy Epoxy Inorganic or organic zinc-rich

Dry film thickness 50 µm / 2 mils or 100 µm / 4 mils 125 µm / 5 mils 125 µm / 5 mils 50 µm / 2 mils

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.

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Key offshore products Tough, tougher... HEMPADUR MULTI-STRENGTH GF 35870 – glass flake epoxy Provides 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.

Benefits

Reinforcement with high content of lamellar glass flakes (more than 25% by weight of pigments and extenders).

Provides excellent corrosion protection through superior barrier effect.

Immersible just 6 hours after application (20°C/68°F), as curing proceeds under water.

Facilitates repair of structures in tidal zones.

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

Features

A breakthrough in tank linings HEMPADUR 85671 – epoxy phenolic (Novolac) A two-component, amine adduct cured phenolic epoxy (Novolac) coating with excellent resistance to high temperature, water and lining in tanks, pipelines, etc. for hot water, brine, crude oil and potable water.

Benefits

Excellent resistance to hydrocarbons. Also approved for jet fuel.

Excellent/safe choice for cargo tanks and all fuel oil tanks.

Excellent resistance to water at high temperatures – also water contaminated with oil.

Excellent/safe choice for process water and slop tanks.

Very good resistance to high pressure and decompression.

Excellent choice for separators and other pressure vessels.

Approved by WRAS/UK and NSF/USA for contact with potable water.

Excellent/safe choice for drinking water tanks.

New thinking in topcoat solutions HEMPAXANE 55000 – polysiloxane Provides exceptional gloss and colour retention along with excellent resistance to abrasion, spillage of chemicals, stains and

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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 a wide range of chemicals.

Greater durability and less risk of damage to steel surfaces.

Excellent barrier effect against diffusion of water and ions.

Longer working life, lower maintenance costs and less risk of premature refurbishment.

Solvent emission to the atmosphere Solvent emission index

NORSOK M-501-approved

UV-light. HEMPAXANE 55000 is not just a topcoat – it is also an integrated part of your corrosion protection.

120 100 80 60 40 20 0

Acrylic

Polyurethane

55000

NORSOK M-501-approved

chemicals. Suitable as an interior

Features

Documentation The specifier, engineer, owner or any other decision-maker

Unfortunately, no accelerated test method used today

responsible for selecting the right coating system to protect

correlates with real-life performance. It is therefore very

offshore installations is very aware of the fact that making

important to understand that even an excellent test result

the wrong choice can be costly.

does not automatically guarantee excellent performance in practice. There are simply too many variables that give rise

Documentation is therefore normally required for major projects

to important differences between laboratory application and

in order to corroborate the performance of the coating system.

testing on the one hand, and real-life situations on the other.

Two types of documentation are often required:

Experience

1) Documentation concerning practical performance, to

Hempel has vast experience in the use of coating systems in

confirm that the coating system has worked satisfactorily

marine and offshore environments. This accumulated know-

under similar conditions.

how makes Hempel an extremely reliable supplier, and the company can deliver extensive documentation on the use of

This documentation is the best possible proof that the system

coating systems in practice.

is efficient under real-life conditions. The main disadvantage of this type of documentation is that many of the coatings

Hempel also carries out comprehensive accelerated tests,

used 10–15 years ago are no longer on the market today.

both internally at its modern Test and Innovation Centre in Denmark, and externally at different recognised independent

2) To

a

certain

extent,

documentation

concerning

laboratories.

performance can also be obtained through accelerated testing. Several standards currently list accelerated test

At the end of the day, optimum corrosion protection is only obtained

methods that should be performed for the qualification

when the coating system is properly applied on-site. In many

testing of coating systems for offshore use.

cases this can only be ensured by a good QAS system, backed up by one of Hempel’s many experienced coating engineers.

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.

Hempel’s internal test: • • • • • • •

Surface preparation Application Water immersion Chemical resistance Pull off Impact strength Flexibility

• • • • • • •

Temperature gradient Cathodic disbondment Rust creepage resistance Thermal cycling resistance Colour/gloss retention Edge build Thick film crack resistance

• • • • • •

Abrasion resistance Aging stability Cyclic testing Blister box Salt spray Physical constants

Most of the tests are according to accredited standards such as, ASTM, NORSOK, NACE and ISO.

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Offshore installations require optimum coating systems Impact and abrasion resistance

Application properties

Recoating intervals

Gloss and colour retention

A balance between crucial performance indicators

Flexibility

Anticorrosive performance Chemical resistance

Gloss and colour retention A good coating system is resistant to the environmental stresses to which it is exposed, and maintains good gloss and colour retention.

Recoating intervals A good coating system provides workable overcoating intervals that ensure better than adequate intercoat

Anticorrosive performance

adhesion.

A good coating system provides good corrosion protection – even in areas that are mechanically damaged.

Application properties A good coating system has good application properties

Chemical resistance A good coating system provides optimum resistance to a

that match the environmental conditions under which it is applied.

wide range of chemicals.

Impact and abrasion resistance Flexibility

A good coating has mechanical properties that match the

A good coating system has sufficient flexibility to withstand

kind of service for which it is intended (flexibility, impact and

steel expansions and contractions at varying temperatures.

abrasion resistance).

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Problems and solutions Problems encountered with offshore maintenance

Hempel solutions • Reliable supplier with almost a century of worldwide

The cost of coating maintenance is increasing – both when

experience.

carried out on-site and when done during shutdowns or a docking.

• Supplier with a proven quality assurance system that ensures products of a uniform, high quality, anywhere in the world.

Labour, equipment, downtime and even paint are also becoming more and more expensive.

• Supplier that can provide coating systems with documented performance (both in the laboratory and in service).

Many of our customers are well aware of this and they fully understand that maintenance costs can be significantly

• Supplier that not only ensures the supply of products, but

reduced if the right coating system is chosen and applied

also provides expert assistance during the application

correctly – the first time.

– ensuring the best possible result.

But how does a customer choose between good and bad

All these benefits are recognised by most global companies

coating systems? And how can the customer make sure that

working in the oil and gas industry.

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 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

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Hempel’s offshore product range Generic type

Product name

Description

Epoxy

HEMPADUR PRO 45601/3

A universal primer and intermediate for highperformance coating systems for atmospheric or submersed service.

66%

125 µ – 200 µ 5 mils – 8 mils

HEMPADUR UNIQ 47741/3

A unique universal newbuilding primer that provides excellent corrosion protection and abrasion resistance for all areas.

80%

125 µ – 200 µ 5 mils – 8 mils

HEMPADUR MASTIC 45880/1

Multi-purpose coating for maintenance including ballast tanks and new steel.

77%

125 µ – 200 µ 5 mils – 8 mils

HEMPADUR MULTI-STRENGTH 45751/3

A high-strength coating for areas exposed to abrasion and aggressively corrosive climates, such as ramps and drilling decks.

79%

150 µ – 250 µ 6 mils – 10 mils

HEMPADUR SPRAY-GUARD 35490/3

A heavy-duty coating for steel and concrete exposed to severely corrosive conditions and/or impact such as splash zones and decks.

100%

2.5 mm – 3 mm 100 mils – 120 mils

High-strength epoxy

Vol. Solids

Normal DFT Range

Glass flake epoxy

HEMPADUR A self-primed, high-build coating mainly for MULTI-STRENGTH GF 35870 areas subject to abrasion and/or a highly corrosive environment, such as splash zones, jetty pilings and work decks.

87%

350 µ – 500 µ 14 mils – 20 mils

Glass flake polyester

HEMPEL’S POLYESTER GF 35920

A rust-preventive coating for areas exposed to high abrasion and impact.

90%

650 µ – 750 µ 26 mils – 30 mils

Epoxy phenolic

HEMPADUR 85671

An interior lining in tanks, pipelines, etc. for hot water, brine, crude oil and potable water.

68%

100 µ – 125 µ 4 mils – 5 mils

Inorganic zinc silicate

HEMPEL’S GALVOSIL 15700 An inorganic zinc silicate as a single, complete coating for long-term protection of steel exposed to severely corrosive environments.

64%

50 µ – 100 µ 2 mils – 4 mils

HEMPEL’S GALVOSIL 15680 An inorganic zinc silicate as a single, complete coating for long-term protection of steel exposed to severely corrosive environments.

90%

50 µ – 75 µ 2 mils – 3 mils

Zinc-rich epoxy

HEMPADUR ZINC 17360

A versatile, VOC-compliant, long-term primer on steel for epoxy, polyurethane and polysiloxane coating systems in severely corrosive environments.

65%

50 µ – 75 µ 2 mils – 3 mils

Polyurethane topcoats

HEMPATHANE TOPCOAT 55210

A two-component, acrylic polyurethane coating with excellent gloss and colour retention. Good resistance to water, impact and abrasion.

52%

40 µ – 60 µ 1.6 mils – 2.4 mils

HEMPATHANE TOPCOAT 55910

A VOC-compliant, high-build finishing coat for protection of structural steel in corrosive environments, especially for maintenance.

66%

75 µ – 125 µ 3 mils – 5 mils

HEMPEL’S URETHANE 5595U

A deluxe finishing coat for protection of structural steel in severely corrosive environments.

63%

40 µ – 60 µ 1.6 mils – 2.4 mils

Polysiloxane topcoat

HEMPAXANE 55000

An isocyanate-free glossy protective finishing coat for new steel structures in severely corrosive environments.

84%

100 µ – 125 µ 4 mils – 5 mils

Modified acrylic – isocyanate-free topcoat

HEMPEL’S PRO ACRYLIC 55880

An isocyanate-free finishing coat in severe atmospheric environments where safety rules preclude the use of isocyanate-cured paints.

56%

50 µ – 100 µ 2 mils – 4 mils

Heat-resistant

HEMPEL’S SILICONE ALUMINIUM 56910

For long-term protection of hot pipelines, exhaust pipes, smoke stacks and other hot surfaces.

35%

25 µ 1 mil

Self-polishing antifouling

HEMPEL’S ANTIFOULING GLOBIC RANGE

Self-polishing antifouling.

58%

50 µ – 100 µ 2 mils – 4 mils

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Availability

Hempel worldwide Most 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

11 / 2004

The Hempel Group Head Office Hempel A/S Lundtoftevej 150 DK-2800 Kgs. Lyngby Denmark Phone: +45 45 93 38 00 Main fax: +45 45 88 55 18 E-mail: [email protected]

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 +54 11 4812 7450 Fax: 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]

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]

Houston Office Hempel (USA) Inc. 600 Conroe Park Nor th Drive Conroe, Texas 77303 USA Phone: +1 936 523 6000 +1 936 523 6073 Fax: E-mail: [email protected]

Hong Kong and China Office Hempel-Hai Hong (China) Ltd. Room 1408, South Tower China Merchants Plaza 333 Chengdu Road Nor th Shanghai 200041 The People’s Republic of China Phone: +86 21 5298 1258 Fax: +86 21 5298 1088

Singapore Office Hempel (Singapore) Pte. Ltd. 25, Tuas Avenue 11, Singapore 639088 Singapore Phone: +65 6 799 8383 Fax: +65 6 799 8400 [email protected] E-mail:

Doha Office Hempel Paints (Qatar) W.L.L. P. O. Box 3484 Doha Qatar Phone: +974 460 0881 +974 460 0901 Fax: E-mail: [email protected]

For other Hempel offices visit our website www.hempel.com 12

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