Corrosion Protection Offshore Installations
Content
CORROSION PROTECTION
Offshore installations
CORROSION PROTECTION
Offshore installations
Contents
Introduction Typical offshore specifications Key offshore products Documentation Crucial performance indicators Problems and solutions Offshore product range 3 5 6 7 8 9 10
2
A lifetime protecting offshore structures
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. 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 expertise
Our 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.
High return on investment
Owners 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
3
1
3 7
2 4
6
5
4
4
Typical offshore specifications
1
Main exterior surfaces
Dry film thickness 50 µm / 2 mils or 100 µm / 4 mils 125 µm / 5 mils 125 µm / 5 mils 50 µm / 2 mils
Generic type Polyurethane or Polysiloxane Epoxy Epoxy Inorganic or organic zinc-rich
xane olysilo ane x e or P than orxPolysilo ane re e Polyu thanEpo yolysiloxane lox P re ox y si Polyu thanEporxy olyzinc-rich Eepor P e ane olyurethan organic siloxanh P re or poxy ly lo -ric e c Ep x P Polyuanic ane oraynolyzin x ich ic si E oxy po P org rethorEe rgr y o zinc-rich o oxy In lyu nic an pox nic c-r Po rga th Eprga zin re E Inolyu nic orEorgxynic el ich po a Po a r o oxytez -r p S Inorganic o Epoxynic einc-rich l Eorgate zinc org In S ic ic or organeel n organic or Steel In St Inorga
el Steel Ste
2
Main exterior decks, escape routes, heavy traffic and helidecks
Dry film thickness 3000 µm / 120 mils
Generic type Heavy-duty epoxy
y epox y-duty xy Heav uty epo vy-d epoxy Hea uty epoxy y-d Heavy-duty eel Heav St poxly e y y-duty epex S eo Heavy-dutyt el Heav Steel
Ste l Steel Stee
3
Hot surfaces
Dry film thickness 25 µm / 1 mil 25 µm / 1 mil 200 µm / 8 mils
Generic type Silicone aluminium Silicone aluminium Thermal sprayed aluminium
m miniu ne alu inium m Silico e aluminiu ium alum m ilicon e alud alumin m icon e minium S il e y iniu iu S n m ium in a on ra e in m Siliclospe alumalum m Silic spraylum luminiu Thermalone alud inium ium a e a iu in Silic in m Thermalone alud aluem m Silicone alud inium iu spraye m eiu l y m Silic spra S lu l m Thermalone aludtin minium Silic Therm icone ye talumin ee Sil spra S a rmal rayed el Thermal sp Steel Ste The
l Steel Stee
4
Tank lining
Dry film thickness 100 µm / 4 mils 100 µm / 4 mils 100 µm / 4 mils
Generic type Epoxy phenolic Epoxy phenolic Epoxy phenolic
nolic y phe lic Epox phenolic o y phen c Epox y henolic oli Epox p henolic yp n poxy e Epoxy phenolic Epox ph olic E oxy hen c poxy p enolic E lic Epoxy phenolic l h noli y pheno Epoxy phenelic Epoxy p S o e Ep Epoxy phet olicl n enoe Epoxy phetelic x S Epoxy ph eel Epo St l
Stee e l Steel St e
5
Splash zone and submerged surfaces
Dry film thickness 500 µm / 20 mils 500 µm / 20 mils
Generic type Glass flake epoxy Glass flake epoxy
y epox flake oxy p Glass ake epox y fl ake epoxy Glass flake epoxy Glass fl e xy la Glass flake epoxy e o G ss flake ep l oxy Glass ak Steey Glass flake epoxl ep Glass flakSteoxy fl e p e Glass flake eeel Glass Steel t
S el Steel Ste
6
Interior surfaces
Dry film thickness 100 µm / 4 mils 100 µm / 4 mils
y Epox y Epox y Epox xy Epoxy Epoxy o Epoxy Epoxyteel S Epoxy eel t EpoSy Ep x el
Generic type Epoxy Epoxy
Ste l Stee l Steel Stee
7
Exterior production equipment
Dry film thickness 50 µm / 2 mils or 100 µm / 4 mils 125 µm / 5 mils 125 µm / 5 mils 50 µm / 2 mils
ne siloxa r Poly loxane si ane o ureth neporxPoly loxane y Poly tha E o olysi xane lo h re y xP Polyu thanEporxy olysiinc-rice Eepor P z ure ne oxy ic siloxane -r n Polyuretha r por an lyzincxaich o oEp rgynic Poly anicane oxaPolysilo ich E rg y o x pox P rEo oxy Inorgrethone or y zinc-rich Polyuantha rEorganic zinc-r u ic po y rg re o Epoxanic l Inoly nic Eorg y e ich Po a r poxy e z -r p S Inorganic o Epoxaticeinc-rich l E Inorg S nic inc n or org te z anic or orgateel Steel Inorganic S Inorg
Generic type Polyurethane or Polysiloxane Epoxy Epoxy Inorganic or organic zinc-rich
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.
e l Steel St e
5
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.
Features
Reinforcement with high content of lamellar glass flakes (more than 25% by weight of pigments and extenders). Immersible just 6 hours after application (20°C/68°F), as curing proceeds under water. Rain-resistant just 4 hours after application.
Benefits
Provides excellent corrosion protection through superior barrier effect.
Facilitates repair of structures in tidal zones.
Structures can be coated indoors and stored outdoors in wet or humid conditions shortly after application. High-build properties ensure greater dry film thickness in just one or two coats. Healthier and safer for applicators, particularly when applied indoors.
NORSOK M-501-approved
High volume solids content (87%). Low volatile organic compound content (180 g/litre).
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 chemicals. Suitable as an interior lining in tanks, pipelines, etc. for hot water, brine, crude oil and potable water.
Features
Excellent resistance to hydrocarbons. Also approved for jet fuel. Excellent resistance to water at high temperatures – also water contaminated with oil. Very good resistance to high pressure and decompression. Approved by WRAS/UK and NSF/USA for contact with potable water.
Benefits
Excellent/safe choice for cargo tanks and all fuel oil tanks. Excellent/safe choice for process water and slop tanks.
NORSOK M-501-approved
Excellent choice for separators and other pressure vessels. 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 UV-light. HEMPAXANE 55000 is not just a topcoat – it is also an integrated part of your corrosion protection.
Features
Excellent colour and gloss retention.
Benefits
Far superior performance compared to other generic types of topcoats. Complies with VOC regulations all over the world. Greater durability and less risk of damage to steel surfaces. Longer working life, lower maintenance costs and less risk of premature refurbishment.
Solvent emission to the atmosphere Solvent emission index
120 100 80 60 40 20 0
High volume solids content (84%).
NORSOK M-501-approved
Excellent resistance to spillage from a wide range of chemicals. Excellent barrier effect against diffusion of water and ions.
Acrylic
Polyurethane
55000
6
Documentation
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. 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.
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
Experience
Hempel has vast experience in the use of coating systems in marine and offshore environments. This accumulated knowhow 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.
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.
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.
7
Offshore installations require optimum coating systems
Impact and abrasion resistance
Application properties
Recoating intervals
A balance between crucial performance indicators
Gloss and colour retention
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 adhesion.
Anticorrosive performance
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 that match the environmental conditions under which it is applied.
Chemical resistance
A good coating system provides optimum resistance to a wide range of chemicals.
Impact and abrasion resistance Flexibility
A good coating system has sufficient flexibility to withstand steel expansions and contractions at varying temperatures. A good coating has mechanical properties that match the kind of service for which it is intended (flexibility, impact and abrasion resistance).
8
Problems and solutions
Problems encountered with offshore maintenance
The 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. • 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. • Supplier that can provide coating systems with documented performance (both in the laboratory and in service). • Supplier with a proven quality assurance system that ensures products of a uniform, high quality, anywhere in the world.
Hempel solutions
• Reliable supplier with almost a century of worldwide experience.
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
9
Hempel’s offshore product range
Generic type Epoxy Product name HEMPADUR PRO 45601/3 Description A universal primer and intermediate for highperformance coating systems for atmospheric or submersed service. A unique universal newbuilding primer that provides excellent corrosion protection and abrasion resistance for all areas. Multi-purpose coating for maintenance including ballast tanks and new steel. A high-strength coating for areas exposed to abrasion and aggressively corrosive climates, such as ramps and drilling decks. A heavy-duty coating for steel and concrete exposed to severely corrosive conditions and/or impact such as splash zones and decks. Vol. Solids 66% Normal DFT Range 125 µ – 200 µ 5 mils – 8 mils Availability
HEMPADUR UNIQ 47741/3
80%
125 µ – 200 µ 5 mils – 8 mils
HEMPADUR MASTIC 45880/1 High-strength epoxy HEMPADUR MULTI-STRENGTH 45751/3
77%
125 µ – 200 µ 5 mils – 8 mils 150 µ – 250 µ 6 mils – 10 mils
79%
HEMPADUR SPRAY-GUARD 35490/3
100%
2.5 mm – 3 mm 100 mils – 120 mils
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. HEMPEL’S POLYESTER GF 35920 HEMPADUR 85671 A rust-preventive coating for areas exposed to high abrasion and impact. An interior lining in tanks, pipelines, etc. for hot water, brine, crude oil and potable water.
87%
350 µ – 500 µ 14 mils – 20 mils
Glass flake polyester
90%
650 µ – 750 µ 26 mils – 30 mils 100 µ – 125 µ 4 mils – 5 mils 50 µ – 100 µ 2 mils – 4 mils
Epoxy phenolic
68%
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. HEMPEL’S GALVOSIL 15680 An inorganic zinc silicate as a single, complete coating for long-term protection of steel exposed to severely corrosive environments.
64%
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. A two-component, acrylic polyurethane coating with excellent gloss and colour retention. Good resistance to water, impact and abrasion. A VOC-compliant, high-build finishing coat for protection of structural steel in corrosive environments, especially for maintenance. A deluxe finishing coat for protection of structural steel in severely corrosive environments. An isocyanate-free glossy protective finishing coat for new steel structures in severely corrosive environments. An isocyanate-free finishing coat in severe atmospheric environments where safety rules preclude the use of isocyanate-cured paints. For long-term protection of hot pipelines, exhaust pipes, smoke stacks and other hot surfaces. Self-polishing antifouling.
65%
50 µ – 75 µ 2 mils – 3 mils
Polyurethane topcoats
HEMPATHANE TOPCOAT 55210
52%
40 µ – 60 µ 1.6 mils – 2.4 mils
HEMPATHANE TOPCOAT 55910
66%
75 µ – 125 µ 3 mils – 5 mils
HEMPEL’S URETHANE 5595U Polysiloxane topcoat HEMPAXANE 55000
63%
40 µ – 60 µ 1.6 mils – 2.4 mils 100 µ – 125 µ 4 mils – 5 mils
84%
Modified acrylic – isocyanate-free topcoat
HEMPEL’S PRO ACRYLIC 55880
56%
50 µ – 100 µ 2 mils – 4 mils
Heat-resistant
HEMPEL’S SILICONE ALUMINIUM 56910
35%
25 µ 1 mil
Self-polishing antifouling
HEMPEL’S ANTIFOULING GLOBIC RANGE
58%
50 µ – 100 µ 2 mils – 4 mils
10
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] 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] 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: 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 Nor th 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 +974 460 0901 Fax: E-mail: [email protected]
For other Hempel offices visit our website www.hempel.com
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Offshore installations
CORROSION PROTECTION
Offshore installations
Contents
Introduction Typical offshore specifications Key offshore products Documentation Crucial performance indicators Problems and solutions Offshore product range 3 5 6 7 8 9 10
2
A lifetime protecting offshore structures
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. 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 expertise
Our 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.
High return on investment
Owners 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
3
1
3 7
2 4
6
5
4
4
Typical offshore specifications
1
Main exterior surfaces
Dry film thickness 50 µm / 2 mils or 100 µm / 4 mils 125 µm / 5 mils 125 µm / 5 mils 50 µm / 2 mils
Generic type Polyurethane or Polysiloxane Epoxy Epoxy Inorganic or organic zinc-rich
xane olysilo ane x e or P than orxPolysilo ane re e Polyu thanEpo yolysiloxane lox P re ox y si Polyu thanEporxy olyzinc-rich Eepor P e ane olyurethan organic siloxanh P re or poxy ly lo -ric e c Ep x P Polyuanic ane oraynolyzin x ich ic si E oxy po P org rethorEe rgr y o zinc-rich o oxy In lyu nic an pox nic c-r Po rga th Eprga zin re E Inolyu nic orEorgxynic el ich po a Po a r o oxytez -r p S Inorganic o Epoxynic einc-rich l Eorgate zinc org In S ic ic or organeel n organic or Steel In St Inorga
el Steel Ste
2
Main exterior decks, escape routes, heavy traffic and helidecks
Dry film thickness 3000 µm / 120 mils
Generic type Heavy-duty epoxy
y epox y-duty xy Heav uty epo vy-d epoxy Hea uty epoxy y-d Heavy-duty eel Heav St poxly e y y-duty epex S eo Heavy-dutyt el Heav Steel
Ste l Steel Stee
3
Hot surfaces
Dry film thickness 25 µm / 1 mil 25 µm / 1 mil 200 µm / 8 mils
Generic type Silicone aluminium Silicone aluminium Thermal sprayed aluminium
m miniu ne alu inium m Silico e aluminiu ium alum m ilicon e alud alumin m icon e minium S il e y iniu iu S n m ium in a on ra e in m Siliclospe alumalum m Silic spraylum luminiu Thermalone alud inium ium a e a iu in Silic in m Thermalone alud aluem m Silicone alud inium iu spraye m eiu l y m Silic spra S lu l m Thermalone aludtin minium Silic Therm icone ye talumin ee Sil spra S a rmal rayed el Thermal sp Steel Ste The
l Steel Stee
4
Tank lining
Dry film thickness 100 µm / 4 mils 100 µm / 4 mils 100 µm / 4 mils
Generic type Epoxy phenolic Epoxy phenolic Epoxy phenolic
nolic y phe lic Epox phenolic o y phen c Epox y henolic oli Epox p henolic yp n poxy e Epoxy phenolic Epox ph olic E oxy hen c poxy p enolic E lic Epoxy phenolic l h noli y pheno Epoxy phenelic Epoxy p S o e Ep Epoxy phet olicl n enoe Epoxy phetelic x S Epoxy ph eel Epo St l
Stee e l Steel St e
5
Splash zone and submerged surfaces
Dry film thickness 500 µm / 20 mils 500 µm / 20 mils
Generic type Glass flake epoxy Glass flake epoxy
y epox flake oxy p Glass ake epox y fl ake epoxy Glass flake epoxy Glass fl e xy la Glass flake epoxy e o G ss flake ep l oxy Glass ak Steey Glass flake epoxl ep Glass flakSteoxy fl e p e Glass flake eeel Glass Steel t
S el Steel Ste
6
Interior surfaces
Dry film thickness 100 µm / 4 mils 100 µm / 4 mils
y Epox y Epox y Epox xy Epoxy Epoxy o Epoxy Epoxyteel S Epoxy eel t EpoSy Ep x el
Generic type Epoxy Epoxy
Ste l Stee l Steel Stee
7
Exterior production equipment
Dry film thickness 50 µm / 2 mils or 100 µm / 4 mils 125 µm / 5 mils 125 µm / 5 mils 50 µm / 2 mils
ne siloxa r Poly loxane si ane o ureth neporxPoly loxane y Poly tha E o olysi xane lo h re y xP Polyu thanEporxy olysiinc-rice Eepor P z ure ne oxy ic siloxane -r n Polyuretha r por an lyzincxaich o oEp rgynic Poly anicane oxaPolysilo ich E rg y o x pox P rEo oxy Inorgrethone or y zinc-rich Polyuantha rEorganic zinc-r u ic po y rg re o Epoxanic l Inoly nic Eorg y e ich Po a r poxy e z -r p S Inorganic o Epoxaticeinc-rich l E Inorg S nic inc n or org te z anic or orgateel Steel Inorganic S Inorg
Generic type Polyurethane or Polysiloxane Epoxy Epoxy Inorganic or organic zinc-rich
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.
e l Steel St e
5
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.
Features
Reinforcement with high content of lamellar glass flakes (more than 25% by weight of pigments and extenders). Immersible just 6 hours after application (20°C/68°F), as curing proceeds under water. Rain-resistant just 4 hours after application.
Benefits
Provides excellent corrosion protection through superior barrier effect.
Facilitates repair of structures in tidal zones.
Structures can be coated indoors and stored outdoors in wet or humid conditions shortly after application. High-build properties ensure greater dry film thickness in just one or two coats. Healthier and safer for applicators, particularly when applied indoors.
NORSOK M-501-approved
High volume solids content (87%). Low volatile organic compound content (180 g/litre).
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 chemicals. Suitable as an interior lining in tanks, pipelines, etc. for hot water, brine, crude oil and potable water.
Features
Excellent resistance to hydrocarbons. Also approved for jet fuel. Excellent resistance to water at high temperatures – also water contaminated with oil. Very good resistance to high pressure and decompression. Approved by WRAS/UK and NSF/USA for contact with potable water.
Benefits
Excellent/safe choice for cargo tanks and all fuel oil tanks. Excellent/safe choice for process water and slop tanks.
NORSOK M-501-approved
Excellent choice for separators and other pressure vessels. 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 UV-light. HEMPAXANE 55000 is not just a topcoat – it is also an integrated part of your corrosion protection.
Features
Excellent colour and gloss retention.
Benefits
Far superior performance compared to other generic types of topcoats. Complies with VOC regulations all over the world. Greater durability and less risk of damage to steel surfaces. Longer working life, lower maintenance costs and less risk of premature refurbishment.
Solvent emission to the atmosphere Solvent emission index
120 100 80 60 40 20 0
High volume solids content (84%).
NORSOK M-501-approved
Excellent resistance to spillage from a wide range of chemicals. Excellent barrier effect against diffusion of water and ions.
Acrylic
Polyurethane
55000
6
Documentation
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. 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.
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
Experience
Hempel has vast experience in the use of coating systems in marine and offshore environments. This accumulated knowhow 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.
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.
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.
7
Offshore installations require optimum coating systems
Impact and abrasion resistance
Application properties
Recoating intervals
A balance between crucial performance indicators
Gloss and colour retention
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 adhesion.
Anticorrosive performance
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 that match the environmental conditions under which it is applied.
Chemical resistance
A good coating system provides optimum resistance to a wide range of chemicals.
Impact and abrasion resistance Flexibility
A good coating system has sufficient flexibility to withstand steel expansions and contractions at varying temperatures. A good coating has mechanical properties that match the kind of service for which it is intended (flexibility, impact and abrasion resistance).
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Problems and solutions
Problems encountered with offshore maintenance
The 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. • 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. • Supplier that can provide coating systems with documented performance (both in the laboratory and in service). • Supplier with a proven quality assurance system that ensures products of a uniform, high quality, anywhere in the world.
Hempel solutions
• Reliable supplier with almost a century of worldwide experience.
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 Epoxy Product name HEMPADUR PRO 45601/3 Description A universal primer and intermediate for highperformance coating systems for atmospheric or submersed service. A unique universal newbuilding primer that provides excellent corrosion protection and abrasion resistance for all areas. Multi-purpose coating for maintenance including ballast tanks and new steel. A high-strength coating for areas exposed to abrasion and aggressively corrosive climates, such as ramps and drilling decks. A heavy-duty coating for steel and concrete exposed to severely corrosive conditions and/or impact such as splash zones and decks. Vol. Solids 66% Normal DFT Range 125 µ – 200 µ 5 mils – 8 mils Availability
HEMPADUR UNIQ 47741/3
80%
125 µ – 200 µ 5 mils – 8 mils
HEMPADUR MASTIC 45880/1 High-strength epoxy HEMPADUR MULTI-STRENGTH 45751/3
77%
125 µ – 200 µ 5 mils – 8 mils 150 µ – 250 µ 6 mils – 10 mils
79%
HEMPADUR SPRAY-GUARD 35490/3
100%
2.5 mm – 3 mm 100 mils – 120 mils
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. HEMPEL’S POLYESTER GF 35920 HEMPADUR 85671 A rust-preventive coating for areas exposed to high abrasion and impact. An interior lining in tanks, pipelines, etc. for hot water, brine, crude oil and potable water.
87%
350 µ – 500 µ 14 mils – 20 mils
Glass flake polyester
90%
650 µ – 750 µ 26 mils – 30 mils 100 µ – 125 µ 4 mils – 5 mils 50 µ – 100 µ 2 mils – 4 mils
Epoxy phenolic
68%
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. HEMPEL’S GALVOSIL 15680 An inorganic zinc silicate as a single, complete coating for long-term protection of steel exposed to severely corrosive environments.
64%
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. A two-component, acrylic polyurethane coating with excellent gloss and colour retention. Good resistance to water, impact and abrasion. A VOC-compliant, high-build finishing coat for protection of structural steel in corrosive environments, especially for maintenance. A deluxe finishing coat for protection of structural steel in severely corrosive environments. An isocyanate-free glossy protective finishing coat for new steel structures in severely corrosive environments. An isocyanate-free finishing coat in severe atmospheric environments where safety rules preclude the use of isocyanate-cured paints. For long-term protection of hot pipelines, exhaust pipes, smoke stacks and other hot surfaces. Self-polishing antifouling.
65%
50 µ – 75 µ 2 mils – 3 mils
Polyurethane topcoats
HEMPATHANE TOPCOAT 55210
52%
40 µ – 60 µ 1.6 mils – 2.4 mils
HEMPATHANE TOPCOAT 55910
66%
75 µ – 125 µ 3 mils – 5 mils
HEMPEL’S URETHANE 5595U Polysiloxane topcoat HEMPAXANE 55000
63%
40 µ – 60 µ 1.6 mils – 2.4 mils 100 µ – 125 µ 4 mils – 5 mils
84%
Modified acrylic – isocyanate-free topcoat
HEMPEL’S PRO ACRYLIC 55880
56%
50 µ – 100 µ 2 mils – 4 mils
Heat-resistant
HEMPEL’S SILICONE ALUMINIUM 56910
35%
25 µ 1 mil
Self-polishing antifouling
HEMPEL’S ANTIFOULING GLOBIC RANGE
58%
50 µ – 100 µ 2 mils – 4 mils
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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] 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] 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: 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 Nor th 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 +974 460 0901 Fax: E-mail: [email protected]
For other Hempel offices visit our website www.hempel.com
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