Item No. 21252 Item no. 21126
Standard Practice
Corrosion Control of Offshore Structures
by Protective Coatings
This NACE International standard represents a consensus of those individual members who have reviewed this document, its scope, and provisions. Its acceptance does not in any respect preclude anyone, whether he or she has adopted the standard or not, from manufacturing, marketing, purchasing, or using products, processes, or procedures not in conformance with this standard. Nothing contained in this NACE International standard is to be construed as granting any right, by implication or otherwise, to manufacture, sell, or use in connection with any method, apparatus, or product covered by Letters Patent, or as indemnifying or protecting anyone against liability for infringement of Letters Patent. This standard represents minimum requirements and should in no way be interpreted as a restriction on the use of better procedures or materials. Neither is this standard intended to apply in all cases relating to the subject. Unpredictable circumstances may negate the usefulness of this standard in specific instances. NACE International assumes no responsibility for the interpretation or use of this standard by other parties and accepts responsibility for only those official NACE International interpretations issued by NACE International in accordance with its governing procedures and policies which preclude the issuance of interpretations by individual volunteers.
Users of this NACE International standard are responsible for reviewing appropriate health, safety, environmental, and regulatory documents and for determining their applicability in relation to this standard prior to its use. This NACE International standard may not necessarily address all potential health and safety problems or environmental hazards associated with the use of materials, equipment, and/or operations detailed or referred to within this standard. Users of this NACE International standard are also responsible for establishing appropriate health, safety, and environmental protection practices, in consultation with appropriate regulatory authorities if necessary, to achieve compliance with any existing applicable regulatory requirements prior to the use of this standard.
CAUTIONARY NOTICE: NACE International standards are subject to periodic review, and may be revised or withdrawn at any time in accordance with NACE technical committee procedures. NACE International requires that action be taken to reaffirm, revise, or withdraw this standard no later than five years from the date of initial publication. The user is cautioned to obtain the latest edition. Purchasers of NACE International standards may receive current information on all --`,,```,,,,````-`-`,,`,,`,`,,`---standards and other NACE International publications by contacting the NACE International FirstService Department, 1440 South Creek Drive, Houston, Texas 77084-4906 (telephone +1 281- 228-6200).
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Foreword
Offshore structures represent large capital investments and are being placed worldwide. Moreover, more and more offshore structures are being placed in deeper waters and, therefore, have become larger, more complex, and more expensive. Control of corrosion on offshore structures is necessary to sustain oil and gas production, provide safe working and living areas, and avoid potential harm to the environment. For this standard, offshore structures includes metallic offshore structures such as fixed-leg platforms, tension-leg platforms (TLPs), semisubmersibles, spar platforms, and floating production storage and offloading vessels (FPSOs).
This NACE International standard is intended for use by facility owners’ corrosion control personnel, coating applicators, and coating manufacturers. It covers coating materials, coating test protocol and acceptance criteria, surface preparation, coating application, quality assurance and control, and repair methods. It also covers generic protective coating systems, flange corrosion control, fastener coatings, pipe support corrosion control, and stainless steel (SS) tubing corrosion control. The purpose is to facilitate more effective corrosion protection of offshore structures by presenting reliable information and providing guidelines for coating manufacturers to develop more durable products.
This standard replaces a portion of NACE Standard RP0176.1
RP0176 was originally issued in --`,,```,,,,````-`-`,,`,,`,`,,`---1976 and revised in 1983 by Task Group (TG) T-1-2 on North Sea Corrosion Problems. It was revised in 1994 by TG T-1-5, and in 2003 by TG 170 on Offshore Steel Platforms—Corrosion Control: Review of NACE Standard RP0176, which is administered by Specific Technology Group (STG) 30 on Oil and Gas Production: Cathodic Protection. All editions of RP0176 prior to 2007 addressed two aspects of corrosion control of steel fixed offshore structures associated with petroleum production: cathodic protection (CP) and protective coatings. In 2007 it was decided to
address these two aspects in separate NACE standards. Therefore, SP01762
was issued in 2007 by TG 170 and STG 30 to address the CP aspects. TG 313—Offshore Platforms: Coatings for Corrosion Control of Steel was formed to address the protective coatings aspects from RP0176 and provide expanded information. TG 313 is administered by STG 02—Coatings and Linings, Protective: Atmospheric. This standard is issued by NACE under the auspices of STG 02.
In NACE standards, the terms shall, must, should, and may are used in accordance with the definitions of these terms in the NACE Publications Style Manual. The terms shall and must are used to state a requirement, and are considered mandatory. The term should is used to state something good and is recommended, but is not considered mandatory. The term may is used to state something considered optional.
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NACE International Standard Practice
Corrosion Control of Offshore Structures
by Protective Coatings
Contents
1. General ............................................................................................................................... 1 2. Definitions ........................................................................................................................... 1 3. Protective Coating Systems .......................................................................................... 2 4. Typical Generic Protective Coating Systems ................................................................ 5 5. Qualification Testing of Coating Systems ................................................................... 13 6. Surface Preparation .................................................................................................... 19 7. Coating Materials and Application ............................................................................... 22 8. Quality Assurance and Control .................................................................................... 23 9. Coating Repair ............................................................................................................ 25 10. Flange Corrosion Control ............................................................................................ 26 11. Fastener Coatings ....................................................................................................... 26 12. Pipe Support Corrosion Control .................................................................................. 27 13. Corrosion Control of Small-Bore Stainless Steel Tubing ............................................ 27 14. Health, Safety, and Environment ................................................................................. 28 References ........................................................................................................................ 28 TABLES
Table 1. Maximum Metal Content in the Dry Coating Film ................................................ 4 Table 2. Routine Batch Testing Report .............................................................................. 5 Table 3A. Typical Atmospheric Zone New Construction Coating Systems on Carbon
Steels ............................................................................................................................ 6 Table 3B. Typical Atmospheric Zone Maintenance Coating Systems on Carbon Steels .. 8 Table 4: Typical Atmospheric Zone Coating Systems on Stainless Steels (New
Construction and Maintenance) .................................................................................... 9 Table 5: Typical Atmospheric Zone Coating Systems for Nonferrous Metals (New
Construction and Maintenance) .................................................................................. 10 Table 6A: Typical Splash Zone New Construction Coating Systems on Carbon Steels ... 11 Table 6B: Typical Splash Zone Maintenance Coating Systems on Carbon Steels .......... 12 Table 7A: Typical Exterior Submerged Zone New Construction Coating Systems on
Carbon Steels.............................................................................................................. 12 Table 7B: Typical Exterior Submerged Zone Maintenance Coating Systems on Carbon
Steels .......................................................................................................................... 12 Table 8A: Typical Ballast Water Tank New Construction Coating Systems on Carbon
Steels .......................................................................................................................... 13 Table 8B: Typical Ballast Water Tank Maintenance Coating Systems on Carbon Steels 13 Table 9: Fingerprinting of Coating Materials ..................................................................... 14 Table 10: Test Protocol for Atmospheric Zone and Splash Zone Coating Systems ......... 15 Table 11: Test Protocol for Ballast Water, Void, and Seawater Holding Tank and Exterior
Submerged Zone Coating Systems ............................................................................ 16 Table 12: Acceptance Criteria for Offshore Structure Coating Testing ............................ 17 Table 13: Surface Finish Grades ...................................................................................... 19 Table 14: Abrasive Specifications ..................................................................................... 20 Table 15: Maximum Total Soluble Chloride Ion Content .................................................. 24
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Section 1: General
1.1 This standard provides guidelines for establishing minimum requirements for the corrosion protective coatings on steel offshore structures associated with oil and gas production, and on the associated handling equipment. It covers coating materials, coating prequalification test methods and the associated acceptance criteria, surface preparation, coating application, quality assurance and control, and repair methods. It also covers generic protective coating systems, flange corrosion control, fastener coatings, pipe support corrosion control, and SS tubing corrosion control. Offshore structures include metallic offshore and coastal structures such as fixed-leg platforms, TLPs, semisubmersibles, spar platforms, and FPSOs.
1.2 For this standard, corrosion on offshore structures is divided into four zones: atmospheric zone, splash zone,
exterior submerged zone, and ballast water tank (internally immersed). The exterior submerged zone also includes subsea facilities, such as valves and manifolds. Each zone may use different protective coating systems.
1.3 This standard does not include corrosion protective coatings for subsea pipelines, pipeline risers, internal portions of production tubing, drill pipes, and chemical tanks that may be in use on the offshore structure, but does include external protection of the chemical tanks on the offshore structure in the atmospheric zone.
1.4. Passive fire protection (PFP) coatings and nickel-(1)
copper alloy (e.g., UNS N04400 [Alloy 400]) splash zone sheathings also are excluded from this standard.
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Section 2: Definitions
Amine Blush: Greasy film on the surface of a coating caused by its amine or polyamide curing agent reacting with carbon dioxide (CO2) and water (H2O). (It can greatly interfere with intercoat adhesion.)
Atmospheric Zone: The portion of a marine structure that extends upward from the splash zone and is exposed to sun, wind, water spray, and rain.
Crevice Corrosion: Localized corrosion of a metal surface at, or immediately adjacent to, an area that is shielded from full exposure to the environment because of close proximity of the metal to the surface of another material.
Dry Film Thickness (DFT): The thickness of a dried film, coating, or membrane.
Cathodic Disbondment: The destruction of adhesion between a coating and the coated surface caused by products of a cathodic reaction.
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Edge Retention: The ratio of DFT of the entire multicoat coating system at peak to average DFT on both flat surfaces of a sharp angle bar; used as a measure of a coating’s ability to retain its film coverage over sharp corners.
Coat: One layer of a coating applied to a surface in a single, continuous application to form a uniform film when dry.
Epoxy: Type of resin formed by the reaction of aliphatic or aromatic polyols (like bisphenol) with epichlorohydrin and characterized by the presence of reactive oxirane end groups.
Coating System: The complete number and types of coats applied to a substrate in a predetermined order.
(Coating) Test Protocol: A written checklist of coating properties that are evaluated by standard test methods to qualify the coating for the intended service conditions. (It is often refined as more is learned about the behavior of the coating system.)
Fingerprinting: Method of identifying a coating material through laboratory analyses of coating density, solids content, pigment content, etc. (Infrared [IR] spectroscopy is often used in the analyses.)
Fish Eye: A small dimple or crater resembling a fish eye that forms in a wet applied coating.
Hot-Dip Galvanized Coating: A coating of virtually pure zinc applied to steel by immersing it in a bath of molten zinc.
Crater: A small, rounded depression in a coating generally resulting from foreign matter in or deposited on a wet coating film.
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Unified Numbering System for Metals and Alloys (UNS). UNS numbers are listed in Metals & Alloys in the Unified Numbering System, latest edition (Warrendale, PA: SAE International [SAE]) and West Conshohocken, PA: ASTM International [ASTM]).
(1)
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Holiday: A discontinuity in a protective coating that exposes unprotected surface to the environment.
Inorganic Zinc-Rich Coating: Coating containing a metallic zinc pigment (typically 75 wt% or more in the dry film) in an inorganic vehicle.
Mill Scale: The oxide layer formed during hot fabrication or heat treatment of metals.
Mud Line: The ocean floor at the location of interest.
Orange Peel: The dimpled appearance of a dried coating resembling the surface of an orange.
Organic Zinc-Rich Coating: Coating containing a metallic zinc pigment (typically 75 wt% zinc or more in the dry film) in an organic resin.
Pipeline: A conduit for carrying produced oil, water, and gas between offshore structures or between offshore structures and onshore processing facilities.
Platform: An offshore structure used to accommodate oil and/or gas wells, related production equipment, pipelines, and/or living quarters.
Pot Life: The elapsed time within which a coating can be effectively applied after all components of the coating have been thoroughly mixed.
Prefabrication Primer: A thin and fast-drying coating that is applied to blast-cleaned steel to provide temporary protection during fabrication while still allowing welding and cutting.
Primer (Prime Coat): A coating material intended to be applied as the first coat on an uncoated surface. The coating is specifically formulated to adhere to and protect the surface as well as to produce a suitable surface for subsequent coats.
Resin: A general term used to designate any polymer, natural or synthetic, used as a binder for coating materials.
Recoat Window: The time period during the drying and curing of a coating in which a subsequent coat can be applied successfully.
Rust Creepage: The penetration of a coating and the spread of delamination or corrosion from a scribe or holiday in the film.
Shelf Life: The maximum length of time packaged materials (e.g., coating materials) can be stored at specified conditions and remain in usable condition.
Splash Zone: The portion of a marine structure that is intermittently wetted by waves, wind-blown water spray, and tidal action. Surfaces that are wetted only during major storms are not included.
Stripe Coat: A coat applied only to edges or to welds on steel structures before a full coat is applied to the entire surface. The stripe coat is intended to give those areas sufficient film build to resist corrosion.
Submerged Zone: The surface area of a marine structure that is always covered with water and extends downward from the splash zone and includes that portion of the structure below the mud line.
Surface Profile: The irregular peak and valley profile on the surface of bare metal that results from abrasive blast cleaning or power tool cleaning.
Thermoplastic: A material capable of being repeatedly softened by heat and hardened by cooling.
Thermoset: A material that undergoes a chemical reaction from the action of heat and pressure, catalysts, and ultraviolet (UV) light, leading to a relatively infusible state.
Thinner: A volatile solvent used to lower the viscosity of a coating material.
Topcoat (Finish Coat): The final coat of a coating system.
Wet Film Thickness (WFT): The thickness of a coating measured immediately after application before any solvent has evaporated or drying has taken place.
Zinc-Rich Primer: A general term used for inorganic zinc-rich coatings and organic zinc-rich coatings used as a primer.
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Section 3: Protective Coating Systems
3.1 General
Because the cost of field-applied maintenance coatings is much higher than that of shop-applied coatings, only the coating systems that have passed the qualification tests
shall be specified for both new construction and
maintenance. In addition to good coating performance, a successful coating system also requires proper surface preparation, coating application, and quality assurance and quality control procedures.
2
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3.2 Liquid Coatings
Liquid coatings used on offshore structures are normally multilayer coating systems composed of primer, intermediate coat(s), and topcoat to avoid holidays and thin spots.
3.2.1 Primers. The primer is the most critical coat of the coating system. Normally, primers have at least one of three different corrosion protection mechanisms: barrier, sacrificial, and inhibitive.
applicable regulations regarding toxicity, safety, and environmental standards. Coating specifiers should note that some inhibitive pigments can shorten coating system service life in immersion or splash zone conditions.
3.2.2 Intermediate Coats and Topcoats. Primers used for offshore structures should be overcoated with intermediate coat(s) and a topcoat. These coatings function as barriers, retarding and restricting the permeation of water vapor, oxygen, and active chemical ions. A topcoat may also provide added abrasion, impact, UV light, and solvent resistance, as well as an aesthetically pleasing finish. Generic characteristics of intermediate coats and topcoats include the following:
3.2.2.1 Chemically Cured Thermoset Coatings. These materials are usually epoxies, epoxy phenolics, polyesters, or vinyl esters.
3.2.2.2 Polyurethanes or Polysiloxanes. These materials are used exclusively as a topcoat in the atmospheric zone to provide UV resistance. In general, polysiloxane provides better UV resistance than polyurethane.
3.3 Thermal-Sprayed Aluminum Coatings
3.2.1.1 Barrier primers. For immersion service, the primer is normally the barrier-type epoxy coating without zinc or corrosion inhibitors. Flake-shaped pigments, such as aluminum flake, glass flake, or micaceous iron oxide flake, may be used to increase its barrier resistance to water and oxygen.
3.2.1.2 Zinc-rich primers. These primers are either organic or inorganic zinc-rich coatings with a high loading of zinc dust. The minimum zinc dust content of the nonvolatile portion of the primer shall be 80% by mass. The zinc dust shall comply
(2)3
with the requirements specified in ASTM D 520
(3)4
(Type II or III) or ISO 3549.Because zinc reacts readily with both acids and strong alkalis, zinc-rich primers must be overcoated with chemically resistant coatings when used offshore because of exposure to alkaline drilling mud and acidic well-completion fluids. However, care must be taken to ensure that the zinc-primed surface is clean prior to overcoating. Because of the porous nature of the film, freshwater washing or power scrubbing may be required to remove contaminants. Inorganic zinc-rich primers, when damaged, are normally repaired with an organic zinc-rich coating. Because zinc-rich coatings sacrifice themselves galvanically when exposed in the splash zone or when immersed, causing rapid breakdown or failure, other coatings should be used in these areas.
3.2.1.3 Organic inhibitive primers. These coatings include inhibiting pigments that generate either alkaline or ionic conditions to retard the corrosion of the base metal when in contact with moisture. Because these primers generally contain reactive pigments and are only part of a protective coating system, they must be protected with overcoats to perform as effective environmental barriers. Organic inhibitive primers must conform to all
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(2)(3)
3.3.1 Thermal-sprayed aluminum (TSA) coatings
(either flame or arc sprayed) sealed with an organic sealer have been used in the atmospheric zone and splash zone, particularly for high-temperature service
(4)5
such as flare booms. NACE No. 2/SSPC-SP 10 or
6
NACE No. 1/SSPC-SP 5 surface cleanliness shall be used for surface preparation. Ninety-nine percent or higher-purity aluminum or Al-5Mg alloy should be used with two or more spray passes used in the application. The sealer enhances service life and appearance.
3.3.2 The sealer shall be thinned adequately to penetrate into the body of the TSA and seal the interconnected surface porosity. The sealer should have a contrasting color to the TSA to aid visual inspection. The overlay of sealer should be less than 38 µm (1.5 mil) on the TSA coating after application. The sealer materials shall be two-component epoxy for operating temperatures less than or equal to 120°C (248°F) or silicone for operating temperatures greater than 120°C (248°F).
3.3.3 All TSA coatings shall be applied in accordance
(5)7
with NACE No. 12/AWS C2.23M/SSPC-CS 23.00.
ASTM International (ASTM), 100 Barr Harbor Dr., West Conshohocken, PA 19428-2959.
International Organization for Standardization (ISO), 1 ch. de la Voie-Creuse, Case postale 56, CH-1211 Geneva 20, Switzerland. (4)
The Society for Protective Coatings (SSPC), 40 24th Street, 6th Floor, Pittsburgh, PA 15222-4656. (5)
American Welding Society (AWS), 550 N.W. LeJeune Road, Miami, FL 33126.
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3.4 Hot-Dip Galvanized Coatings
3.4.1 Hot-dip galvanized coatings are an effective method for protecting complex steel shapes that would be costly and difficult to coat by conventional means. Such shapes as gratings, handrails, stairs, meter houses, and equipment skids may be protected by hot-dip galvanized coatings.
3.4.2 Hot-dip galvanized coatings, like other zinc-rich coatings, are subject to attack by acid and alkaline conditions, and should not be exposed to cement, drilling mud, or well-completion fluids.
3.4.3 Because hot-dip galvanized coatings sacrifice themselves galvanically when exposed in the splash zone or when immersed, causing rapid breakdown or failure, other coatings should be used in these areas.
3.4.4 Hot-dip galvanized coatings should be overcoated by primers and topcoats in applications requiring chemical and saltwater resistance. New hot-dip galvanized coatings should be uniformly roughened with a light abrasive blast in accordance with NACE
8
No. 4/SSPC-SP 7 or chemically etched with a phosphoric acid-based conversion coating. A preliminary solvent cleaning in accordance with SSPC-9
SP 1 should be used to remove any preservative oils applied to the hot-dip galvanized coating. Epoxy
coatings can be applied to weathered hot-dip galvanized coatings (typically greater than one year of outdoor exposure) following surface preparation by low-pressure water cleaning (LPWC) in accordance with
10
NACE No. 5/SSPC-SP 12.
3.4.5 All hot-dip galvanized coatings shall be applied
11
in accordance with ASTM A 123/A 123M and ASTM
12
A 153/A 153M.
3.5 Health, Safety, and Environmental Requirements for Coating Materials
The health, safety, and environmental requirements for coating materials shall be in full compliance with any local and/or national governmental regulations. The following regulations may not be applicable outside the United States. The coating systems shall contain no carcinogens (e.g., asbestos, coal tar, polychlorinated bisphenyl). Tributyltin (TBT) shall not be used as the biocide in antifouling coatings. The metal content of a pulverized dry coating film shall be determined in accordance with 40 CFR (Code of Federal Regulations) Part 261, Appendix II,
13(6)14
Method 1311, or U.S. EPA Publication SW-846. The coating manufacturers shall provide written certification that the metals in the dry coating film do not exceed the maximum values listed in Table 1. These maximum values
15
are the same as in MIL-PRF-23236C.
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Table 1. Maximum Metal Content in the Dry Coating Film
Metal Maximum wt% Metal Maximum wt%
Antimony 0.015 Mercury 0.0002 Arsenic 0.001 Molybdenum 0.35 Barium (excluding barite) 0.10 Nickel 0.02 Beryllium 0.0002 Selenium 0.001 Cadmium 0.0005 Silver 0.001 Chromium VI compounds 0.0005 Tantalum 0.10 Chromium or Chromium III 0.56 Thallium 0.007 compounds
Copper 0.01 Tungsten 0.10 (A)Lead 0.005 Vanadium 0.01
(A) If the source of the lead is the zinc dust used in the zinc-rich primer, the maximum lead content in the zinc dust must be agreed to by the facility owner and the coating manufacturer. Four types of zinc dust are used in zinc-rich primers and each type has a different lead content.
3.6 Coatings for Stainless Steels and High Nickel-Chromium Alloys
SSs susceptible to crevice corrosion and stress corrosion cracking in chloride-containing environments shall be coated unless otherwise specified by the facility owners.
Coatings for SSs or high nickel-chromium alloys shall not contain more than 200 mg/kg leachable chloride in
16
accordance with ASTM C 871. In general, epoxy resin
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(6)
itself does not contain more than 10 mg/kg leachable chloride. Such coating formulations shall not contain metallic zinc, because of the possibility of inducing liquid metal cracking.
3.7 Routine Batch Testing
Routine batch testing shall be carried out by the coating manufacturers for all batches of coating delivered. The test report shall include at least the parameters listed in Table 2.
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Table 2. Routine Batch Testing Report
Coating Name Batch number Manufacturing Date Test Date
Property Component Test Result Specification Test Standard
with Tolerance Density
Solids content by weight
Part A and B, each component
Mixed Parts A and B
XX ±0.05 g/cm XX ±3 wt%
3
ASTM D 1475 ASTM D 2369
18
17
3.8 Random Batch Testing
The facility owner may randomly choose an 8-L (2-gal) sample of liquid coating (part A & B) delivered to the field and carry out a random batch testing in a third-party laboratory to verify the fingerprint in accordance with the test methods listed in Paragraph 5.2. If a sample fails to
meet the required specification, the unused coating material shall be quarantined and the facility owner should contact the coating manufacturer to reach a resolution. The facility owner may reject the entire lot, if the coatings have not been applied. The contractor should remove this coating from areas already coated and recoat with a coating that meets the specification.
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Section 4: Typical Generic Protective Coating Systems
4.1 General
Steel offshore structures are exposed to several different service environments or conditions, which require different coating systems for corrosion protection. For the majority of the coated surface areas, test protocols have been developed to compare the laboratory performance of the coating systems for atmospheric zone and splash zone (see Paragraph 5.3) and exterior submerged zone and ballast water tanks (see Paragraph 5.4). The coating systems that pass the acceptance criteria (see Paragraph 5.5) shall be selected for the specific service. For each service category, typical generic coating systems are listed in this section. Coating systems that are not included in the generic coating tables may be used if they pass the acceptance criteria in Paragraph 5.5.
4.2 Identification of Generic Coating Systems
For the purpose of easy communication and identification, each generic coating system in the tables that follow is assigned a system code. The system code consists of two letters followed by a hyphen and a number. Definitions of the letters used are as follows:
C: Carbon steel M: Maintenance N: New construction
O: Other surfaces (e.g., nonferrous metals) S: Stainless steel
4.3 Typical Atmospheric Zone Coatings
4.3.1 General
The selection of atmospheric zone coating systems shall also consider local weather conditions (e.g., ambient temperature and relative humidity [RH]) to ensure the coating systems cure within the specified time. For maintenance coating application, the pot life and recoat window shall also be considered.
4.3.2 Typical Atmospheric Zone Coating Systems on Carbon Steels
Typical atmospheric zone coating systems on carbon steels are listed in Table 3A for new construction and Table 3B for maintenance. Polyurethane, polysiloxane, or fluoropolymer should be used as the topcoat for UV resistance.
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Table 3A. Typical Atmospheric Zone New Construction Coating Systems on Carbon Steels
Service Category
Coat Coating System DFT, µm (mil) Target DFT, µm (mil) 1 Zinc-rich primer
50-75 (2-3) 75 (3) CN-1
2 Epoxy 125-175 (5-7) 125 (5) Atmospheric zone 3 Polyurethane 50-75 (2-3) 75 (3) -50 to 120°C (-58
1 Epoxy primer
125-175 (5-7) 125 (5) to 248°F) 2 Epoxy 125-175 (5-7) 125 (5) with/without 3 Polyurethane
50-75 (2-3) 75 (3) insulation
1 TSA
250-375 (10-15)
250 (10)
2 Thinned sealer (epoxy)
Do not add to DFT(A)
No additional DFT 3 Sealer (epoxy) Do not add to DFT(A)
No additional DFT
1 2 Inorganic zinc-rich primer
50-75 (2-3) 75 (3) CN-2
Silicone acrylic 25-50 (1-2) 50 (2) Atmospheric zone 120 to 150°C TSA
(248 to 302˚F) 1 Thinned sealer (acrylic silicone or
250-375 (10-15)
250 (10)
without insulation
2 epoxy phenolic)
Do not add to DFT(A)
No additional DFT 3 Sealer (acrylic silicone or epoxy
Do not add to DFT(A)
No additional DFT
phenolic)
1 2 Epoxy phenolic 100-125 (4-5) 125 (5) CN-3
Epoxy phenolic
100-125 (4-5) 125 (5) Atmospheric zone 120 to 150°C TSA
(248 to 302°F) 1 Thinned sealer (silicone acrylic or
250-375 (10-15)
250 (10)
with insulation 2 epoxy phenolic)
Do not add to DFT(A)
No additional DFT 3 Sealer (silicone acrylic or epoxy
Do not add to DFT(A)
No additional DFT phenolic) CN-4
1 TSA
250-375 (10-15)
250 (10)
Atmospheric zone 2 Thinned sealer (silicone)
Do not add to DFT(A)
No additional DFT 150 to 450°C 3 Sealer (silicone) Do not add to DFT(A)
No additional DFT
(302 to 842˚F) 1 Inorganic zinc-rich primer
50-75 (2-3) 75 (3) with/without 2 Silicone 25-50 (1-2) 50 (2) insulation
3 Silicone 25-50 (1-2) 50 (2) 1 Zinc-rich primer 50-75 (2-3) 75 (3) 2 High-solids epoxy
125-175 (5-7)
125 (5)
3 Antiskid epoxy(B)
125-175 (5-7)(C)
125 (5)(C)
4 Polyurethane 50-75 (2-3) 75 (3) CN-5
1 Epoxy primer 125-175 (5-7) 125 (5) Decks & floors—2 High-solids epoxy
125-175 (5-7)
125 (5)
light and normal
3 Antiskid epoxy(B)
125-175 (5-7)(C)
125 (5)(C)
duty
4 Polyurethane
50-75 (2-3) 75 (3) 1 TSA
250-375 (10-15)
250 (10)
2 Sealer (polyurethane) Do not add to DFT(A)
No additional DFT
1
Antiskid high-build (HB) epoxy
Vendor specification
Vendor specification
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Service Category
Coat 1 2 3 4 1 2 3 4 1 2 1
(A)Coating System
Zinc-rich primer High-solids epoxy
(B)
Antiskid epoxy
Polyurethane safety marking
Epoxy primer High-solids epoxy
(B)
Antiskid epoxy
Polyurethane safety marking Prealloyed aluminum/aluminum oxide
(D)TSA
Sealer (polyurethane)
DFT, µm (mil) 50-75 (2-3) 200-300 (8-12)
(C)
200-300 (8-12) 50-75 (2-3) 125-175 (5-7) 200-300 (8-12)
(C)
200-300 (8-12) 50-75 (2-3) 300-400 (12-16)
(A)
Do not add to DFT
CN-6
Decks & floors—heavy duty and helidecks
Target DFT, µm (mil) 75 (3) 250 (10)
(C)
250 (10) 75 (3) 125 (5) 250 (10)
(C)
250 (10) 75 (3) 300 (12)
No additional DFT
Vendor (B)
Antiskid HB epoxy Vendor specification specification
The sealers seal the porosity of the TSA coating and should not add DFT to the existing TSA coating. Allow thinned sealer to dry >30 minutes before application of next sealer coat. (B)
Antiskid grits should be mixed in the liquid coating prior to application to obtain good wetting of the grits. Fine grits should be used with the application of antiskid epoxy. (C)
DFT of the applied coating shall be calculated prior to the addition of antiskid grits. (D)
TSA gun parameters and gun hardware should be adjusted so that the finished TSA coating has an antiskid profile set at a desired
coarseness specification. Although TSA coatings inherently contain hard, wear-resistant aluminum oxide particles that are part of the TSA matrix, prealloyed TSA wire, which is 90% aluminum/10% aluminum oxide, or its equivalent with even greater amounts of aluminum oxide, should be used.
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Table 3B. Typical Atmospheric Zone Maintenance Coating Systems on Carbon Steels
Service Category CM-1
Water condensing
pipes CM-2
Atmospheric zone -50 to 120°C (-58 to 248°F)
with/without insulation CM-3
Atmospheric zone 120 to 150°C (248 to 302°F) with/without insulation
--`,,```,,,,````-`-`,,`,,`,`,,`---Coat Coating System
DFT, µm (mil)
(A)
Target DFT, µm
(mil)
500 (20) 125 (5) 125 (5) 75 (3) 75 (3) 125 (5) 75 (3) 100 (4) 100 (4) 100 (4) 125 (5) 125 (5) 150 (6) 150 (6) 25 (1) 25 (1) 150 (6) 150 (6)
125 (5) 125 (5)
(E)
125 (5) 75 (3) Vendor specification 250 (10)
(E)
250 (10) 75 (3) Vendor specification
1 Underwater-curable epoxy 1 2 3 1 2 3 1 2 3 1 2
Epoxy primer High-solids epoxy Polyurethane
Organic zinc-rich primer
Epoxy Polyurethane
Moisture-cured urethane primer
Moisture-cured urethane Moisture-cured urethane
Epoxy phenolic Epoxy phenolic Silicon-based HB coating
(C)
Silicon-based HB coating
Silicone Silicone
(C)
375-750 (15-30) 125-175 (5-7) 125-175 (5-7) 50-75 (2-3) 50-75 (2-3) 125-175 (5-7) 50-75 (2-3)
(B)
75-125 (3-5)
(B)
75-125 (3-5)
(B)
75-125 (3-5) 100-125 (4-5) 100-125 (4-5) 100-200 (4-8) 100-200 (4-8) 25-50 (0.5-1) 25-50 (0.5-1)
1 2 1 2
CM-4
Atmospheric zone 150 to 450°C (302 to 842°F) with/without insulation CM-5
Decks & floors— heavy duty and helidecks CM-6
Decks & floors— heavy duty and helidecks
1 2 1 2 3 4 1 1 2 3 1
Silicon-based HB coating
(C)
Silicon-based HB coating
Epoxy primer High-solids epoxy
(D)
Antiskid epoxy Polyurethane Antiskid HB epoxy Epoxy primer
(D)
Antiskid epoxy
Polyurethane safety marking
Antiskid HB epoxy
(C)
100-200 (4-8) 100-200 (4-8) 125-175 (5-7) 125-175 (5-7)
(E)
125-175 (5-7) 50-75 (2-3) Vendor specification 200-250 (8-10)
(E)
200-250 (8-10) 50-75 (2-3) Vendor specification
For wet pipes, the underwater-curable epoxy coating should be brush-applied. Wax or petrolatum tape of 1.1-mm (45-mil) minimum thickness may also be used. (B)
Moisture-cured urethane requires reacting with moisture to generate carbon dioxide in its curing process. If it is too thick, it will generate too many bubbles. The DFT range must be strictly followed. (C)
This is a recently developed high-temperature coating material to be used as a maintenance coating under insulation. This coating material contains silicon, but is not classified as a silicone coating. Its qualification requirement shall be mutually agreed to by the supplier and facility owner. (D)
Antiskid grits should be mixed with the liquid coating prior to application to obtain good wetting of the grits. Fine grits should be used with the application of antiskid epoxy. (E)
DFT of the applied coating shall be calculated prior to the addition of antiskid grits. .
(A)
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4.3.3 Typical Atmospheric Zone Coating Systems on Stainless Steels
SSs such as UNS S30400 (Type 304 SS), UNS S31600 (Type 316 SS), and UNS S31700 (Type 317
SS) are the most widely used SSs on offshore structures. SSs shall be protected with coatings to prevent crevice corrosion and stress corrosion cracking in offshore environments. Typical coating systems on SSs are listed in Table 4.
Table 4: Typical Atmospheric Zone Coating Systems on Stainless Steels (New Construction and
Maintenance)
Service Category SM-1
Water condensing
pipe
(A)
for maintenance only SN-2/SM-2 Atmospheric zone -50 to 120°C (-58 to 248°F) SN-3/SM-3 Atmospheric zone 120 to 150°C (248 to 302°F)
Coat 1
Coating System Underwater-curable
epoxy
DFT µm (mil) 375-750 (15-30)
Target DFT µm (mil) 500 (20)
1 2 1 2 1 2 1 2 1 2 1
Epoxy primer Polyurethane Epoxy phenolic Epoxy phenolic Silicon-based HB
coating
Silicon-based HB
coating Silicone Silicone
Silicon-based HB
coating
Silicon-based HB
coating TSA
150-200 (6-8) 50-75 (2-3) 100-125 (4-5) 100-125 (4-5) 100-200 (4-8) 100-200 (4-8) 25-50 (1-2) 25-50 (1-2) 100-200 (4-8) 100-200 (4-8) 50-100 (2--4)
200 (8) 75 (3) 125 (5) 125 (5) 150 (6) 150 (6) 50 (2) 50 (2) 150 (6) 150 (6) 75 (3)
___________________________
(7)
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--`,,```,,,,````-`-`,,`,,`,`,,`---SN-4/SM-4 Atmospheric zone 150 to 450°C (302 to 842°F)
(A) For wet pipes, underwater-curable epoxy coating should be brush-applied. Wax or petrolatum tapes of 1.1-mm (45-mil) minimum thickness may also be used.
Alternatively, SS tubing should be wrapped with aluminum foil to prevent chloride stress corrosion cracking (CSCC) and corrosion under insulation (CUI) for applications in the pH range of 4 to 9, service temperature range of 50 to 150°C (122 to 302°F), with no heat tracing, and for dry heat under insulation
(8)
exposure of up to 450°C (842°F); see also BSI BS
19
5970. The foil used in this application should be 98%
20
aluminum (see ASTM B 479), without an adhesive backing, and 0.04 to 0.15 mm (1.5 to 6 mil) thick.
4.3.4 Typical Atmospheric Zone Coating Systems on Nonferrous Metals
Typical atmospheric zone coating systems on nonferrous metals are listed in Table 5.
BSI British Standards (BSI) (formerly British Standards Institution), 3 Chiswick High Road, London W4 4AL, United Kingdom.
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Table 5: Typical Atmospheric Zone Coating Systems for Nonferrous Metals (New Construction and
Maintenance)
Service Category
Coat 1 2 3
Coating System Epoxy primer Antiskid epoxy Polyurethane (>0°C[32°F]) or Antiskid tile system
(A)
(< 0°C [32°F]) Epoxy primer Polyurethane
DFT µm (mil) 125-175 (5-7) 150-200 (6-8) 50-75 (2-3)
Target DFT µm (mil) 125 (5) 150 (6) 75 (3)
ON-1/OM-1
Aluminum helidecks—
antiskid ON-2/OM-2 Hot-dip galvanized
coatings
Atmospheric zone -50 to 120°C (-58 to 248°F)
(A)1 2
150-200 (6-8) 50-75 (2-3) 150 (6) 75 (3)
Aluminum helidecks deflect a relatively large amount. More flexible coating systems shall be used. Particularly for cold weather, a more flexible antiskid tile system should be used.
4.4 Typical Splash Zone Protective Coatings
4.4.1 General. In general, the splash zone is more corrosive than the atmospheric or immersion zones. The liquid epoxy coating systems should be filled with glass flakes to enhance barrier properties and mechanical strength. When polychloroprene rubber coating is used, it should have a thickness range of 6 to 13 mm (0.25 to 0.50 in).
4.4.2 New Construction Protective Coating Systems. Protective coating systems for the splash zone for new construction are listed in Table 6A.
4.4.2.1 Vulcanized polychloroprene rubber. Vulcanized polychloroprene should be applied in thicknesses of 6 to 13 mm (0.25 to 0.50 in). Because this coating is usually applied in the shop, it is normally restricted to straight runs of tubular members.
4.4.2.2 Liquid coating systems. The splash zone
--`,,```,,,,````-`-`,,`,,`,`,,`---
coating systems require good water resistance; therefore, epoxy with good barrier properties should be used. The coatings are usually filled with silica glass flakes to enhance barrier properties and mechanical strength. A polyurethane topcoat does not have good water resistance and should not be used in the splash zone.
4.4.2.3 TSA. TSA applied to 200 to 250 µm (8 to 10 mil) and sealed with a sealer (epoxy or silicone acrylic) may be used in the splash zone. To reduce delamination caused by thermal cycling, DFT of the TSA coating in the splash zone shall be
21
in a narrow DFT range. Good surface cleanliness and a high surface profile must be achieved. The coating should be applied in a minimum of two passes. The sealers seal the porosity of the coating to enhance its service life and appearance, but should not add DFT to the
22
existing TSA coating.
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Table 6A: Typical Splash Zone New Construction Coating Systems on Carbon Steels
Service Category
Coat 1 2
CN-7 Splash zone <60°C (140°F)
1 2 3 1 2 3
CN-8 Splash zone >70°C (158°F) & <100°C (212°F) CN-9 Splash zone >100°C (212°F) & <130°C (266°F)
(A)(B)
Coating Systems Glass-flake epoxy Glass-flake epoxy
(A)DFT µm (mil)
[unless otherwise
indicated] 450-550 (18-22) 450-550 (18-22)
Target DFT µm (mil) 500 (20) 500 (20) 250 (10)
No additional DFT No additional DFT
25 (1) 25 (1) End user specification 25 (1) 25 (1) End user specification 25 (1) 25 (1) End user specification
TSA 200-250 (8-10)
(B)
Thinned sealer (epoxy) Do not add to DFT
(B)
Do not add to DFT Sealer (epoxy)
Primer
25-50 (1-2) Bonding agent
25-50 (1-2) Polychloroprene
6-13 mm (0.25-0.50 in) rubber Primer
Bonding agent Polychloroprene
(C)
rubber Primer Bonding agent
(D)
EPDM rubber
25-50 (1-2) 25-50 (1-2)
6-13 mm (0.25-0.50 in)
1 2 3
1 2 3
25-50 (1-2) 25-50 (1-2)
6-13 mm (0.25-0.50 in)
The average surface profile shall be 75 µm (3 mil) minimum.
Allow thinned sealer to dry >30 minutes before application of next sealer coat. Do not add to DFT. (C)
For service temperature > 70°C (158°F), polychloroprene rubber shall only use carbon black pigment, which gives better thermal resistance. (D)
Ethylene propylene diene elastomer
4.4.3 Typical Maintenance Splash Zone Coating Systems
Because the physical accessibility in the splash zone is limited and the access window is short during low tide, a one-coat system should be used to repair the splash
zone. The surface is often damp from mist and high humidity; therefore, a coating system that is compatible with a damp surface should be used. Because of these difficulties, some relatively thick repair materials, which are not liquid coating systems, have been commercialized. The end users shall examine these options and assess their integrity prior to use.
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Table 6B: Typical Splash Zone Maintenance Coating Systems on Carbon Steels
Service Category
Coat Coating System DFT
µm (mil) 300-2,000 (12-80) 125-175 (5-7) 200-500 (8-20) 450-550 (18-22) Vendor specification
(B)
Target DFT µm (mil) Vendor
(B)
specification 125 (5) 375 (15) 500 (20) Vendor
(B)
specification
1 1 2
Surface-tolerant epoxy Epoxy primer Glass-flake epoxy
(A)(A)CM-7 Splash zone <60°C (140°F)
--`,,```,,,,````-`-`,,`,,`,`,,`---1 Glass-flake epoxy
Underwater-curable epoxy
primer + two half
fiberglass composite outer
sheaths
(A)(B)
The average surface profile shall be 75 µm (3 mil) minimum. Vendors have specific recommended DFT on their products.
4.5 Typical Exterior Submerged Zone Coatings
Submerged offshore structures are protected by sacrificial anodes and protective coatings. Protective coating systems
are applied to reduce the quantity or weight of sacrificial anodes. Protective coating systems for the exterior submerged zone are listed in Table 7A (new construction) and Table 7B (maintenance).
Table 7A: Typical Exterior Submerged Zone New Construction Coating Systems on Carbon Steels
Service Category CN-10 Exterior submerged zone <60°C
(A)
(140°F)
(A)(B)
Coat 1 2 3 1 2 3
Coating System High-solids epoxy Stripe coat High-solids epoxy TSA
Thinned sealer
(epoxy) Sealer (epoxy)
DFT, µm (mil) 150-200 (6-8)
150-200 (6-8) 250-375 (10-15)
(B)
Do not add to DFT
(B)
Do not add to DFT
Target DFT, µm (mil)
175 (7)
175 (7) 300 (12)
No additional DFT No additional DFT
Sacrificial anodes are normally installed in conjunction with the protective coating systems.
Allow thinned sealers to dry >30 minutes before application of next sealer coat. Sealers should not add DFT to the existing TSA coatings.
Table 7B: Typical Exterior Submerged Zone Maintenance Coating Systems on Carbon Steels
Service Category CM-8
Exterior submerged
zone
<60°C (140°F)
(A)Coat Coating System Underwater-curable
(A)
epoxy
DFT, µm (mil) Target DFT, µm (mil)
1 500-1,000 (20-40) Vendor specification
It is extremely difficult to apply the underwater-curable epoxy in the field. CP is a good option.
4.6 Typical Ballast Water Tank Coatings
4.6.1 General
A ballast water tank is a dark and confined space, so solvent-free or high-solids epoxy coating materials are more desirable. A light-colored topcoat should be used
to facilitate visual inspection. A multicoat system with the same coating formulation but different colors should be used because it reduces the intercoat delamination caused by different swelling or shrinkage for each layer. Typical coating systems for ballast water tanks are listed in Table 8A (new construction) and Table 8B (maintenance). For an epoxy coating
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system with a total film thickness of 375 to 500 µm (15 plural-component sprayed coating shall be qualified in to 20 mil), three thin coats is a better choice than two accordance with this standard before it can be thicker coats because of better film integrity and fewer considered. holidays. Two stripe coats shall be used to achieve
good film coverage at the weld seams and sharp 4.6.3 Void Tank and Seawater Holding Tank
corners.
4.6.2 Plural-Component Spray Deepwater offshore structures also may have void
tanks that may convert into ballast water tanks during A plural-component spray gun may also be used to their service. Therefore, it is better to coat them with spray a thick layer (wet on wet) coating directly onto the the same coating systems as the ballast water tanks. substrate with one stripe coat. However, the one-coat
The coating systems for seawater holding tanks shall also be treated the same as the ballast water tanks.
Table 8A: Typical Ballast Water Tank New Construction Coating Systems on Carbon Steels
Service Category Coat Coating System DFT, µm (mil) Target DFT, µm (mil)
1 High-solids epoxy
CN-11
2 Stripe coat 125-175 (5-7)
125 (5)
Ballast water tank 3 High-solids epoxy
<60°C (140°F)
4 Stripe coat
125-175 (5-7)
125 (5)
5
High-solids epoxy(A)
125-175 (5-7)
125 (5)
(A) The ballast water tank is dark; a white or other light-colored topcoat should be used to ease visual inspection.
Table 8B: Typical Ballast Water Tank Maintenance Coating Systems on Carbon Steels
Service Category Coat Coating System DFT, µm (mil) Target DFT, µm (mil)
CM-9
1 High-solids epoxy
200 (8)
Ballast water tank 2 Stripe coat
200-250 (8-10)
<60°C (140˚F)
3
High-solids epoxy(A)
200-250 (8-10)
200 (8)
(A) The ballast water tank is dark; a white or other light-colored topcoat should be used to ease visual inspection.
________________________________________________________________________
Section 5: Qualification Testing of Coating Systems
5.1 General
5.2 Required Product Information
5.1.1 Coating systems shall be tested and pass all the When each coating system is submitted for qualification acceptance criteria in accordance with this standard. testing, the coating manufacturer shall provide the following An independent laboratory qualified by the facility information as part of the test report. owner shall carry out the qualification testing.
(a) Product data sheet 5.1.2 Additional testing may not be required for a
coating system on SS if the proposed coating system (b) Material safety data sheet (MSDS) on carbon steel panels has been approved by the
facility owner. (c) Fingerprinting. The requirements for fingerprinting for
each coat of a multicoat coating system are listed in Table 5.1.3 If the coating formulation is changed after the 9.
qualification, the coating system shall be requalified by an independent laboratory.
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Table 9: Fingerprinting of Coating Materials
# Property 1 2 3 4A
Density
Solids content by weight Pigment content by weight
Fourier transform infrared-attenuated total reflection (FTIR-ATR) scan with pigment; or
Infrared (IR) scan without pigment
Component Tolerance Standard ± 0.05 g/cm ± 3 wt% ± 2 wt%
3
Part A and B, each component
Mixed parts A and B Part A and B, each component Part A and B, each component Part A and B, each component
ASTM D 1475 ASTM D 2369 ASTM D 2371
23
Equipment manufacturer’s instruction
ASTM D 2621
24
4B
If the fingerprinting test is performed by the coating manufacturer, the test results shall be certified by the manufacturer’s quality assurance/quality control manager or the senior technical manager.
(d) All of the following information:
Manufacturer’s name, address, and telephone/fax numbers Surface preparation standard (NACE, SSPC, ISO, etc.) Surface profile (µm or mil)
For each of the primer, intermediate coat(s), and topcoat, the following information shall also be provided:
Product name Color
Material type
Batch numbers, Parts A and B Manufacturing date Shelf life
Volatile organic compounds (VOCs) (g/L or lb/gal) Cleaning solvent Thinner type
Maximum percentage of thinner content by volume
--`,,```,,,,````-`-`,,`,,`,`,,`---Mixing ratio by volume or weight Application method
Application temperature range (°C or °F) Application RH range (% RH) Pot life (hours @ temperature) Induction time (minutes)
Minimum recoat and dry-to-touch time (hours @ temperature)
Maximum recoat time (days @ temperature) Solids content by weight and/or volume WFT range (µm or mil) DFT range (µm or mil)
5.3 Coating Test Protocol for Atmospheric Zone and Splash Zone
The test protocol for atmospheric zone and splash zone coating systems applied on carbon steels for both new construction and maintenance for the maximum service temperature of 120ºC (248ºF) is listed in Table 10.
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Table 10: Test Protocol for Atmospheric Zone and Splash Zone Coating Systems
Atmospheric Zone, Decks Splash Zone
Coating Property
Surface Preparation New
Construction Maintenance New
Construction Maintenance NACE No. 2 /SSPC-SP
NACE
NACE
NACE TM0304 Rust creepage 10 TM040425
TM030426
NACE TM0404
resistance
200 mg/m2 c
hloride No test NACE TM0304
No test NACE TM0304 Damp
No test No test No test NACE TM0304 Edge retention Abrasive paper NACE TM0404 NACE TM0304 NACE TM0404 NACE TM0304 NACE No. 2 Thermal cycling
/SSPC-SP
NACE TM0404
NACE TM0304
NACE TM0404
NACE TM0304
10
NACE No. 2 Flexibility /SSPC-SP
NACE TM0404 NACE TM0304 NACE TM0404 NACE TM0304
10 Impact strength NACE No. 2 (decks & boat /SSPC-SP
ASTM G 1427
10 ASTM G 14 ASTM G 14 ASTM G 14 landing only)
NACE No. 1 /SSPC-SP 5
No test No test NACE TM0404
NACE TM0304 Water immersion
200 mg/m2
c
hloride No test No test No test NACE TM0304 Damp No test No test No test NACE TM0304 NACE No. 1 /SSPC-SP 5
No test No test NACE TM0404
NACE TM0304 Cathodic disbondment
200 mg/m2 c
hloride No test No test No test NACE TM0304 Damp
No test
No test
No test
NACE TM0304
5.4 Test Protocol for Ballast Water, Void, and Seawater The test protocol for ballast water, void, and seawater Holding Tanks and Exterior Submerged Zones
holding tank and exterior submerged zone coating systems
applied on carbon steels for both new construction and maintenance is listed in Table 11.
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Table 11: Test Protocol for Ballast Water, Void, and Seawater Holding Tank and Exterior Submerged Zone
Coating Systems
Surface Preparation
Ballast Water, Void, Seawater
Holding Tank New Construction
Edge retention
Abrasive paper NACE No. 1 /SSPC-SP 5
2 100 mg/mc
hloride Damp NACE No. 1 /SSPC-SP 5
2100 mg/m chloride Damp Free film NACE No. 1 /SSPC-SP 5 NACE No. 1 /SSPC-SP 5 NACE No. 1 /SSPC-SP 5
2 100 mg/mc
hloride Damp
NACE TM0104 NACE TM0104
No test No test NACE TM0104
No test No test NACE TM0104 NACE TM0104 NACE TM0104 NACE TM0104
No test No test
28Coating Property
Exterior Submerged
Zone New
Construction NACE TM0204 NACE TM0204
No test No test NACE TM0204
No test No test NACE TM0204 NACE TM0204
No test No test No test No test
29Maintenance NACE TM0104 NACE TM0104 NACE TM0104 NACE TM0104 NACE TM0104 NACE TM0104 NACE TM0104 NACE TM0104 NACE TM0104 NACE TM0104 NACE TM0104 NACE TM0104 NACE TM0104
Water immersion
Cathodic disbondment
Dimensional stability Aging stability
--`,,```,,,,````-`-`,,`,,`,`,,`---Thick-film cracking
Hot/wet cycling (FPSO
only)
5.5 Acceptance Criteria
Acceptance criteria of the coatings tested for
atmospheric zone and splash zone; ballast water, void, and seawater holding tanks; and exterior submerged zone are listed in Table 12.
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Table 12: Acceptance Criteria for Offshore Structure Coating Testing
Coating Property Rust creepage resistance
Test Method NACE TM0304 NACE TM0404
Acceptance Criteria
<3.5 mm (0.14 in) for non-zinc-primed coating system <1.5 mm (0.06 in) for zinc-primed coating system
No blistering/rusting/cracking/flaking away from the scribe and edge
Edge retention
NACE TM0104
NACE TM0204 >50% of the average DFT measured on the flat surfaces adjacent NACE TM0304 to the edge NACE TM0404
Thermal cycling NACE TM0304 No cracking
NACE TM0404
Flexibility NACE TM0304 >1% at the lowest service temperature
NACE TM0404 Impact strength Water immersion
ASTM G 14 NACE TM0104 NACE TM0204 NACE TM0304 NACE TM0404 NACE TM0104 NACE TM0204 NACE TM0304 NACE TM0404 NACE TM0104 NACE TM0204 NACE TM0104 NACE TM0204 NACE TM0104 NACE TM0104
>5.6 J (50 in-lbf) for decks and boat landing splash zone <7.0 mm (0.28 in) disbondment
No blistering/rusting/cracking/flaking away from the scribe and edge
<7.0 mm (0.28 in)
No blistering/rusting/cracking/flaking away from the scribe and edge Optional >50% No cracking
<3.5 mm (0.14 in)
No blistering/rusting/cracking/flaking away from the scribe and edge
(B)
(A)
Cathodic disbondment
Dimensional stability Aging stability
--`,,```,,,,````-`-`,,`,,`,`,,`---Thick-film cracking Hot/wet cycling (FPSOs only)
(A) Wet disbondment test (Method B) should be used to evaluate the water immersion resistance of coating systems. Only one holiday shall be drilled on each test specimen and all edges must be sealed. (B)
This test method is optional. If the facility owner requests the test, the acceptance criterion shall be agreed to by the facility owner and the coating manufacturer.
5.6 Test Methods
5.6.1 Rust Creepage Resistance
The rust creepage resistance test shall be in accordance with NACE Standard TM0304 or TM0404. The average rust creepage shall be less than 3.5 mm (0.14 in) for non-zinc-primed coating systems and less than 1.5 mm (0.06 in) for zinc-primed coating systems. The average rust creepage shall be obtained by averaging the test data of the four test specimens.
5.6.2 Cathodic Disbondment Test
The cathodic disbondment test shall be in accordance with NACE Standard TM0104, TM0204, TM0304, or TM0404. The acceptable cathodic disbondment shall be less than 7.0 mm (0.28 in) after a test period of 12 weeks. With the current test method, there is still an uncertainty in the determination of disbondment from
the intact area. Some data scattering has been observed. Therefore, the acceptance criterion is allowed to be less than 7.0 mm (0.28 in), which may be higher than the true coating performance. After the test method is improved to better define the disbondment area, the acceptance criterion may be tightened.
5.6.3 Water Immersion
There are two acceptable methods in NACE Standards TM0104, TM0204, TM0304, or TM0404 to measure the water immersion resistance: the pull-off adhesion test, and the wet disbondment test. For some samples, the pull-off adhesion can still be very high, although some blisters appear on the coating surface. Therefore, the wet disbondment test should be used. The wet disbondment test is modified in this standard to improve data reproducibility. Instead of one holiday on each surface of the two test specimens, only one side of each test specimen shall have a holiday. Four test
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specimens shall be prepared for each test. The test specimen edges shall be sealed off completely with immersion-type coatings and checked with a wet-sponge holiday detector to make sure no holidays exist at the edges. The uncertainty in separating the disbonded area from the intact area produces data scatter. Therefore, the acceptance criterion is set at less than 7.0 mm (0.28 in), which is much larger than the real disbondment. The acceptance criterion may be tightened after the test method is improved to better define the disbonded area from the intact area. The dissolved oxygen content is a function of the water depth and temperature. Different types of water baths with air sparger may be used. Because the dissolved oxygen content affects the test results, the dissolved oxygen content of the test solution shall be maintained at its saturation value at the test temperature of 40ºC (104ºF), which is 4.6 ± 0.1 mg/L. A calibrated dissolved oxygen meter shall be used to measure the dissolved oxygen content at the location of the test specimens to ensure the oxygen content meets the specification.
5.6.4 Edge Retention
The edge retention test shall be in accordance with NACE Standard TM0104, TM0204, TM0304, or TM0404. The minimum DFT measured on the edge shall be greater than 50% of the average DFT measured on the flat surfaces adjacent to the edge.
5.6.5 Impact Strength
The impact strength test shall be in accordance with ASTM G 14. The minimum acceptable value is 5.6 J (50 in-lbf). This test shall only be performed for the deck coating and boat landing area in the splash zone.
5.6.6 Thermal Cycling
The thermal cycling test shall be in accordance with NACE Standard TM0304 or TM0404. In addition to the C-channel steel, a T-bar-shaped test specimen of either 300 x 100 x 5 mm (12 x 4 x 0.20 in) or 300 x 50 x 5 mm (12 x 2 x 0.20 in) may be used. The coating shall exhibit no cracking after at least 232 cycles.
5.6.7 Thick-Film Cracking
The thick-film cracking test shall be in accordance with NACE Standard TM0104. In addition to the C-channel steel, a T-bar-shaped test specimen of either 300 x 100 x 5 mm (12 x 4 x 0.20 in) or 300 x 50 x 5 mm (12 x 2 x 0.20 in) may be used. The coating shall not show any cracking after 12 weeks of aging at 40ºC (104˚F) in synthetic seawater immersion.
5.6.8 Flexibility Test
The flexibility test shall be in accordance with NACE Standard TM0304 or TM0404. The flexural strain at the lowest field service temperature shall be greater than 1%.
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5.6.9 Dimensional Stability
The dimensional stability test is optional. If this test is required by the facility owner, the acceptance criterion shall be agreed to by the facility owner and the coating manufacturer.
5.6.10 Aging Stability
The aging stability test shall be in accordance with NACE Standard TM0104 or TM0204. The flexural strain retention shall be greater than 50% after 12 weeks aging at 40ºC (104ºF) in synthetic seawater.
5.6.11 Hot/Wet Cycling
This hot/wet cycling test shall be in accordance with NACE Standard TM0104. The average rust creepage for clean, salted, and damp surface shall be less than 3.5 mm (0.14 in) after 12 weeks in the cycling salt fog test. The average rust creepage value shall be obtained by averaging test data results of the four specimens tested. This test is intended for FPSOs only.
5.7 Test Precision
A high degree of uncertainty is involved in the testing of
coatings. Variable results may be obtained depending on steel test specimen preparation, application, overcoating intervals, curing time, and curing conditions. Likewise, the actual testing will induce uncertainties because of differences in test equipment, procedures, etc. Even the final evaluation has a degree of subjectivity that is a source of variation.
A coating system that fails by a small margin in one test series has a good chance of passing in another test series and vice versa.
Round robin testing indicates the following standard deviations on the test methods/test criteria:
(a) Rust creepage resistance: 0.5 mm (0.02 in) for zinc-primed coating systems and 1 mm (0.04 in) for non-zinc-primed coating systems for the rust creepage measurement;
(b) Water immersion: 2 mm (0.08 in) for the disbondment measurement;
(c) Cathodic disbondment: 2 mm (0.08 in) for the disbondment measurement;
(d) Flexibility test: ASTM D 52230 includes precision data that are believed to be representative of the test method used in NACE Standards TM0304 and TM0404; and
(e) Impact strength test: See ASTM G 14 and ASTM
D 2794.31
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For the remaining tests used in this standard, no precision data are available. The precision is improved when all coating systems to be evaluated/compared
are applied by the same applicator and tested in the same laboratory in the same test series.
________________________________________________________________________
Section 6: Surface Preparation
6.1 General
6.1.1 Solvent cleaning or detergent degreasing shall
be in accordance with SSPC-SP 1.
6.1.2 All surface imperfections such as slivers, laminations, welding flux, weld spatter, and underlying mill scale exposed before or during operations shall be removed prior to surface preparation.
6.1.3 Automated blast-cleaning machines are economically desirable as a means of preparing plate, beams, and tubular members prior to fabrication.
6.1.4 Dry abrasive blast cleaning shall be used for surface preparation to reach near-white or white metal finish in accordance with NACE No. 2/SSPC-SP 10 or NACE No. 1/SSPC-SP 5, respectively. The surface profile shall be specified by the coating manufacturer, or 40 to 75 µm (1.5 to 3 mil) shall be used if not specified.
6.1.5 For areas where abrasive blasting is not possible, power tool cleaning to the bare metal in
32
accordance with SSPC-SP 11 should be used.
6.1.6 Prefabrication primers shall be removed by blasting unless otherwise specified by the facility owner.
6.1.7 For maintenance coating work, high-pressure waterjetting (HPWJ) and ultrahigh-pressure waterjetting (UHPWJ) to WJ-2/L surface cleanliness in accordance with NACE No. 5/SSPC-SP 12 may be used as alternatives to dry abrasive blast cleaning.
6.1.8 Surface preparation performed outdoors should be completed during daylight hours, and early enough to permit proper priming of the surface prior to the development of any moisture or flash rusting of the prepared surface. Tests for soluble salts shall be performed prior to coating in accordance with Paragraph 8.7.
6.1.9 At the time of surface preparation and priming, the surface temperatures shall be at least 3°C (5°F) above the dew point.
6.1.10 Wet abrasive blasting or slurry blasting may provide adequate surface preparation and reduce dust problems created by dry abrasive blasting.
6.2 Surface Preparation Standards
The recognized international surface finish grades commonly used for offshore structures are summarized in Table 13.
Table 13: Surface Finish Grades
Surface finish grade White metal
Near-white metal Brush-off
Solvent cleaning Power tool cleaning
Power tool cleaning to bare metal HPWJ and UHPWJ
WJ-1 Clean to Bare Substrate WJ-2 Very Thorough or Substantial Cleaning
WJ-3 Thorough Cleaning WJ-4 Light Cleaning Wet abrasive blasting
TR 2 6G198
3535ISO
33
8501-1 Sa 3 Sa 2½ Sa 1 St 2 or 3
SSPC NACE SP 5 SP 10 SP 7 SP 1
34SP 3 SP 11 SP 12
No. 1 No. 2 No. 4 No. 5
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6.3 Precleaning
6.3.1 Prior to the blast cleaning and prior to any coating operation, the surface shall be free of any oil/grease contamination, and any excessive rust scale shall be removed. Biodegradable detergent/freshwater solution treatment followed by copious rinsing with clean, potable water shall be used to remove oil/grease contamination. For small areas of oil/grease contamination, solvent cleaning in accordance with SSPC-SP 1 shall be used.
6.3.2 Maintenance coating work should always start with a high-pressure steam/detergent cleaning to remove dirt, grease, or salt deposits. In addition, after a long interval prior to the application of the subsequent coats of a coating system or after a storm, the surface shall be cleaned by LPWC before the application of the next coat.
6.3.3 Detergents with a pH >9 shall not be used on aluminum substrates.
6.4 Centrifugal Wheel Cleaning. This method is applicable to a fabrication plant where new welded assemblies can be processed through an automated, wheel-type machine using metal abrasives. The cost of wheel blast surface preparation is significantly lower than the cost of air blast surface preparation work.
produce a sharp surface profile with high peak densities.
6.4.3 Surface cleanliness and surface profile should be tested and recorded on a regular, agreed-upon basis to ensure that the prepared surface of the components meets the cleanliness and surface profile requirements of the coating to be applied.
6.5 Air Blast Cleaning. This method is used when components are not suitable for the available automated machines, when cleaning is performed on the job (field) location, or when maintenance work is performed on offshore structures.
6.5.1 Air Supply. Initial inspection of the air supply shall include the following:
6.5.1.1 Air supply capacity shall be sufficient to obtain 690 kPa (100 psi) air pressure at all operating nozzles.
6.5.1.2 The compressor shall be equipped with properly operating safety equipment.
6.5.1.3 Oil/moisture separators with properly maintained filters must be used in air lines. These shall be tested at least once each shift in
37
accordance with ASTM D 4285.
6.5.2 Abrasives. The blast-cleaning abrasive used for surface preparation shall be limited to the type specified in the contract documents and shall be of appropriate size to produce the required surface profile using the equipment available for the job. The abrasives must be dry, clean, free from contamination, and graded to a standard size. Each batch of abrasive should be tested in accordance with the relevant abrasive specification in Table 14. .
6.4.1 Good Painting Practice, SSPC Painting Manual should be referred to for centrifugal blast cleaning.
6.4.2 Abrasive Material. Steel grit of the appropriate mesh size and hardness should be used to produce the required surface profile using the equipment selected to perform the work. Steel shot shall not be used for surface preparation for coatings as it does not
36
Table 14: Abrasive Specifications
Type Generic Name Metallic
Natural mineral
Characteristics Standard 38Synthetic mineral
(A)Steel grit 0.8 to 1.2% carbon
(A)Silica sand Crystalline silica Olivine Magnesium/iron silicate Staurolite Iron/aluminium silicate Specular hematite Crystalline Fe2O3 Garnet Calcium iron silicate Coal slag Aluminium silicate Aluminum oxide Crystalline corundum ISO 11124-3
39ISO 11126-8
40ISO 11126-9
41ISO 11126-10
42ISO 11126-4
43ISO 11126-7
Silica sand may not be allowed because of the silicosis health concern. If it is used, local and national health and safety regulations shall be followed.
6.5.2.1 Selection of Abrasives
Products within a given generic class of abrasives vary widely in performance. These variations are likely the result of varying raw material sources or manufacturing processes. Surface profile is
directly proportional to the abrasive particle size. The larger the abrasive particle size, the higher the surface profile. Cleaning rate is inversely proportional to the abrasive particle size. The larger the abrasive particle size, the slower the cleaning rate. A balanced mixture of particle sizes
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produces the optimum level of cleanliness, cleaning rate, and surface profile.
6.5.2.2 Abrasives for Stainless Steels, Nonferrous Metals, and Hot-Dip Galvanized Coating Surfaces
Aluminum oxide, garnet, or other nonferrous abrasives shall be used for blasting SS, cleanliness in accordance with NACE No. 5/SSPC-SP 12. Use of HPWJ and UHPWJ shall be used only in maintenance coating operations for removal of failed coating systems to reveal an adequate surface profile.
6.7.2.2. Waterjetting does not alter the existing surface profile, and, thus, other methods of nonferrous metal, and hot-dip galvanized coating surfaces. The grit size for hot-dip galvanized coating surfaces shall be small to produce a surface profile of 25 µm (1 mil). Aluminum oxide normally produces a very clean surface finish with very little abrasive particle embedment. The zinc layer of hot-dip galvanized coatings shall not be damaged; no defects such as breakthrough or crisping of the zinc layer shall occur.
6.6 Safety equipment for surface preparation should include, but shall not be limited to, the following:
(a) Air-fed blast hood, properly fitted, with good vision;
(b) Charcoal-filtered and regulated compressed breathing air supply;
(c) Operator-controlled deadman remote control valves;
(d) Operator protective clothing, gloves, etc.; (e) Operator safety belts; (f) Proper scaffolding; and (g) Proper lighting.
6.7 Alternative Methods of Surface Cleaning
6.7.1 Wet Abrasive Blasting
Wet abrasive blast cleaning techniques may be used to reduce dust or in cases in which fire or explosion risks are present. The blast cleaned surface should be washed off immediately with fresh water. Only after written approval of the facility owner may a suitable corrosion inhibitor such as 0.3 wt% sodium nitrite with 1.2 wt% ammonium phosphate be used to prevent flash rusting. Chromate inhibitors shall not be used. In general, the residues of the inhibitor may not be removed before coating. Compatibility of the inhibitor with the overcoat system shall be verified with the coating manufacturer. The cleaned surface shall be thoroughly dry at the time of coating.
6.7.2 Waterjetting
6.7.2.1 If abrasive blasting is not permitted for certain areas where dusting and overblasting may damage process equipment, HPWJ and UHPWJ may be used to achieve WJ-2/L surface
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surface preparation must be used if the revealed surface profile is not adequate for the specified primer/coating system.
6.7.2.3 HPWJ and UHPWJ are hazardous operations and require the use of well-trained and experienced operators. Operators shall wear earplugs, a face shield, a raincoat, proper footwear, and gloves and must have firm footing when using the waterjet. Proper personal protective equipment (PPE) shall be used during operation of the waterjetting equipment. ---
`,,`,6.7.2.4 No corrosion inhibitor is necessary in the `,,`,,jetting water to prevent flash rusting. If corrosion `-`-``inhibitors are to be used, the manufacturer of the ``,,,waterjetting equipment shall be consulted to ,```,,ensure compatibility of the inhibitors with the `--equipment. The coating manufacturer shall also be consulted to ensure the compatibility of the inhibitors with the coatings.
6.7.2.5 The cleaned surface shall be thoroughly dry at the time of coating.
6.7.3 Centrifugal Abrasive Blasting
A portable blasting machine may be used to prepare steel decks and tank floors using recyclable steel abrasives.
6.7.4 Vacuum Blasting
Vacuum blasting may be used in the areas where open abrasive blasting is not permitted or desirable or for spot repair of damaged or corroded areas.
6.7.5 Power Tool Cleaning to Bare Metal
Power tool cleaning to bare metal in accordance with SSPC-SP 11 shall be used only when blast cleaning is not feasible. Care shall be taken to ensure that the steel surface does not become polished after power tool cleaning. If the surface being prepared lies adjacent to a coated surface, the power tool cleaning shall overlap the coated surface by at least 25 mm (1 in) and the coated surface shall be feathered.
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________________________________________________________________________
Section 7: Coating Materials and Application
7.1 General
7.1.1 Single-manufacturer responsibility should be
maintained by using primers, intermediate coats, and topcoats from the same manufacturer.
7.1.2 SSs may be susceptible to liquid metal cracking. Coatings containing metallic zinc or other low-melting-point metals, such as cadmium, shall never be used, oversprayed, or dropped on SS components.
7.1.3 Before commencing any spot coating repair work, the compatibility with existing coating systems
shall be assessed in accordance with ASTM D 50.44
7.2 Storage and Handling of Coating Materials
7.2.1 Coating materials shall be furnished in the
manufacturer’s original, unopened container, clearly labeled to identify the contents.
7.2.2 Coating materials shall be stored and handled in accordance with the coating manufacturer’s --`,,```,,,,````-`-`,,`,,`,`,,`---instructions.
7.2.3 All coating materials should be stored in a manner that prevents exposure to weather extremes, with 10 to 32°C (50 to 90°F) being optimum.
7.2.4 Manufacturer’s specified shelf life for coating components shall be followed.
7.2.5 Thinners or cleaners shall comply with the coating manufacturer’s recommendation, or if independently purchased, shall be of compositions approved by the coating manufacturer.
7.2.6 Solvent can closures shall be kept tight at all times to prevent the entrance of humid air, which can lead to condensation.
7.3 Mixing and Thinning
7.3.1 All coating materials shall be thoroughly mixed prior to application.
7.3.1.1 If the pigment settles, it shall be redispersed with a power mixer to form a uniform mixture.
7.3.1.2 For two-component coating materials, the catalyzed mixture also shall be mixed with a power mixer.
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7.3.1.3 For heavily pigmented coatings, such as zinc-rich primers, mixing shall be continued during application to prevent settling.
7.3.2 The mixer and pot shall be thoroughly cleaned before new coating materials are mixed.
7.3.3 Thinners shall not be used unless specified by the coating manufacturer. If used, thinners shall be of the type and in the amount specified by the coating manufacturer.
7.3.4 Mixed coatings should be strained through a 250 to 600-µm (30- to 60-mesh) screen to remove any foreign materials or undispersed pigment particles.
7.4 Coating Application
7.4.1 Spray Application
All coatings that are applied by conventional spray, airless spray, or other spray equipment shall be applied only with equipment specified or approved by the coating manufacturer.
7.4.2 Brush Application
Provided that the coating manufacturer considers the coating material suitable, brush application should only be used under the following circumstances:
(a) Spot repair;
(b) Stripe coating on edges, corners, or other irregular surfaces; (c) Small-bore parts not suitable for spray application; and
(d) Water condensing pipes.
7.4.3 Stripe Coat
Irregular surfaces such as sharp edges, welds, small brackets, and interstices may be stripe coated, usually by brush or roller, to ensure the specified film thickness is provided, particularly for steels in immersion service. The color of the stripe coat shall be different from the previous or subsequent coat.
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________________________________________________________________________
Section 8: Quality Assurance and Control
8.1 General
8.1.1 The coating contractor shall ensure that updated product technical data sheets are obtained from the manufacturer and that coating materials are within their shelf life before commencing any coating work.
8.1.2 The facility owner may hire third-party inspectors (e.g., NACE Coating Inspector Level 2 – Certified, or higher) to carry out regular inspection.
8.2 Quality Plan
Before commencing any work, the coating contractor shall submit a specific quality plan for approval. This plan shall include:
(a) A sequence for the various activities in relation to the total work to be done;
(b) The required surface preparation, and coating system to be applied;
(c) A list of the coating materials to be used, including batch numbers;
(d) Full details of the blast and spray equipment including, where appropriate, dehydration, temperature, any other environmental control measures, and methods of access;
(e) Details of the personnel involved in the work together with a clear definition of their responsibilities and lines of communication;
(f) Detailed procedures for testing and inspection, including the methods and equipment to be used, the test frequency, and acceptance criteria;
(g) Acceptable weather conditions (temperature and RH); and
(h) Calibration methods for the inspection equipment.
8.3 Reporting
The coating contractor shall, not less than once per week, submit inspection reports giving details of weather
__________________________________________
(8)(9)
conditions, ambient temperature/RH, particulars of
application (e.g., blast cleaning, WFT and DFT measurements, and anomalies), and progress of work versus approved program. All parts and areas that have been inspected and accepted or rejected shall be clearly identified and documented.
8.4 Inspection Personnel
Inspection personnel shall be individually certified by an approved organization (e.g., NACE Coating Inspector Level
(8)(9)
2 – Certified, or higher, ACQPA, FROSIO).
8.5 Inspection Equipment
The coating contractor shall provide and use all inspection equipment necessary to ensure that the specified conditions and quality requirements are achieved. 8.6 Dew Point, Relative Humidity, and Ambient and Substrate Temperature
No coating work shall be carried out when the temperature of the substrates is less than 3°C (5°F) above the dew point or the RH is greater than 85% and the ambient temperature is below 5°C (40°F). Some coating systems may be used below 5°C (40°F), and moisture-cured urethane coating systems may be used at higher than 85% RH. No coatings shall be applied to steel surfaces exceeding a substrate temperature specified by the coating manufacturer. Some hot-surface-applied maintenance coatings may be used for application on high-temperature surfaces if their performance has been demonstrated. The measurements shall be made a minimum of three times per day during the progress of the work.
8.7 Residual Salt Contamination
8.7.1 Among all the soluble salts, the chloride ion is the most detrimental to coating service life. The maximum total allowable soluble chloride ion content on the surface is listed in Table 15. The assessment of the soluble chloride ion content shall be carried out in
4546
accordance with ISO 8502-6 and 8502-9 or an approved (by facility owner) commercial field test kit to measure the soluble chloride ion content. Because of the short test time, the measured values may be approximately 50% of the true values.
Association for Certification and Qualification of Anticorrosive Paintwork (ACQPA), 10 rue du Debarcadere 75852, Paris cedex 17, France. The Norwegian Professional Council for Education and Certification of Inspectors for Surface Treatment (FROSIO), Strandveien 18, Lysaker, Norway.
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Table 15: Maximum Total Soluble Chloride Ion Content
Coating Category
New Construction
Maintenance
Splash zone, exterior submerged 20 mg/m2 (A) 20 mg/m2 (A) zone, and ballast water tank Atmospheric zone 20 mg/m22Stainless steels (A)
20 mg/m2 50 mg/m 20 mg/m2
The level of residual salt contamination on the surface has a very significant effect on the service life of the
immersion-type coating systems. A clean surface should be obtained prior to coating. However, if the soluble chloride ion content is high and obtaining a clean surface is too costly, the allowable soluble chloride ion content shall be agreed to by the coating applicator and facility owner.
8.7.2 Testing of the soluble chloride ion content shall 8.8.4 Amine Blush be carried out at least on each component, once per
200 m2 (2,000 ft2
), and a minimum of three times per Amine blush frequently occurs at low curing shift during the progress of the work. Special attention temperatures/high RH and shall be removed in shall be given to areas where water has been trapped accordance with the coating manufacturer’s and dried out. recommendation. It is a surface defect and does not
affect the quality of the film if it occurs on the topcoat. 8.8 Surface Cleanliness
To prevent amine blush, the epoxy coating material
requires an induction period specified by the 8.8.1 General
manufacturer after mixing and before use. At lower
ambient temperatures, induction time is lengthened. The blast-cleaned surfaces shall be examined for For some epoxy coating systems, even a long traces of oil, grease, and contamination. The black induction time does not permit enough reaction in the lighting level for examination shall be 500 lx minimum. pot to prevent amine blush on coats applied at low If present, these substances shall be removed by temperature.
solvent washing. No acid washes, cleaning solutions,
solvents, or other chemical treatments shall be used on 8.9 Surface Profile
metal surfaces after they have been blast cleaned.
This restriction includes inhibitive washes intended to The surface profile shall be specified by the coating prevent flash rusting. manufacturers. If not specified, the surface profile shall
be in the range of 40 to 75 µm (1.5 to 3 mil) for all liquid 8.8.2 Surface Dust coatings, and 63 to 150 µm (2.5 to 6 mil) for TSA. The
surface profile shall be measured by the replica tape
The dust level on the blast-cleaned surface at the time method in accordance with NACE Standard RP0287,49
of coating shall not exceed quantity-rating 2 in
or ISO 8503-5.50
Surface profile shall be measured on
accordance with ISO 8502-3.47
Checks on dust levels each component, at least once per 200 m2 (2,000 ft2
) of shall be made on each component at least once per
prepared surface, and a minimum of three times per 200 m2 (2,000 ft2
) of prepared surface, and a minimum shift during the progress of the work. of three checks per shift during the progress of the
work. Vacuum cleaning is normally required in confined 8.10 Coating Application
spaces (tanks, vessels, etc.), particularly for immersion
service applications. 8.10.1 Coating Appearance
8.8.3 Mill Scale The completed coating shall be free from defects such
as runs, sags, pinholes, fish eyes, bubbles, orange Blast-cleaned new construction carbon steel surfaces peel, grit/dust inclusions, or other deleterious shall be tested for the presence of mill scale. The anomalies, and be of good visual appearance. The cleaned surfaces shall be examined with optical topcoat shall completely hide the color of the magnifying instruments or chemical tests such as a
underlying coat. copper sulfate test in accordance with ASTM A 380.48
At the beginning of each project, inspections for the 8.10.2 Wet Film Thickness presence of mill scale shall be made on each
component at least once per 200 m2 (2,000 ft2
) of Spot checks of WFT shall be carried out during the prepared surface. After two days, a minimum of three course of coating application to ensure that film inspections per day shall be made during the progress thickness is being maintained. Coating WFT of the work. measurement shall be performed in accordance with
ISO 2808,51
Method No. 1A—comb gauge.
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8.10.3 Dry Film Thickness
Coating DFT measurement shall be in accordance with ISO 2808. Type II electromagnetic gauges should be used for ferrous substrates and eddy current type gauges should be used for nonferrous substrates. Type I magnetic “banana” type gauges shall not be used. The DFT gauge calibration, DFT specification, number of measurements, and DFT acceptance criteria
52
shall be in accordance with SSPC-PA 2.
8.10.4 Holiday Testing
Holiday testing shall be conducted in accordance with
53
NACE SP0188. For immersion and splash zone services, 100% of the coated areas shall be inspected for holidays. For atmospheric services, 10% of the coated areas, which include weld seams, corners, and edges, shall be holiday detected. Any holiday is unacceptable and shall be marked and repaired according to spot repair procedures.
8.10.5 Adhesion
Adhesion of the primer to the steel substrate and intercoat adhesion of the subsequent coat(s) after curing for at least a week after application of the topcoat shall be examined by a knife test in
54
accordance with ASTM D 6677. For the knife test, if the rating is better than 8, the adhesion is considered acceptable. The adhesion test is destructive and tested areas shall be repaired afterward using the spot repair procedure. Alternatively, the applicator may perform the adhesion test on a steel coupon coated using the same surface preparation and coating application procedures as the work piece. Adhesion testing shall be carried out for each component at least
22
once per 200 m (2,000 ft) of coated surface.
8.11 Final Inspection
A final inspection shall be conducted prior to the acceptance of the work. The coating contractor and the facility owner shall both be present and they shall sign an agreed inspection report. Such reports shall include:
General - Names of the coating contractor and the
responsible personnel - Dates when work was performed
Coating materials - Information on coating materials being applied - Condition of coating materials received
Environmental conditions - Weather and ambient conditions - Coating periods
Surface preparation - Condition of surface before preparation - Tools and methods used to prepare surface - Condition of surface after preparation
Coating application - Equipment used - Mixing procedure prior to application - Coating application techniques used
Testing
- Type and calibration of inspection instruments
used
- Type of quality control tests performed, and
results.
________________________________________________________________________
Section 9: Coating Repair
9.1 General
The average DFT shall be within the specified DFT range. All coating defects, including low DFT and damaged coatings, shall be repaired. Damaged or low DFT inorganic zinc-rich primers cannot be repaired and require replacement. The areas to be repaired shall be precleaned onto the secure surrounding coating for not less than 25 mm (1 in) all around and the edges shall be feathered over a width of at least 50 mm (2 in).
9.2 Low Dry Film Thickness
If the average DFT is less than the minimum value of the specified DFT range, the area shall be repaired with additional coating. If the existing coating has exceeded its recoat window, the surface shall be abraded by either
brush-off blast cleaning with fine abrasives in accordance with NACE No. 4/SSPC-SP 7 or abrasive paper prior to recoat. To ensure good bonding to the substrate coating, a patch test shall be performed in accordance with ASTM D 50. If the bonding to the substrate coating is not sufficient, an adequate liquid penetration sealer should be applied to promote bonding prior to the application of the repair coat.
9.3 High Dry Film Thickness
If the average DFT exceeds the maximum value of the specified DFT range, the corrective action shall be determined by the facility owner and the coating manufacturer. Under no circumstances shall the maximum DFT on a flat surface be more than three times the specified maximum DFT. If this occurs, the surface shall be
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reblasted to bare metal and recoated with the specified coating system.
9.4 Damaged Coating
If coating defects, such as holidays, blistering, cracking, mud cracking, wrinkling, disbonding, lifting, peeling, over-runs, drips, and smears appear, coating in the entire damaged area shall be removed to bare metal by abrasive blasting to near-white metal in accordance with NACE No. 2/SSPC-SP 10 (Sa 2.5) or power tool cleaning to bare metal in accordance with SSPC-SP 11. The full coating system shall be applied. The undamaged area shall be feathered.
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Section 10: Flange Corrosion Control
10.1 General
Because it is extremely difficult to abrasive blast the bolt holes and the crevice between the flanges, liquid coating may not be an effective measure to prevent flange corrosion at these trouble spots. A corrosion control material (such as inhibitor grease) should be installed correctly initially after the flange has been assembled on the offshore structure. The bolt holes and flange crevices shall be sealed off completely from the offshore corrosive environment.
10.2 Sealants
Commercially available viscous sealants, such as soft and low-molecular-weight polyolefin sealants or corrosion inhibitor greases, should be injected into the flange crevice.
The sealants are very hydrophobic. A polymeric tape or SS tape should then be wrapped around the flange to enclose the flange crevice completely.
10.3 Petrolatum or Wax Tapes
Petrolatum or wax tapes may be used for ambient to moderate temperature service applications in accordance with the product manufacturer’s specification. For maintenance, the entire flange should be overwrapped with a commercial petrolatum or wax tape, which is made of polyester felt impregnated with very hydrophobic petrolatum or wax to provide encapsulation against water. Visual inspection cannot be conducted without unwrapping the tape. However, the flange shall be wrapped again after the inspection. Tape shall be replaced if the encapsulation is broken.
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Section 11: Fastener Coatings
11.1 General
Fastener coatings are generally applied at 7.5 µm (0.3 mil) or less, and, consequently, can be easily damaged during handling. Thicker coatings can be applied, but the nuts must be oversized for proper make-up. Waterborne inorganic and cadmium coatings may provide longer service life than hot-dip galvanized coatings or other polymeric coatings for service on offshore structures. Use of cadmium coatings may be restricted in some applications because of health and safety issues.
Because of the corrosiveness of the offshore environment and the low DFT required for make-up, commercial fastener coatings such as fluoropolymer fastener coating should be treated as temporary protection and overcoated with a flexible organic coating and topcoated with a UV-resistant coating after installation for both new construction and maintenance.
11.2 Corrosion Inhibitor Grease
For temporary corrosion protection (less than two years), the coated or bare fasteners may be encapsulated with corrosion inhibitor grease.
11.3 Cadmium Coating
Cadmium fastener coatings used in the past with good performance are being replaced by other coatings because of health and safety concerns. If cadmium coatings are used, local and national health and safety regulations shall be followed.
11.4 Hot-Dip Galvanized Coating
Hot-dip galvanized coatings shall be applied in accordance with ASTM A 153/A 153M. These coatings have better resistance to mechanical damage than the conventional organic coatings, but shall not be used for coating of some SS fasteners, immersion service, or under insulation
o
applications above 60C (140°F).
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Section 12: Pipe Support Corrosion Control
12.1 General
If steel pipes are laid directly on the flat steel plate, the coating at the contact point is under high compression load. This may cause creep that results in thinning of the coating. Water also will be trapped at the crevice between the pipe and the steel pipe support plate. Therefore, rusting at the pipe support is a very common failure mode on offshore structures.
12.2 Anchoring Steel U-bend
Pipes are also anchored with a steel U-bend. The U-bend is normally protected with a carbon black pigmented polychloroprene rubber sheath. The rubber sheath can also provide abrasion resistance; however, moisture is typically trapped in these crevices, facilitating coating failures.
Corrosion inhibitor grease should be applied onto the steel U-bend prior to inserting in the rubber sheath.
12.3 Overwrapping with Fiberglass-Reinforced Composite Tape
The pipe should be overwrapped with a layer of fiberglass-reinforced composite tape with adhesive backing. The fiberglass-reinforced composite provides good mechanical resistance at the contact point with the pipe support plate.
12.4 Semisphere-Shaped Thermoplastic Pipe Support Rod
Semisphere-shaped thermoplastic rod may be used under the pipe to facilitate water drainage. This rod material must have good compression creep resistance. This technique also allows for future corrosion inspection and access to recoat.
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Section 13: Corrosion Control of Small-Bore Stainless Steel Tubing
13.1 General
Small-bore SS tubing is commonly used on offshore structures for instrument lines or transportation of hydraulic fluids and chemicals. The commonly used SS tubing material, UNS S31600/S31603 (Type 316/316L SS), is susceptible to pitting and crevice corrosion as well as CSCC in a chloride-laden environment. Crevice corrosion is caused by a differential aeration cell (oxygen concentration cell). Accumulation of deposits on the surface of SS may also cause crevice corrosion under deposits. The severity of attack depends on chloride concentration and operating temperature, and in the case of CSCC, also on tensile stress (applied or residual). Thus, external extruded thermoplastic coatings, proper mechanical installation, corrosion-resistant alloys (CRAs), and/or CP by galvanic coupling may be used to mitigate the corrosion of SS tubing on offshore structures.
13.2 Crevice Corrosion Under Anchor Clamps and Clips
Small-bore SS tubing has been commonly anchored with a plastic clamp and clips. Under these mechanical devices, a crevice may form and cause crevice corrosion in the offshore environment. Plastic clamps and clips that facilitate crevice corrosion shall not be used on offshore structures.
--`,,```,,,,````-`-`,,`,,`,`,,`---13.3 Crevice Corrosion Between Two Touching SS Tubes
A crevice may form between two touching SS tubes and cause crevice corrosion in an offshore environment. Proper separation between neighboring tubes shall be provided during installation. It has been the practice of some offshore operators to attach the SS tubing to marine-grade aluminum support trays, thus using the galvanic couple to protect the SS tubing.
13.4 Liquid Protective Coatings
In general, it is difficult to provide appropriate surface preparation and apply coatings on small bore tubing. Thin-film coatings can be easily damaged, and, therefore, they are not a reliable method for corrosion mitigation.
13.5 Nonmetallic Jacket (Coating) on SS Tubing
Extruded polyvinyl chloride (PVC) jacketed SS tubing has been used on offshore structures. However, the chloride ion can be released upon heating and cause pitting. Flexible polyurethane thermoplastic rubber coating is more durable in protecting SS tubing. Carbon black pigment must be included to improve UV resistance. The polyurethane must also be of fire retardant grade. Coating thickness should be in a range of 1 to 3 mm (0.06 to 0.13 in) depending on the tubing size. Care must be taken not to introduce crevices at the various splices.
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Section 14: Health, Safety, and Environment
14.1 All coating materials shall comply with relevant hats, goggles, respirators, earplugs, fresh-air-fed hoods and regulatory requirements of the country where the coating any other necessary safety equipment. All the safety operation takes place. equipment shall be maintained in a good working condition.
All blasting equipment shall be fitted with an automatic 14.2 All waste material (hazardous or otherwise) generated deadman device. as a result of the coating operations shall be properly
stored, transported, and disposed. All handling of waste 14.5 The coating applicator shall be required to test work material, including but not limited to spent abrasives, areas for flammable vapors with an appropriate vapor tester coatings, thinners, solvents, and cleaners, shall be prior to and throughout abrasive blasting and coating performed in a safe and legal manner and shall comply with operations. all applicable regulations and laws.
14.6 The coating applicator shall post appropriate warning 14.3 The coating manufacturers shall provide the current signs and erect appropriate barriers in the work area. MSDS to the coating applicator prior to starting the work.
14.7 For confined spaces, such as ballast water tanks, all 14.4 The coating applicator shall provide all workers with safety rules shall be followed prior to the coating operation.
approved PPE including safety glasses, safety shoes, hard
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References
1. NACE Standard RP0176-2003 (superseded), “Corrosion 8. NACE No. 4/SSPC-SP 7 (latest revision), “Brush-Off Control of Steel Fixed Offshore Structures Associated with Blast Cleaning” (Houston, TX: NACE, and Pittsburgh, PA: Petroleum Production” (Houston, TX: NACE). (Available SSPC). from NACE as an historical document only.)
9. SSPC-SP 1 (latest revision), “Solvent Cleaning” 2. NACE SP0176 (latest revision), “Corrosion Control of (Pittsburgh, PA: SSPC). Submerged Areas of Permanently Installed Steel Offshore
Structures Associated with Petroleum Production” 10. NACE No. 5/SSPC-SP 12, “Surface Preparation and (Houston, TX: NACE). Cleaning of Metals by Waterjetting Prior to Recoating”
(Houston, TX: NACE, and Pittsburgh, PA: SSPC). 3. ASTM D 520 (latest revision), “Standard Specification for
Zinc Dust Pigment” (West Conshohocken, PA: ASTM). 11. ASTM A 123/A 123M (latest revision), “Standard
Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron 4. ISO 3549 (latest revision), “Zinc dust pigments for paints and Steel Products” (West Conshohocken, PA: ASTM). – Specifications and test methods” (Geneva, Switzerland:
ISO). 12. ASTM A 153/A 153M (latest revision), “Standard
Specification for Zinc Coating (Hot-Dip) on Iron and Steel 5. NACE No. 2/SSPC-SP 10 (latest revision), “Near-White Hardware” (West Conshohocken, PA: ASTM). Metal Blast Cleaning” (Houston, TX: NACE, and Pittsburgh,
PA: SSPC). 13. 40 CFR (Code of Federal Regulations) Part 261,
Appendix II, Method 1311 (latest revision), “Toxicity 6. NACE No. 1/SSPC-SP 5 (latest revision), “White Metal Characteristic Leaching Procedure (TCLP)” (Washington Blast Cleaning” (Houston, TX: NACE, and Pittsburgh, PA: DC: Office of the Federal Register). SSPC).
14. U.S. EPA Publication SW-846 (latest revision), “Test 7. NACE No. 12/AWS C2.23M/SSPC-CS 23.00 (latest Methods for Evaluating Solid Waste Physical/Chemical revision), “Specification for the Application of Thermal Spray Methods” (Washington, DC: EPA).
Coatings (Metallizing) of Aluminum, Zinc, and Their Alloys and Composites for the Corrosion Protection of Steel” (Houston, TX: NACE; Miami, FL: AWS; Pittsburgh, PA: SSPC).
28
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15. MIL-PRF-23236C (latest revision), Performance 29. NACE Standard TM0204 (latest revision), “Exterior Specification for Coating Systems for Ship Structures
Protective Coatings for Seawater Immersion Service” (Philadelphia, PA: DODSSP(10)
). (Houston, TX: NACE).
16. ASTM C 871 (latest revision), “Standard Test Methods for Chemical Analysis of Thermal Insulation Materials for 30. ASTM D 522 (latest revision), “Standard Test Methods Leachable Chloride, Fluoride, Silicate, and Sodium Ions” for Mandrel Bend Test of Attached Organic Coatings” (West (West Conshohocken, PA: ASTM). Conshohocken, PA: ASTM).
17. ASTM D 1475 (latest revision), “Standard Test Method 31. ASTM D 2794 (latest revision), “Standard Test Method for Density of Liquid Coatings, Inks, and Related Products” for Resistance of Organic Coatings to the Effects of Rapid (West Conshohocken, PA: ASTM). Deformation (Impact)” (West Conshohocken, PA: ASTM).
18. ASTM D 2369 (latest revision), “Standard Test Method 32. SSPC-SP 11 (latest revision), “Power Tool Cleaning to for Volatile Content of Coatings” (West Conshohocken, PA: Bare Metal” (Pittsburgh, PA: SSPC). ASTM).
33. ISO 8501-1 (latest revision), “Preparation of steel 19. BSI BS 5970 (latest revision), “Code of Practice for substrates before application of paints and related Thermal Insulation of Pipework and Equipment in the
products—Visual assessment of surface cleanliness—Part Temperature Range of -100oC to +870o
C” (London, UK: 1: Rust grades and preparation grades of uncoated steel BSI). substrates and of steel substrates after overall removal of
previous coatings” (Geneva, Switzerland: ISO). 20. ASTM B 479 (latest revision), “Standard Specification
for Annealed Aluminum and Aluminum-Alloy Foil for 34. SSPC-SP 3 (latest revision), “Power Tool Cleaning” Flexible Barrier, Food Contact, and Other Applications” (Pittsburgh, PA: SSPC) (West Conshohocken, PA: ASTM).
35. NACE 6G198/SSPC-TR 2 (latest revision), “Wet 21. W.H. Thomason, “Deterioration of Thermal Spray Abrasive Blast Cleaning” (Houston, TX: NACE, and Aluminum Coating on Hot Risers Due to Thermal Cycling,” Pittsburgh, PA: SSPC). CORROSION/2004, paper no. 04021 (Houston, TX: NACE,
2004). 36. A.W. Mallory, “Mechanical Surface Preparation,” in
SSPC Painting Manual—Good Painting Practice (latest 22. O. Knudsen, “Rapid Degradation of Painted TSA,” revision) chapter 2.1 (Pittsburgh, PA: SSPC). CORROSION/2004, paper no. 04023 (Houston, TX: NACE,
2004). 37. ASTM D 4285 (latest revision), “Standard Test Method
for Indicating Oil or Water in Compressed Air” (West 23. ASTM D 2371 (latest revision), “Standard Test Method Conshohocken, PA: ASTM). for Pigment Content of Solvent-Reducible Paints” (West
Conshohocken, PA: ASTM). 38. ISO 11124-3 (latest revision), “Preparation of steel
substrates before application of paints and related products 24. ASTM D 2621 (latest revision), “Standard Test Method – Specifications for metallic blast-cleaning abrasives – Part for Infrared Identification of Vehicle Solids from Solvent-3: High-carbon cast-steel shot and grit” (Geneva, Reducible Paints” (West Conshohocken, PA: ASTM). Switzerland: ISO)
25. NACE Standard TM0404 (latest revision), “Offshore 39. ISO 11126-8 (latest revision), “Preparation of steel Platform Atmospheric and Splash Zone New Construction substrates before application of paints and related products Coating System Evaluation” (Houston, TX: NACE).
– Specifications for non-metallic blast-cleaning abrasives –
Part 8: Olivine sand” (Geneva, Switzerland: ISO). 26. NACE Standard TM0304 (latest revision), “Offshore
Platform Atmospheric and Splash Zone Maintenance 40. ISO 11126-9 (latest revision), “Preparation of steel Coating System Evaluation” (Houston, TX: NACE). substrates before application of paints and related products
– Specifications for non-metallic blast-cleaning abrasives – 27. ASTM G 14 (latest revision), “Standard Test Method for Part 9: Staurolite” (Geneva, Switzerland: ISO). Impact Resistance of Pipeline Coatings (Falling Weight
Test)” (West Conshohocken, PA: ASTM). 41. ISO 11126-10 (latest revision), “Preparation of steel
substrates before application of paints and related products 28. NACE Standard TM0104 (latest revision), “Offshore – Specifications for non-metallic blast-cleaning abrasives – Platform Ballast Water Tank Coating System Evaluation” Part 10: Almandite garnet” (Geneva, Switzerland: ISO).
(Houston, TX: NACE).
___________________________ (10)
Department of Defense Single Stock Point (DODSSP), Document Automation and Production Services, 700 Robbins Ave., Building 4/D, Philadelphia, PA 19111-5094.
NACE International
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42. ISO 11126-4 (latest revision), “Preparation of steel substrates before application of paints and related products – Specifications for non-metallic blast-cleaning abrasives – Part 4: Coal furnace slag” (Geneva, Switzerland: ISO).
43. ISO 11126-7 (latest revision), “Preparation of steel substrates before application of paints and related products – Specifications for non-metallic blast-cleaning abrasives – Part 7: Fused aluminum oxide.” (Geneva, Switzerland: ISO).
44. ASTM D 50 (latest revision), “Standard Practice for Conducting a Patch Test to Assess Coating Compatibility” (West Conshohocken, PA: ASTM).
45. ISO 8502-6 (latest revision), “Preparation of steel substrates before application of paints and related products – Tests for the assessment of surface cleanliness – Part 6: Extraction of soluble contaminants for analysis – The Bresle method” (Geneva, Switzerland: ISO).
46. ISO 8502-9 (latest revision), “Preparation of steel substrates before application of paints and related products – Tests for the assessment of surface cleanliness – Part 9: Field method for the conductometric determination of water-soluble salts” (Geneva, Switzerland: ISO).
47. ISO 8502-3 (latest revision), “Preparation of steel substrates before application of paints and related products – Tests for the assessment of surface cleanliness – Part 3: Assessment of dust on steel surfaces prepared for painting (pressure-sensitive tape method)” (Geneva, Switzerland: ISO).
30
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48. ASTM A 380 (latest revision), “Standard Practice for Cleaning, Descaling, and Passivation of Stainless Steel Parts, Equipment, and Systems” (West Conshohocken, PA: ASTM).
49. NACE Standard RP0287 (latest revision), “Field Measurement of Surface Profile of Abrasive Blast-Cleaned Steel Surfaces Using a Replica Tape” (Houston, TX: NACE).
50. ISO 8503-5 (latest revision), “Preparation of steel substrates before application of paints and related products – Surface roughness characteristics of blast-cleaned steel substrates – Part 5: Replica tape method for the determination of the surface profile” (Geneva, Switzerland: ISO).
51. ISO 2808 (latest revision), “Paints and varnishes – Determination of film thickness” (Geneva, Switzerland: ISO).
52. SSPC-PA 2 (latest revision), “Measurement of Dry Coating Thickness with Magnetic Gages” (Pittsburgh, PA: SSPC).
53. NACE SP0188 (latest revision), “Discontinuity (Holiday) Testing of New Protective Coatings on Conductive Substrates” (Houston, TX: NACE).
54. ASTM D 6677 (latest revision), “Standard Test Method for Evaluating Adhesion by Knife” (West Conshohocken, PA: ASTM).
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