Offshore Arabia 2010

”losses due to corrosion, erosion and chemical degeneration”

By John Moritzen and Morten Fich-Olsen Jakob Albertsen A/S

Agenda

Functional coating and surface preparation

1. Surface preparation with sponges2. Functional coating with composites3. References 4. Benfits of anti corrosion coating

Surface preparationswith sponges

Surface preparation

New ”blasting”technology with sponges reinforced with silicium oxides and steel grit

Benfits:1. Less dust2. Worker safety and visibility3. Chloride removal4. Recycles up to 15 times

The Sponge media makes a perfect surface, clean and rough for the protective coating

Petrobras test of surface preparation methods

UHP Grit Sponges

Worker safety Poor Good Ideal

Surface quality Poor Ideal Ideal

Lifetime before coating Reasonable Good Ideal

Costs Poor Poor Good

Productivity Good Ideal Ideal

National Aeronautics and Space Administrationdid a big comparable test of the new generation of surface preparation methods. Following were testet:

•Plastic Blast Media. •Hard Abrasive Steel Media. •Sponge Blast Media •Liquid Nitrogen.•Mechanical Vacuum Cleaning. •Portable Laser Coating Removal System.

NASA test Feb, 2007

The NASA conclusion: Sponge technology is the superior technology

Economic in use

Functional coatingwith composites

Ceramic composites

Composite polymer reinforced with ceramics

1. High adhesion to the substrate2. Low permeability3. High resistance to erosion and wear

COMPOSITE: A Substance Composed of Two or MoreMaterials in Separate Phases

Matrix Phase

Polymers• Epoxy

• Phenolic• Polyester

Reinforcements

Fibers• Aramid• Graphite• Glass• Nylon

Particles• Ceramic• Mineral• Metals• Quartz

Reinforcement Phase

Ceramic composites for MetalsEngineered to Rebuild and Upgrade Metal Surfaces

Severe Abrasion

Corrosion / Erosion

Chemical Attack

Erosion

Corrosion

Rebuilding

Protection

Why Do Coatings Fail ?Assuming Correct Surface Preparation and the Coating is Not Chemically Attacked -- Example: 2-Part Solvent Based Epoxy

At the Gel Point the Film Takes Final Form.

Solvent Remaining Leaves Microscopic Voids When it Evaporates

All Coatings Breathe.Voids at the Metal Surface Become Ideal Corrosion Cells

Most Metal Oxides Have a Larger Volume Than the Base Metal thus Creating an Expansive Force on the Coating When it Corrodes. If the Coating Cannot Resist the Expansive Force Created the Result is Underfilm Corrosion

Ceramic composite Technology100% Solids, No Solvent, Vacuum Mfg.

Goal- Eliminate Microscopic Voids Throughout Film

XX

Goal is to Get 100% Contact with the Surface

Real World is That a Film Break Will Eventually Occur

No Underfilm Corrosion

To Ensure Optimum Resistance to Underfilm Corrosion Material must have High Tensile Adhesion; High Flexural Strength & High Permeation Resistance

>200 kg/cm2 +

Comparative Salt Fog Results

C163-22-Part, Solvent

Epoxy

A3512-Part, 100% Solids

Epoxy

Ceramic composite

6000 Hours - Complete Failure20,000 Hours -

Surface Stains Only

Corrocell Test CellTests Material Resistance to Both Liquid and Vapor

Phase Exposure

Can Control and Test Variables:1. Chemical2. Temperature3. D Temp.-”Cold Wall Effect”

Coated Test Panels

Meets:

ASTM D 4398

NACE TM-01-74

ANSI/ASTM C 868

Corrocell Test Laboratory

Corrocell Test in 10% Sulphuric Acid at 50C

B5811 Panel after 14 weeks * Composite Panel after 14 weeks

* First Blisters recorded after 3 weeks

Maersk decompression Test

Tests a coatings ability to withstand explosive decompression. Composites passed the test with no apparent change.

Before Test After Test

References

Trash Racks for Major New Dam

Trash Racks Provide Critical Protection for Turbines. The Protective Coating Must be Able to Protect Long Term Under extremely demanding Conditions. Ceramic composites was Chosen

Trash Racks During the Application of Composites

Inlet Section to Dam Where the Trash Racks Will be Installed

Wastewater Storage Tanks

Two Coats of Composites were spray applied at 375 microns (15 mils) per coat

View of one of the four completed

tanks

Heat ExchangerProtected with

Ceramic Composites

Corrosion on Cover and Water Boxes of Heat Exchanger

End Cover of Water Box Coated With Ceramic Composites

Heat ExchangersStandardized

Protection with Ceramic Composites

Largest Chemical

complex in Africa.

Heat exchangers

exhibit extensive

galvanic corrosion,

even with zinc

anodic protection.

The Replacement Cost of Zinc Anodes Alone Was $250,000 Per Year!!

After 5 Years of Service and Over 1500 Heat Exchangers, Composites Has Become the Standard “Workhorse” for Corrosion Protection Throughout the Plant

98% Sulfuric Acid (H2SO4) Storage Tanks

Corroded, Above Ground, 98% H2SO4

Tanks with Failed Epoxy Coating

New Tanks Coated With Composites Inside and Out

Atmospheric Corrosion Protection

Ceramic Reinforcements Eliminate Corrosion / Erosion

• Tolerances unchanged after 15 years in service. Original uncoated alloy lost 9 mm (3/8 inch) in first two years of operation.

• Tolerances remain virtually unchanged thus maintaining efficiency throughout the life of the pump.

Waste Water Screw

Waste water screw damaged by erosion / corrosion. Edge strip welded on to rebuild, Composites to protect. After 5 years - perfect condition.

Main Water Pump - Nuclear Power Plant

Extreme Galvanic Corrosion, Suction Bell Fell Off !New Pump Cost $175,000

Main Water Pump - Nuclear Power Plant

Solution: After Blasting, Rebuilt with 240kg of Composites.Results: After 10 years in Service, only 2% of surface needed touch up.

Cooling Water pump from power plant protected with Ceramic composites

After 12 years continuous operation. Result: In perfect condition.

Main Cooling Water pump with Ceramic composites

Sulzer Pumps upgraded with Ceramic composites

Seawater

pump

protected

with

Ceramic Composite

Vacuum Pumps30% of New Part Cost, Longer Life, Saves Energy

Typical Corrosion/Erosion Damage to Vacuum Pump Rotor

Rebuilding with Composites

Cost - 30% of New Cast Iron Parts, Longer Life, Tolerances Maintained Thus Maximum Efficiency

Over 15 Years Proven Results in Industry

1995 SCEMM Award Given to Motola (Nash Partner, Sweden) for Saving the Paper Industry Electricity by Using Composites on Vacuum Pumps

Original Equipment Upgraded

Result:1995 Nash Introduced XL Series -New Product Line -Cast Iron, Upgraded with Composites

Over 15 Years of Successful Performance Rebuilding Vacuum Pumps

OEM pump for seawater

protected

with

Ceramic Composite

Seawater cooling system pipes at a power plant, coated external and internal with composites.

Fusion Bonded Epoxy internal coating of pipes, spools and risers

Fan Blade at Cement Plant

Fan Blade Previously Welded as Shown, Now Rebuilt Using Composites

Method Months

New Fan - 2 to 4

Weld Overlay - 2

Composites >7 1/2

Savings After 71/2 Months $126,000

sewage pump coatedwith Ceramic composites.

More than 8 years liftetime. Large savings in wear and energy comsumption

Pump impeller

rebuild and coated with

Ceramic composite

Pump impeller

exposed to severe wear

application

protected with

wear resistant

Ceramic

Composite

Before After

Pump rebuild with Ceramic Composite material

Fan protected with

Ceramic Composite

Deaerator

Offshore protected

with Ceramic Composite

spray applied

Degasser

Offshore protected

with Ceramic Composite

spray applied

Dual Media Filter

protected

with Ceramic Composite

Cooler

protected

with Ceramic Composite

Hydro

Cyclone

protected

With Ceramic Composite

Benefits of anti corrosion coating

From “Centrifugal and Axial Flow Pumps, 2nd Edition”

Energy savings of 10-20% by coating pumps

•Safety (no leakages)•Longer life-time of your investment•Less ”down-time”•Higher efficiency of your production•Low cost of maintainance•Reduced wear

Main Benefits:

Questions please !

Thanks for listening !