Marine Coatings Issues and Solutions - HZScorrosion.hzs.be/Presentations/Johnny Eliasson.pdf · Marine Coatings Issues and Solutions ... Chevron Shipping Co. ... Coating deflection

Corrosion and Fouling Two Curses for a Ship's Hull – Antwerp Maritime Academy

Marine CoatingsIssues and Solutions

Johnny Eliasson - Structural and Corrosion Engineer - Chevron Shipping Co.

3/4/2017 Johnny Eliasson 1


Presentation Content• How coatings actually work, stick and

fail

• Ballast tank coatings Good, Bad and the Ugly• Cold cure and the risk• New construction• Ballast Coating Maintenance Plans

• Antifouling – the issues, and solutions• Fouling and the risk• The state of antifouling solutions• Biofouling Management Plans

• General fabric maintenance• Example of a poor strategy• Example of a good strategy

• Impressed Cathodic Current Protection (ICCP) – what can go wrong


http://images-app.chevron.com/scripts/WebObjects.dll/TSWeb.woa/2/wo/QmOmmdqt2ib38ysH617DW0/17.35.23.3.1

http://images-app.chevron.com/scripts/WebObjects.dll/TSWeb.woa/2/wo/QmOmmdqt2ib38ysH617DW0/17.35.23.3.1


Introduction to how coatings actually work!

• Prevents ions (the electrolyte) to move along the coating/steel interface

• Does:• Act as barrier to ions (salts, etc.)

• Hydrated sphere of influence

• Does NOT:• Act as barrier to water

• Vapor transmission rate

• Act as barrier to oxygen• Gases passes

• Do not believe the fairytales!!!

• The prerequisites for corrosion:• Anodic site• Cathodic site• Electron pathway• Electrolyte



How Coatings Actually stick!

• Organic coatings bonds by primarily by “hydrogen bonding” (Van Der Waals attraction ..)

• Need intimate contact to active sites on the steel

• Inorganic zinc coatings (and some adhesion promoters in organic coatings) bonds primarily covalently

• Need intimate contact to clean steel to bond



How Coatings Fail!

• Blistering• Osmosis

• Cracking• Shrinkage

• Delamination• Shrinkage• Swelling

• Through rusting• Ionic penetration

• Main cause to late loss of life• Interfacial changes, part of aging

• The interface matters!• Cleanliness at application• Painting over salt = loss of life• Painting over rust = loss of life



Typical PSPC “Good” Result

• 12 years of age, top class ballast tank coating

• 15 years target useful life design per PSPC

• Not perfect but clearly GOOD by MSC.1-circ/1330.



Typical PSPC “Not So Good” Result

• Ship 11 years old, with 2nd

class ballast tank coating

• Again 15 years target design service life intent per PSPC

• Result not good, several tank rated FAIR, now upgraded at a high cost back to GOOD.



Ballast Tank Coatings – “The Very Good”

• Things can go well:• Series of chemical tankers all

approaching mature age:• No tanks recoated, saving $millions• All tanks in an excellent condition at

ages from 18 to 21 years (99.9% intact)

• Reasons for the success:• Good coating selection• Appropriate (Owner driven)

specification • TSCG Guide – 25 years

• Honest SY execution• Sensible M&R strategy



TSCF Guidelines to Selection and Application of Ballast Tank Coatings

• Guidelines for Ballast Tank Coatings Systems and Surface Preparation, 2014 Revised Edition

• Provides guidance and advice on technical matters related to the design, building, operating, maintenance and repair of the corrosion protection systems of ships’ ballast tanks.

• Provides options and information for designers, shipyards and ship owners and

• Is specific enough to be used as a reference document for shipbuilding, ship repair and ship maintenance purposes.



Ballast Tank Coatings – The Bad

• Things can go bad:• Series of crude oil tankers at less

than 12 years of age:• Coating failing by shrinkage

• All tanks needed SY intervention, and onboard coating crews

• Reasons for the poor result:• Poor coating selection

• SY standard specification

• Average SY execution

• Poor M&R strategy



Ballast Tank Coatings – The Ugly

Things can get real ugly:• Examples of real serious trouble when

the tanks are not in a GOOD condition by ESP:• Unsafe tanks • Risk for loss of cargo• Problems trading the ship

• The fact is that this no longer acceptable on the market

• The IMO PSPC is helping to alleviate this:• 15 years life• Minimalistic• TSCF gap analysis



The TDS – What Does It Tell You?

• Solids by volume ratio – SVR

• Mixing

• Surface preparation

• Application conditions

• Colors

• Safety aspects

• Tip size

• Potlife, etc.

• Lots of good information!

• Often controlled by the commercial department.



The TDS – What Does It Tell You?

So apply under any condition, and on any surface preparation, and get the same result??



The MSDS – What Does It Tell You?

• Part A

1-Methoxypropan-2-0lExtremely water soluble - osmosisPolyamideEster – anodes?



The MSDS – What Does It Tell You?

• Part BEthylenediamineA CO2 scavenger, and a curing “kicker” for cold temp coatings- Amine carbazationButanolWater soluble solventOsmosis

These are just some examples! Other species to look for:Benzyl alcohol, nonyl-phenol –shrinkage during aging, etc.



Ballast Tank Coatings – Risk by cold cure

• To apply the coatings at lower temperature during construction; • Is convenient

• Is a compromise, and has a cost• Increase solvent retention

• Decreased wetting

• Competing reactions – good and bad

• Leads to shrinkage related coating delamination and cracks

• Resulting in expensive M&R and even premature recoating



Ballast Tank Coatings – Excellent Analysis

Also worth noting is ISO 19030 –“Measurement of changes in hull and propeller performance”has been published a promise to help owners properly measure hull performance :• Help keeping paint ,manufacturers honest• Help operators optimize hull cleaning interventions• Reduce CO2 emissions• Reduce fuel usage

Study on alternative approaches to corrosion protection of ballast tanks using an economic model - De Baere Kris Verstraelen Helen Rigo Philippe Van Passel Steven Lenaerts Silvia Potters Geert - Marine structures - ISSN 0951-8339-32 (2013) p. 1-17



Water Absorption/Desorption StudiesShrinkage Cracking Risk• ASTM D570 modified, a low cost test that gives interesting values

• Can be one tool to test coatings in the selection process



Other Cracking Related Research

• Dr. George Mills paper, “Factors Influencing Early Crack in Marine Cargo and Ballast Tank”, supported by data from HHI, and yours truly, JPCL/PCE, February 2006


Coating deflection as a result of coating shrinkage

Curing shrinkage valueThe resultant of 2 or more stress vectorsis always greater than either of the stress vectors


Ballast Tank Coatings – New Construction

• Vital parameters:– Coating selection– Grit blasting– Vacuum cleaning– Temperature control– Humidity control– Pre-striping– Proper mixing– Thickness control– Inspection– Record keeping– Final cure– Seawater testing



Ballast Coatings Maintenance Plans

• Before ship is contracted the management must state what their expectations are;• Service life of vessel• Expected end of life condition

• Using NB application records and condition data;• Map alternative strategies to meet the

expectations• Calculate NPV to ascertain the most cost

effective path• Develop a Ballast Tank Coating

Maintenance Plan to be a guide for how to meet the expectations:• High level• Subject to annual updates

No Plan = Chaos!

3/4/2017 Johnny Eliasson


Antifouling – the issues, and solutions –Fouling and the risk

• Aquatic Invasive Species infestation• Increased fuel usage• Increased CO2 and other acid gas

emissions• MRV in Eu

• Reduced speed• Regulatory violations

• USCG• EPA• States and Nations

• Taxes • Damages to company image



Antifouling – the issues, and solutions –Fouling and the risk



Antifouling – the issues, and solutions –The state of antifouling solutions

• Solutions:• Biocide containing anti-fouling paints

• High quality hydrolysis based polymers• Low quality natural or synthetic pine rosin

based• Hybrids

• Biocide free hull coatings• Fouling release• Surface Treatment Coatings

• Hull fouling surveys during propeller polishing events

• Hull cleaning• Hard cleaning• Soft cleaning



Antifouling – the issues, and solutions -Biofouling Management Plans

• Biofouling Management Plans;• Should have been onboard since a few

years• Mandatory by USCG• Must meet EPA requirements• Should by harmonized to satisfy IMO

guidelines, and:• California CSLC regs (1/1/2017)• Australia, New Zeeland, etc

• ABS Template a good start• Stays onboard, kept updated by ship• Auditable when the ballast tank

convention enters into force September 2017

A p p e n d i x 1 : B i o f o u l i n g M a n a g e m e n t P l a n

BIOFOULING MANAGEMENT PLAN

SHIP NAME: Andromeda Voyager

IMO NUMBER: 9288875



General fabric maintenance –Example of a poor strategy• With a poor coating system to start and a non-optical

M&R strategy the consequence is poor

• This ship was only 12 years young



General fabric maintenance –Example of a good strategy

• With a good costing system and an optimal M&R strategy the result can be very good

• This ship has a much more complicated deck to maintain, but still after 18.9 years (the age when picture was taken) she in an excellent condition



Impressed Cathodic Current Protection (ICCP) – what can go wrong

Malfunctioning ICCP “blew” the paint off the hull



Guarantees and Warranties

• Shipyard warranties;• DD 6 months• NB 1 year• Few exclusions but short duration

• Coating manufacturers guarantees;• Define responsivities • Simple resolution to issues• Lots of exclusions• Burden of proof on the Operator

Is it really in the Operator’s interest to sign the paint suppliers warranty documents?

• Shipyard warranties;• 2 % breakdown allowed• Not much risk to shipyards• Often signed over to paint makers

• Paint makers’ warranties:• Designed to protect the paint vendor• Lots of confusing exclusions and

restrictions.

Consumer laws offer good protection!• The supplier is the “expert”• The end user the “innocent user”• Burden of proof

Actual situation



Honorable Mention

Stanley Lopata

John Montle

Chuck Munger

George Mills

A few of my mentors



Conclusion

• All is well when optimization guides us considering:• NB coating systems and application

• Maintenance strategies

• Crew support

• Antifouling paint and hull performance

• Responsibilities

Target = Improved Quality @ Lower Cost

We serve the common good!


Documents

Marine Coatings Issues and Solutions - HZScorrosion.hzs.be/Presentations/Johnny Eliasson.pdf · Marine Coatings Issues and Solutions ... Chevron Shipping Co. ... Coating deflection