What You Can’t See Will Cost You

What You Can’t See Will Cost You

Predictable, Less Costly, Surface Preparation Corrosion Prevention Technologies LLC

8 Greenway Plaza Suite 910 Houston, Texas 77046

MakingCorrosionHistory.com

Current Method(s) for Coating Maintenance

• Degrease

• Blast • Media

• Water Jet

• Vapor/ Slurry

• Tool Abrasion • Hand

• Machine

• Rinse (optional) • To hold the blast

• To remove salt

• Coat • Cycle time 1-2 days

8 Greenway Plaza, Suite 910 Houston, TX 77046 713-625-7505 www.corrprevention.com

Result of Blast/ Coat • Corrosion

• Paint blisters

• Weld lines

• Lamination peeling of coatings

• Anomalies

• Everywhere


What if? • Blast/coat maintenance happens regardless of weather conditions?

• Blasting was performed on bad weather days?

• The blast and coat functions were separated?

• Blasting could be performed on bad weather days?

• Flash rust buildup was not an issue?

• Reblasting was eliminated?

• The blast/coat cycle went from one day to two weeks, or more?

• Waste of daily changeover, blast to coat, was eliminated?

• Waste from coating, pot bottoms and solvent, was reduced?

• All metal sulfides and microscopic contaminants were removed from metal?

• Surfaces were coated at their cleanest?

• Project overruns were significantly curtailed, or eliminated?

• Project costs could be significantly reduced through greater efficiency of time and labor?

• Coating life was guaranteed to double over current life expectancy?

• The process was non-toxic and environmentally safe?


CorrX Process 1- Apply acidic gel

2- Fugitive alkaline rinse

Yields; passive surface

• Removal of electrolyte from the corrosion process (ACME)

• Reduced surface conductivity

• Surface not affected when water vapor penetrates coating

Thinking differently to remove flash rust and metal sulfides solved the problem


Atmospheric Protective Coating Testing • Study Results Courtesy of a Large Oil Company: Results of Coating

Performance Testing over Various Levels of Surface Cleaning; a Major Coating Testing Laboratory, October, 2013

• All coatings were applied at ambient laboratory conditions.

• The Carboguard® 893 was applied to all panels on the day following the decontamination procedures

• The panels were then coated with two coats of the Carboguard® 890. All coating application occurred over a period of eight days


Results of Atmospheric Protective Coating Testing

• Three coats of marine epoxy • 24 hour deionized water soak at 66 C (151 F)


Inefficiencies and Opportunities with Current Practices

• Work tied to atmospheric conditions

• Weather

• Corrosive environments

• Change over time between blast/ coats

• Surface exposure time prior to coating

• Increase conductivity using one step washes

Hint: If you are not blasting or coating your not efficient


Petra Consultants, Inc. Offshore Statistics

• Coating from 60,000 ft2/yr to 100,000 ft2/yr

• From $45/ft2 to $23/ft2

• Yearly budget reduced

• Coating failures from 50% (3-6 months) to less than 1%

• Coatings holding up after four years


Main Drill Deck - Before CorrX

8 Greenway Plaza, Suite 910 Houston, TX 77046 713-625-7505 www.corrprevention.com8 Greenway Plaza, Suite 910 Houston, TX 77046 713-625-7505 www.corrprevention.com

U.S. OffshorePlatform

Offshore surface following blasting. Prior coatings have beenremoved. Visible flash rust hasbegun.

CorrX technology requires only a commercial blast. White metal blast is no longer necessary. Coatings do not

have to be applied immediately following a cleaning or blasting. Once blasted, projects canbeput onhold until

the applicator is readyto coat.TheCorrX technologywill remove any flashrust that occurs.


U.S. Offshore Platform

CorrX technology will be applied to remove the flash rust and other surface contaminants.

When the applicator is ready to coat, metal is cleaned using the CorrX technology and coated according to the

prescribed coating standards.




CorrX PREP (Step 1) applied at 12 to 16 mils. Rinsing has begun on the far left of the photo

using CorrX WASH (STEP 2).

CorrX PREP may be applied by an airless or conventional sprayer suitable for mild acid product. CorrX WASH

applied using a 3000 PSI power washer.




CorrX PREP applied and reacting with the contaminants on the surface.

CorrX PREP is left on the surface for a minimum of 30 minutes to clean and passivate the surface. Additional dwell time may be required and is recommended for badly contaminated surfaces, for very deep anchor profiles, or for colder surface temperatures.



U.S. OffshorePlatform After CorrX

Without No Additional Blasting

Fully rinsed surface using CorrX WASH and a 3000 PSI power washer.

Carbon steel surfaces prepared with CorrX PREP/WASH may exhibit a wide variety of appearances, from abright mirror like finish to a dull gray appearance, depending on the composition of the steel, method of surface preparation, and anchor profile.


U.S. Offshore Platform After CorrX

Without No Additional Blasting

Coated surface after cleaning with the CorrX technology.

This photo compare the “before” on the bottom right and top left to the “after” on the middle and just abovethe newly coated area. The CorrX technology does not need to be applied immediately following a blast.Projects can be put on hold; however, for offshore and other corrosive environments, coating need to beapplied within four to six hours of treatment to prevent recontamination of the surface.


Main Drill Deck Top Coat


Areas treated with CorrX and Coated

(3 Years Later)


Pipeline Case StudiesMajor Chemical Company Case 1

Conclusions• “It can be cost effective on larger pipeline recoat jobs

or using on large vessels and tanks throughout _ _ _”.

• “From a pipeline application it did prevent flash rusting

to occur from our sometimes sweating pipe or wet

atmospheric conditions due to humidity and light

rains/drizzles. Did not have to re-blast or try to cover

pipe to prevent which was time savings and cost savings”.

• “ I recommend that someone else in a _ _ _ site use this

on a vessel or tank and determine the advantages/disadvantages

prior to making this standard practice for certain applications”.

- _ _ _ ‘s Corrosion/Protective Coating Engineer


Local Pipeline CompanyCase 2

• Failed 40 of 100 welds

• Up against deadline: Panic Mode

• One foreman remembered CorrX solved issue with weld undercutting in a Port Arthur Facility

• Used CorrX prior to welding

• Passed 110 of 110 welds.


CorrX Cleaning Process • Reduced number of paint/coat cycles

• Removes flash rust • Allows separation of blasting and coating activities

• Removes soluble salts

• Not tied to weather

• Removes insoluble conductive materials • Metal sulfides, metal carbonates, and certain blast media

• Leaves surface in passive state


Protective Liner Testing • O’Donoghue, M. and Datta, V.J.: Old New and

Forgotten Wisdom for Tanks and Vessel Linings, presented at SSPC National Conference,Lake Buena Vista, Florida, February, 2014

• Idlibi, Yasir, PhD., Jason Hart, O’Donoghue, Mike, PhD, Datta, Vijay, and Johnson, Bill, AScT: Russian Roulette: Coating Performance and Sulfide Removal Treatment, JPCL, November, 2016, pp.38-50


SEM EDX Image New Mild Steel Abrasive Blasted SSPC-SP-5/NACE 1

Image Courtesy of Mike O’Donoghue PhD


SSPC-SP-5/NACE 1, Contaminated, Pressure Washed, Blasted Again



SSPC-SP-5/NACE 1, Contaminated, Pressure Washed, Not Reblasted



SSPC-SP-5/NACE 1, Contaminated, Pressure Washed, Two-Step Cleaned



Gold Standard for Over 70 Years



CorrX: The New Benchmark



What Does Good Look Like in 20 Years?

• CorrX will be in coating specifications that have predicted lifetimes of 100 years or more.

• A field test, non-destructive of course, will be developed and commercially available to determine if a surface is CorrX clean.

Jim Knocke

Corrosion Prevention Technologies

[email protected]

Cell (423) 304-1919

Documents

What You Can’t See Will Cost You