Surfaces 16 - Protective Coatings | International Paint
Transcription
Surfaces 16 - Protective Coatings | International Paint
www.surfaces-international.com Siag Aerisyn LLC > Fire Protection > Skarv FPSO > Challenges in the VOC world INSIDE > Growth in Offshore Wind Power > Lansdowne Road Stadium > Mining and Mineral Processing INTERNATIONAL-PC.COM ISSUESIXTEEN2010 GROWTH IN CONTENTS The wind power industry has seen rapid growth in recent years, with unprecedented development of onshore wind in the USA and China. While onshore growth is expected to continue the offshore market is beginning to establish itself as a mainstream industry. Having developed with the wind industry, International Protective Coatings have coated one in every four wind turbines worldwide, establishing industry best practice over the last 15 years. The following are some of the recent offshore projects which International Protective Coatings has been involved with: Rødsand B substation (Energinet) Denmark Belwind Wind Farm – Zeebrugge, Belgium Project: Connecting 90 turbines of the Rodsand B offshore wind farm to the shore, International Protective Coatings coated the 900 tonne Rodsand B substation. Project: Located on the Bligh Bank, 46 kilometers off the coast of Zeebrugge, Belgium the Belwind wind farm required a coating system which would ensure the turbines offered maximum productivity. An anti-corrosion system of Interzone® 954 and Interthane® 990 was applied to the transition pieces, keeping them protected for longer. Component: Offshore Substation System: Structure: Interzinc® 52, Intergard® 475HS, Interthane® 990 Decks: Interzone® 954 Project Size: 10,000 m2 ISO Environment: ISO 12944-2 C5-M Applicator: Bladt Industries A/S Year: 2008/2009 Component: Monopile Transition Pieces System: Interzone® 954, Interthane® 990 Project Size: 30,000m2 ISO Environment: ISO 12944 C5-M, IM2 Applicator: Bladt Industries Year: 2009 2 Growth in Offshore Wind Power Ormonde Gas/Wind Cogeneration Project, Scotland, UK Project: This project had a number of requirements which the coating system for this project had to meet, including being a NORSOK approved system, weekly technical support, local and fast supply to meet a tight schedule and proven track record. International Protective Coatings met all these requirements and supplied high build coatings to the turbines, which are located just off the Irish Sea. Components: Jacket and transition pieces System: Jacket: Interzone® 100 Decks: Interzone® 954, Interzone® 1000 Transition Pieces: Interzinc® 52, Intergard® 475HS, Interfine® 691 ISO Environment: ISO 12944 C5-M, IM2 Applicator: Burntisland Fabricators Year: 2010 Lansdowne Road Stadium 4 Mining and Mineral Processing 6 Siag Aerisyn LLC 8 Fire Protection 10 Skarv FPSO 12 Challenges in the VOC world 14 WIND POWER Being located miles from the shoreline, and facing harsh environmental conditions, offshore wind turbines and their foundations require excellent corrosion protection to prolong turbine life and limit costly maintenance. While the massive onshore growth rates have transferred overseas in recent years, offshore wind has presented northern Europe with an opportunity to once again lead the market in volume installations. With countries such as Denmark, Germany and the UK among those investing heavily in offshore, the North Sea is becoming the proving ground for emerging offshore wind technologies. Editor: James Morton Liaison: Clare Goldie Publisher: International Protective Coatings Produced By: Sheridan Design studio@sheridandesign.co.uk www.sheridandesign.co.uk Although having many elements in common with onshore wind turbine designs, offshore wind installations present a number of new technical and engineering challenges to the wind industry. Many of these challenges stem from the inaccessibility of the turbines once they are installed and operating. The harsh conditions of the North Sea can make it very difficult and expensive for maintenance vessels to operate, with most of the work having to be carried out in the calmer summer months. It is therefore absolutely essential that every component, including the coating system, is rigorously tested and performs reliably for the lifetime of the offshore asset. Furthermore the selection, design and installation of offshore foundations is a completely new element to the wind industry. Here much of the technology has been developed from oil and gas assets, allowing the offshore wind industry to utilise already proven solutions. With extensive track record in North Sea offshore oil and gas installations stretching back more than 35 years, International Protective Coatings are able to combine extensive offshore experience with a detailed understanding of the wind business to deliver a complete offshore coatings solution. With coating systems for hubs, blades, nacelles, components, towers and foundations International Protective Coatings offers the opportunity to reduce complexity by dealing with one supplier. Through a product range including Intergard®, Intercure® and Interzone® International Protective Coatings offers customers products which have all been rigorously tested to ISO and NORSOK standards. Cover photo: Offshore wind farm 2 international-pc.com international-pc.com 3 Lansdowne Road Stadium BS8901 is a management system for event venues that deals with sustainability. This standard had to be adhered to during the redevelopment of the renowned stadium and the project’s environmental, social and economic impact were all taken into account from conception of the project. International Protective Coatings is committed to sustainability. Coating the exposed roof on the new Lansdowne Road Stadium in Dublin, Ireland, with a polysiloxane finish will prolong the design life and will contribute to the venue adhering to be certifiably sustainable. ALL PHOTOGRAPHY CHRIS GASCOIGNE The original stadium first opened as a multi-purpose venue and, after hosting the first rugby game in 1876 became synonymous with the game. In 2007 the stadium was demolished and, to ensure sustainability was met throughout the project, most of the existing stadium was crushed onsite and the materials were reused where possible. Over 1,500 tonnes of steelwork from the old stadium was recycled. 4 international-pc.com The architect who designed the new stadium was Populous, formerly HOK Sports with credit to associate architects Scott Tallon Walker (STW). As the stadium is located in an ISO 12944 C4 environment, the structural engineers contracted on this project, Buro Happold, specified a three coat system which would offer anti-corrosive protection and a quality durable finish for steelwork on the exposed roof. These criteria were met by utilising a system of Interzinc® 52, Intercure® 384 and Interfine® 979 from International Protective Coatings. four times the colour and gloss retention compared to traditional polyurethanes to the project, limiting the need for aesthetic maintenance and reducing environmental impact as VOC solvents are reduced over the life of the asset. The project involved the fabrication of 5,000 tonnes of structural steel. The tubular steelwork for the roof was fabricated by Cimolai in Italy and the lower tier was painted and fabricated by Siac Butler in Ireland. Interfine 979 has excellent abrasion and impact resistance which helps during transit and limits the need for touch up application on site, reducing any related disruption to the construction schedule. Areas at the Lansdowne Road Stadium coated with products by International Protective Coatings: Interfine® 979 has excellent abrasion and impact resistance Faying surfaces Interzinc® 22 Zinc Silicate With a global presence in the coatings industry, International Protective Coatings were able to coordinate this multi-national project with ease and ensure the same product is applied in all countries for consistency making them the ideal coatings partner. Lower Tier exposed steelwork Interzinc® 52 Intercure® 384 Interthane® 878 Bolts and joint connections Interplus® 256 Interplus® 770 Interfine® 979 Roof steelwork Interzinc® 52 Intercure® 384 Interfine® 979 Track Record : Recent Sporting Venues: The decision to use Interfine 979 was supported by the projects architects as they required a finish with enhanced cosmetic properties. Together with the zinc primer and intermediate coating, the polysiloxane finish delivers • Parc y Scarlets Stadium, Wales, UK • Cape Town Stadium, South Africa • Nelson Mandela Bay Stadium, Port Elizabeth, South Africa • Soccer City, Johannesburg, South Africa international-pc.com 5 Mining and Mineral Processing Interplan® Takes the Pain Away Producing 700,000 ounces of gold per annum, Kalgoorlie Consolidated Gold Mine (KCGM), owned by Newmont Australia and Barrick Gold Corporation, is one of the largest gold producers in Australia. In gold mining, structural steel, concrete and processing equipment must be continually maintained due to the harsh corrosive environments they face. Using their Interplan® tool, International Protective Coatings worked closely with KCGM to devise a custom made maintenance plan to proactively manage corrosion. Shaun Traves, KCGM Maintenance Engineer, faces the daily challenge of ensuring the KCGM gold processing facility continues to run at optimal capacity. Maintenance is expensive, time consuming and in many key areas, such as process tanks and conveyor systems, maintenance due to corrosion will affect production levels. Despite this, maintenance is an essential procedure to ensure the health and safety of employees and the continual operation of a facility. In order to proactively manage corrosion related maintenance and optimise spend for KCGM, International Protective Coatings completed an Interplan® to evaluate the priority maintenance areas. The Interplan took the pain away from the time consuming process of devising a detailed coatings maintenance plan and this enabled KCGM to devise a five year maintenance plan to address the site's corrosion problems with minimal disruption to production (and hence profit). It also provided a living document that can be used to help justify the capital expenditure required to maintain a large gold processing site. modified epoxy, have been specified for dry and wet areas. These high performing products were required to protect the steel from a combination of acidic and hyper saline ground water. Tierney Coating Services were contracted by KCGM owners to apply the products due to their good reputation and experience with coatings from International Protective Coatings. Interzone 954 has excellent surface tolerance properties allowing applicators to apply the product in the challenging environment experienced on the KCGM site. As the maintenance project develops International Protective Coatings will continue to work with KCGM to periodically assess the site maintenance and offer solutions. A number of factors were behind International Protective Coatings being selected to help maintain the site including superior products and technical service, good working relationship with contractors, good representation in the local area and a long history of practical maintenance success. Interplan®, from International Protective Coatings, delivers: • Bespoke maintenance painting plans for effective corrosion protection • Optimised maintenance budgets to help reduce maintenance spend over an asset’s lifetime • Enhanced productivity Please contact International Protective Coatings to find out more about Interplan and how it can work for you. protectivecoatings@akzonobel.com Currently, KCGM is at stage one of the maintenance plan. Products from International Protective Coatings including Intercure® 200, rapid dry epoxy primer, and Interzone® 954, a high build 6 international-pc.com international-pc.com 7 SIAG AERISYN LLC International Protective Coatings have supplied Aerisyn with protective coatings since the company began trading in 2005 and have developed a close relationship with the staff and management at the facility. It was this relationship which lead SIAG Aerisyn LLC to approach International Protective Coatings at the end of 2009 to ask for some guidance in their painting schedules. New Interzinc® 22 Series Ready for overcoat in just 41/2 hours* The series consists of four zinc silicate products each with a different zinc dust level, giving you the flexibility to tailor specifications to a variety of standards and end use requirements. Best of all, each has the same overcoating performance characteristics, allowing enhanced productivity in your fabrication yard. • Interzinc 22 – 85% zinc dust content • Interzinc 2280 – 80% zinc dust content • Interzinc 2277 – 77% zinc dust content • Interzinc 2265 – 65% zinc dust content SIAG Aerisyn LLC, located in Chattanooga, Tennessee, are a leading manufacturer of tubular steel wind turbine towers, producing finished units for the booming North American wind market. They currently have a potential capacity of around 250 wind turbine towers per year and have worked with international turbine manufacturers such as Clipper, Gamesa and Mitsubishi. SIAG Aerisyn LLC wanted to know how they could improve the productivity of their paint shop, reduce their paint usage and streamline their coatings process, ahead of an expected increase in demand. With demand picking up and the future of the North American wind industry looking bright, SIAG Aerisyn LLC called upon the expertise of their local sales representative. Working with SIAG Aerisyn LLC International Protective Coatings conducted a full site audit in December 2009 covering all the aspects of their coatings process including: The shop audit was compiled into a complete report including photographs and comments. This was delivered to SIAG Aerisyn LLC as a formal presentation where the findings were presented and discussed, SIAG Aerisyn LLC were also given a bound hard copy of the audit and its findings for their future reference. Find out more by visiting www.international-pc.com/22series The service offered by International Protective Coatings in assisting SIAG Aerisyn LLC lead to the signing of an 18 month contract for paint supply using International Protective Coatings' industry leading Intergard® 3450 and Interthane® 990UHS coating systems. Consisting of a direct to metal epoxy primer intermediate, Intergard 3450 and a high solids polyurethane finish Interthane 990UHS, this system protects one in every three wind turbines manufactured in North America providing long term corrosion protection and aesthetic performance, with zero HAPs and low VOC. • Housekeeping • Equipment • Painting Practice • Documentation And finishing up with observations and potential improvement. * at 25°C (77°F), 55% relative humidity International Paint. Tested products, trusted solutions. 8 international-pc.com international-pc.com 9 SIAG AERISYN LLC International Protective Coatings have supplied Aerisyn with protective coatings since the company began trading in 2005 and have developed a close relationship with the staff and management at the facility. It was this relationship which lead SIAG Aerisyn LLC to approach International Protective Coatings at the end of 2009 to ask for some guidance in their painting schedules. New Interzinc® 22 Series Ready for overcoat in just 41/2 hours* The series consists of four zinc silicate products each with a different zinc dust level, giving you the flexibility to tailor specifications to a variety of standards and end use requirements. Best of all, each has the same overcoating performance characteristics, allowing enhanced productivity in your fabrication yard. • Interzinc 22 – 85% zinc dust content • Interzinc 2280 – 80% zinc dust content • Interzinc 2277 – 77% zinc dust content • Interzinc 2265 – 65% zinc dust content SIAG Aerisyn LLC, located in Chattanooga, Tennessee, are a leading manufacturer of tubular steel wind turbine towers, producing finished units for the booming North American wind market. They currently have a potential capacity of around 250 wind turbine towers per year and have worked with international turbine manufacturers such as Clipper, Gamesa and Mitsubishi. SIAG Aerisyn LLC wanted to know how they could improve the productivity of their paint shop, reduce their paint usage and streamline their coatings process, ahead of an expected increase in demand. With demand picking up and the future of the North American wind industry looking bright, SIAG Aerisyn LLC called upon the expertise of their local sales representative. Working with SIAG Aerisyn LLC International Protective Coatings conducted a full site audit in December 2009 covering all the aspects of their coatings process including: The shop audit was compiled into a complete report including photographs and comments. This was delivered to SIAG Aerisyn LLC as a formal presentation where the findings were presented and discussed, SIAG Aerisyn LLC were also given a bound hard copy of the audit and its findings for their future reference. Find out more by visiting www.international-pc.com/22series The service offered by International Protective Coatings in assisting SIAG Aerisyn LLC lead to the signing of an 18 month contract for paint supply using International Protective Coatings' industry leading Intergard® 3450 and Interthane® 990UHS coating systems. Consisting of a direct to metal epoxy primer intermediate, Intergard 3450 and a high solids polyurethane finish Interthane 990UHS, this system protects one in every three wind turbines manufactured in North America providing long term corrosion protection and aesthetic performance, with zero HAPs and low VOC. • Housekeeping • Equipment • Painting Practice • Documentation And finishing up with observations and potential improvement. * at 25°C (77°F), 55% relative humidity International Paint. Tested products, trusted solutions. 8 international-pc.com international-pc.com 9 Infosys Building Victoria Hospital Melbourne Airport Wuxi Airport Extension New York Times Tower Heathrow Airport Terminal 5 India Scotland Australia China USA UK Interchar 963 Interchar 1120 Interchar 963 Interchar 963 Interchar 212 Interchar 212 Victoria Hospital UK Protective coatings designed to prolong the life of steel by retarding the rate of heating are known as fire proofing or fire protection materials. The Interchar® brand from International Protective Coatings is an advanced material designed to offer a fire protection solution to the building industry. Recent global projects involving Interchar products: Wuxi Airport Extention China At temperatures above 400°C (752°F) steelwork loses its structural integrity and at 600°C (1112°F) the steel would have lost about 75 percent of its strength. Steel does not burn in a fire, but loss of integrity will lead to structural failure putting both lives and assets at risk. Track Record New York Times Tower New York Fire Protection A building should be designed and constructed so that in the event of a fire, its stability will be maintained for a reasonable period. Is your building protected against cellulosic fires? This one simple question will help in understanding the importance of, and the need for fire protection. The technology found in the Interchar material is designed to react to the heat generated during a fire and to intumesce, or ‘swell up’ providing an insulating layer (also known as char) over the steel to prevent it from heating too rapidly. Offering the highest standards against cellulosic fires (fires caused by the burning of materials such as paper and wood) to facilities such as office buildings, airports, stadia and hotels Interchar allows buildings to be fire protected without compromising aesthetic appeal. "Interchar® fire protection provides a complete solution for the building industry" The Interchar Product Range Interchar® 212 Interchar 212 is a 100 percent volume solids, epoxy based intumescent product. Offering effective fire protection for up to three hours Interchar 212 also has anticorrosive properties and an ability to be applied to four finish standards, making it an ideal choice where quality finish is important. Interchar® 404 This thin film, single pack intumescent coating will follow the contours of any steel building and the smooth film will give you a visual finish with competitive loadings. Interchar® 1120 As the latest edition to the Interchar range, Interchar 1120 is a thin film water borne coating designed to protect the interior of exposed steelwork. When combined with water based primers and topcoats Interchar 1120 can offer a truly sustainable coating package. Interchar® 963 Fast dry charactertics found in Interchar 963, a single pack intumescent material allows you to improve your productivity and is suitable for both onsite and offsite application. The Interchar range has been providing solutions to infrastructure projects across the globe such as New York Times Building, USA, Victoria Hospital, UK, Wuxi Airport Expansion, China and to help combat cellulosic fires International Protective Coatings is launching the established passive fire protection range in the Sri Lankan market. 10 international-pc.com To learn more about the fire protection range from International Protective Coatings, visit the product pages at www.international-pc.com international-pc.com 11 International Protective Coatings is supplying high performance coatings and passive fire protection to the turret and topside structures of the Skarv FPSO (floating, production, storage & offloading) as well as subsea production equipment. BP has announced that 80% of the Skarv oil and gas development project in the Norwegian Sea is now complete. The Skarv FPSO vessel should begin production from the well in August 2011. The owners of the Skarv field, BP, set aside $6.5 billion for development of the field, first discovered in 1998, and believed to hold 106 million barrels of oil and 35 billion standard cubic metres of natural gas. The Skarv FPSO will be the largest to be deployed in the area. Protected by high performance coatings with a 25 year service life. The field, located just 30 miles south of the Arctic Circle is in one of the harshest offshore environments in the world and has water depths of 400 metres (1,310 feet). BP decided that an FPSO was the most economical and safest type of floating production unit to be used on the field. Not only can FPSOs store the crude oil in the hull before offloading to shuttle tankers, but they are also able to process gas from the well on their topsides. This gas can then be transported via subsea pipelines to land. A design feature of an FPSO is their ability to maintain stability in stormy conditions and strong currents by weather-vaning around a central turret. The turret can be internal or external to the hull. Flow lines and risers carry oil and gas through the middle of the turret to the topsides for processing and storage. In the case of the Skarv FPSO, an internal turret was chosen, designed and fabricated by SBM Offshore at a cost of $250 million. The design and fabricated was based on their “bogie-wheel” concept, already used on FPSOs in the North Sea and Brazil and is the world largest turret as far as mooring loads are concerned. © BP. Plc Construction of the turret was carried out in the Keppel shipyard in Singapore where it was recently transported for integration into the hull at Samsung Heavy Industries on Geoje Island, South Korea. 12 international-pc.com A high performance coatings system was needed to provide the turret and FPSO with a 25 year service life. The coating systems used were certified to the NORSOK standard M-501 which was developed by the Norwegian petroleum industry. Two coats of Interzone® 1000 were applied below the splash zone of the turret, with upper sections using a three coat scheme of Interzinc® 52, Intergard® 475HS and Interfine® 691, as a non-isocyanate finish. The same three coat scheme was applied to 16,000 tonnes of piping and un-insulated carbon steel operating at temperatures below 120°C (248°F) on the topside. This offered the fabricator reduced coatings complexity whilst meeting the needs of the customer. In addition, over 230 tonnes of Chartek® 7, a passive fire protection coating, were applied to offer excellent steel protection and help maintain steel integrity during a fire. In total 16 wells will be used to develop the oil and gas field. Vetco Gray was given the Engineering, Procurement & Construction (EPC) contract for the subsea production units by BP worth over $260 million. International Protective Coatings were chosen to protect over 60,000 m2 of subsea equipment much of this was fabricated at Burntisland, Scotland. A coating specification of two coats of Interzone® 954 was favoured, which provides excellent barrier protection for immersed offshore environments. In addition, being high build properties makes it favoured by applicators. International Protective Coatings protects over 50% of the current FPSO fleet deployed around the world. High performance coatings such as Intershield 300, for water ballast tanks, Chartek 7, for passive fire protection, and Intersleek® 900, as an easy clean hull coating, are key products which can be used on FPSOs. As offshore shallow water oil reserves diminish, production from deepwater fields using FPSOs holds the key to sustaining the world’s oil and gas needs. international-pc.com 13 challenges in th t e C world r Volatile Organic Compound (VOC) regulations drive the research and development efforts of high performance coating manufacturers. Various responses towards VOC stringency have been introduced; solvent-free coatings, innovative high solids coatings and new generation water borne high performance coatings. This article investigates why these are important developments for the coatings industry and its customers, and the challenges we face. 14 international-pc.com High performance coatings facilitate molecular lubricity, molecular mobility, dissolve high molecular weight resins, lower surface tension and are far removed from what some might interpret as “the stuff that makes paint dry". The Technologies The coatings technical community has made great technological strides to reduce the VOC in coatings by using: Water Borne Coatings Water borne, high performance acrylics have been formulated to provide enhanced barrier performance and corrosion resistance. High Solid Coatings A variety of proprietary low VOC, low viscosity and high solids coatings with far superior wetting properties have been developed for harsh industrial and marine environments. Unique mono and di-functional reactive resins, together with curing agents which have excellent molecular mobility have been identified for complete corrosion protection. Solvent-Free Two-Component Coatings Applied at high dry film thicknesses, new generation low or zero VOC, one coat lining products cure in a few hours. With outstanding chemical resistance and no risk of solvent entrapment they save time and labour as well as satisfy VOC regulations. Challenges to Consider Surface Preparation Correct surface preparation for applying solventfree, or high solids lining systems, is imperative for long term coating success. This is even more true for coatings designed for immersion service. One of the keys to success, therefore, is to obtain a deeper profile of 75-100 microns (3 to 4 mils) in the abrasive blasted steel. In addition, it is even more important that the profile be jagged as opposed to having a peen pattern. Published studies of accelerated tests by International Protective Coatings have demonstrated that the level of corrosion resistance for immersion grade linings is indeed a function of profile angularity and profile amplitude in abrasive blasted steel. High Viscosity With respect to solvent free coatings, there are other concerns besides surface profile characteristics to deal with. Achieving low VOC coatings by a solvent free route often results in coatings that possess high viscosity, shorter pot lives and limited recoat windows. Care must be taken to select the proper application equipment. Any addition of exempt or non-exempt solvent to increase the working time of the coating will drastically affect the coating performance. All these issues highlight the need to properly follow the coating manufacturer’s instructions. Application Methods Coatings that address VOC issues can have specific application requirements. The range of possible application methods has widened in order to provide the optimum delivery method for each type of coating. Air assisted and spray equipment considerably improve the application of high solids coatings containing exempt solvent and new generation heated plural-component equipment is ideal for one coat, thick film and short pot life solvent-free coatings. Customer Benefits Modern solvent-free coatings are gaining popularity with customers because, in general, one coat systems save time and money and can be placed in service within hours of application. They have minimal occupational health and safety hazards associated with them and risk of solvent entrapment is removed. International Protective Coatings are forging ahead with better understanding of what is required for success with low or zero VOC high performance coatings. VOC regulations have elicited an industry-leading response from coating formulators to provide owners with life cycle extension benefits, applicators with lower numbers of applied coats, and all parties a quicker return to service. international-pc.com 15 www.surfaces-international.com Siag Aerisyn LLC > Fire Protection > Skarv FPSO > Challenges in the VOC world INSIDE > Growth in Offshore Wind Power > Lansdowne Road Stadium > Mining and Mineral Processing INTERNATIONAL-PC.COM ISSUESIXTEEN2010