DEVELOPMENTS IN SPRAY APPLIED COATINGS FOR THE PROTECTION .
DEVELOPMENTS IN SPRAY APPLIEDCOATINGS FOR THE PROTECTIONOF PROCESS VESSELSPresented By :Mr. Ron CampbellSenior Vice PresidentBelzona Asia PacificNACE Jubail MeetingOctober 2009
Protective Coatings Performance of Hand AppliedProtective Coatings iswell documented Used for the internal lining of process vesselsSubject to erosion and corrosion from aggressivefluids.HOWEVER Internal linings are limited by their immersiontemperature resistance
Alternative to Protective CoatingsMaterials of Construction Stainless Steel Exotic Alloys Overlaid Carbon Steel Fusion Bonded alloysLimitations Must be applied at Construction phase Can be expensive for marginal projects Difficult to maintain / repair on-site Can suffer galvanic effects
Protective Coating Selection ConsiderationsEquipment Operating Conditions Operating and design temperatures Operating and design pressures Process Fluids Solids entrainmentShutdown / Maintenance Conditions Steam out conditions Chemical Cleaning Mechanical cleaning Hot work restrictions Turn-around times
Protective Coating Selection ConsiderationsEnsure Coating is Suitable forOperating Conditions Analyze equipment operating modes Select coating based on most aggressiveoperating condition :- Dry Heat ( Gas Phase )- Wet Heat ( Vapor Phase ) - Immersion ( Immersion Phase )GasPhaseVaporPhase Check Coating Manufacturers Data to ensurecorrect coating selectionImmersionPhase
Protective Coating Selection ConsiderationsConsider Other operating Factors Operating and Design Pressure- Pressure vessels can be subject tosudden depressurization resultingin coating failure. Decontamination procedures- Steam out at elevated temperature- Chemical cleaning
Protective Coating Selection ConsiderationsConsider Other operating Factors Erosion from Entrained Solids- Process vessels can haveentrained solids presenteither by design orchanges to original operatingparameters. Attack from Chemicals- Process vessels may in may situationsrequire or produce chemical reactions that cancause deterioration in protective coatings e.g. :- Corrosion Inhibitors- Amine Solutions ( MEA / MDEA )- High levels of CO2 / H2S
Protective Coating Selection ConsiderationsConsider all factors before making yourcoating selection OR discounting the useof a Coating Solution Operating and Design Temperatures Operating and Design Pressures Vessel Operating Phases Shutdown conditions Erosion from entrained solids Chemical attack Application characteristics “ Repairability “ Cost effectiveness
Hand Applied Protective CoatingsPhase 1 - Completed in 1994 utilizing modifiedPhenol Epoxy Novolac technology todesign a product to withstand immersiontemperatures in aqueous / hydrocarbonfluids up to 120 C.Coating Properties :Type: Two Component binary reacting Modified Epoxy NovalacSystem containing abrasive fillers to enhance abrasionand erosion resistance.Immersion TemperatureResistance: 120 CSteam-Out TemperatureResistance: 210CExplosive DecompressionResistance: 100 bar ( limit of testing to date )
Hand Applied Protective CoatingsPhase 2 - Further developments using enhancedresins and chemically bonded fillers toincrease immersion temperatureresistance up to 180 C.In-house and Independent testing wascompleted to confirm performanceCoating Properties :Type ( 1591 ): Two Component binary reacting silicone Modified EpoxyNovalac System containing abrasive fillers to enhanceabrasion and erosion resistance.Immersion TemperatureResistance: 180 CSteam-Out TemperatureResistance: 210C Explosive DecompressionResistance: 80 bar ( limit of testing to date )
Hand Applied Coatings – Application HistoriesEquipment- Existing Oil and Gas TestSeparatorsMaterial ofConstruction- Carbon SteelLocation- Global LocationsService Conditions - Variable depending on wellconditions between 80 and155 C and pressures up to100 bar.Coating System- 1591Application Date- 1997 to dateSpecification- Grit blasting to SA 2.5 with a75 micron profile after whichcoating was applied at athickness of 800microns
Hand Applied Coatings – Application HistoriesEquipment- Process vessels for newMajor Offshore PlatformLocation- SingaporeMaterial ofConstruction- Carbon SteelService Conditions - Variable depending on wellconditions between 60 and110 C and pressures up to 75 bar.Coating System- 1391Application Date- 2004Specification- Grit blasting to SA 2.5 with a75 micron profile after whichcoating was applied at a thicknessof 1000microns
Hand Applied Coatings – Application HistoriesEquipment- Mercury Extraction vessels forNew Major Offshore installationLocation- MalaysiaMaterial ofConstruction- Carbon SteelService Conditions - Variable depending on wellconditions between 60 and105 C and pressures up to 40 bar.Coating System- 1391Application Date- 2006Specification- Grit blasting to SA 2.5 with a75 micron profile after which coatingwas applied at a thickness of 1000microns
Hand Applied Coatings – Application HistoriesEquipment- Distilled water production unit inRefineryLocation- ThailandMaterial ofConstruction- Stainless SteelService Conditions - Operating condition of 97CCoating System- 1391Application Date- 1999Specification- Grit blasting to SA 2.5 with a75 micron profile afterwhich coating was applied at athickness of 1000microns
Hand Applied Coatings – Application HistoriesEquipment- Sour Water Stripper inRefineryLocation- AustraliaMaterial ofConstruction- Carbon steelService Conditions - Operating condition of70 – 105CCoating System- 1391Application Date- 2004Specification- Grit blasting to SA 2.5 with a75 micron profile afterwhich coating was appliedat a thickness of 1000microns
Hand Applied Coatings – Summary Temperature range up to 180C immersionresistance Pressure let-down resistance up to 100Bar Excellent erosion resistance Good application characteristics Solvent free Excellent resistance to hydrocarbons ,amines and aqueous solutions Short cure times / fast return to service Repairable on-site Proven track record Available globally
Spray Applied Coatings DevelopmentSprayable Coating Design Considerations To be based on proven hand applied coatingresin and filler technology Use minimum level of resin modifier toachieve spray viscosity Optimize the filler blend and filler level tominimize effect on viscosity Remove coarse silicon carbide filler which wouldcause severe wear on the spray equipment Target immersion temperature resistance atminimum 120 C (248 F)
Spray Applied Coatings DevelopmentFunctionality and Cross Linked DensityCross link density is the number of reactivechemical sites within a givenvolume of Polymer material and the higherthe cross linked density , the higher the polymerbecomes to permeation.ConventionalHigher Cross linked density results in :- Increased glass transition/heat distortiontemperature- Higher resistance to water & gaspermeation- Higher resistance to explosivedecompressionModified
Spray Applied Coatings DevelopmentThe development therefore of the sprayable hightemperature resistant coating systems hasrevolved around increasing the number ofreactive sites within the matrix using knownpolymer technology based on the hand appliedsystems BUT reducing the viscosity of theresins systems to enable them to be sprayed.
Spray Applied Coatings DevelopmentSprayable Coating Testing ProgramSprayability :The products were designed to be appliedusing either SINGLE component heatedairless spray OR DUAL componentheated airless sprayImmersion Temperature Resistance :The products were designed to performin immersion temperatures up to 150Cin pressurized service – Hydrocarbonand Water mixtures
Spray Applied Coatings DevelopmentSprayable Coating Testing ProgramAdhesion :High levels of adhesion are required to resistthe effects of osmosis a well as the forcesexerted on the coating during decompressioncycling.Chemical Resistance at Elevated Temperatures :The ability of the coatings to resist attack fromthe service liquids is important to ensure longterm performance
Spray Applied Coatings DevelopmentSummary Range of Coating systems available Sprayable using single or dual componentheated airless spray Solvent free systems Immersion temperature resistance upto 150C and down to - 40C Resistant to explosive decompression Resistant to process fluids and well chemicals Suitable for sour gas service ( H2S / CO2 )
Independent Testing to Support Coating PerformanceSolvent-free Ceramic filled Epoxy Phenol NovolacStatoil1 month85 C1160psi( Stabilised crude/produced water/methane/1% carbon dioxide )ELF1200 hours80 C435psi1 month98 C1305psi( Water and Gas Mixture )Charter Coatings(Gas condensate/methane/4% carbon dioxide/3% hydrogen sulphide )Advantica300 hours(Stabilised crude/water/carbon dioxide )85 C435psi
Independent Testing to Support Coating PerformanceIntermolecularly bonded Epoxy Phenol Novolac Composite CoatingsNNC6 months130 C435psi( Stabilised crude/produced water /methane / 2% carbon dioxide 50ppm HydrogenSulphide )SACMET600 hours160 C145psi300 hours85 C435psi( Water/steam cycling )Advantica( Stabilised crude/water/carbon dioxide )
Spraying Capabilities and SpecificationTypical Spray Set - Up- Minimum 56:1 ratio pump- Heated circulating water forspray lines at 60 - 70C- Spray tip size 423-527- Tip pressure 4300 psi- Tip temperature approx 50CSingle Component HeatedAirless SprayDual Component HeatedAirless Spray
Spray Applied Coatings – Application HistoriesEquipment- New Construction OffshoreProcess VesselsLocation- Middle EastMaterial ofConstruction- Carbon SteelService Conditions - 80 to 110 C and pressures upto 60 bar.Coating System- 1521Application Date- 2007Specification- Grit blasting to SA 2.5 with a75 micron profile after whichcoating was applied at athickness of 850 microns.
Spray Applied Coatings – Application HistoriesEquipment- New Construction OffshoreProcess VesselsLocation- Middle EastMaterial ofConstruction- Carbon SteelService Conditions - 95 to 115 C and pressuresup to 55 bar.Coating System- 5891/1391SApplication Date- 2008Specification- Grit blasting to SA 2.5 with a75 micron profile after whichcoating was applied at athickness of 850 micronsin 2 coats
Spray Applied Coatings – Application HistoriesEquipment- New Construction OffshoreProcess VesselsLocation- IndonesiaMaterial ofConstruction- Carbon SteelService Conditions - 60 to 95 C and pressuresup to 25 bar.Coating System- 1521Application Date- 2008Specification- Grit blasting to SA 2.5 witha surface profile of 75microns followed by theapplication of the coating at athickness of 750 microns.
Spray Applied Coatings – Application HistoriesEquipment- Portable Methanol Storage TanksLocation- AustraliaMaterial ofConstruction- Carbon SteelService Conditions - Ambient Temperature ( 50C )Coating System- 5891Application Date- 2004Specification- Grit blasting to SA 2.5 with a75 micron profile afterwhich coating was applied at athickness of 600 microns
Spray Applied Coatings – Application HistoriesEquipment- Effluent Treatment Tank / DearatorLocation- ChinaMaterial ofConstruction- Carbon Steel / ConcreteService Conditions - Ambient Temperature 15 – 50CCoating System- 5811Application Date- 2005Specification- Grit blasting afterwhich coating was applied at athickness of 600 microns
Spray Applied Coatings – Application HistoriesEquipment- Chemical Treatment TankLocation- ThailandMaterial ofConstruction- Carbon SteelService Conditions - Ambient Temperature 55 – 80CCoating System- 5891Application Date- 2006Specification- Grit blasting afterwhich coating was applied at athickness of 600 microns
Developments in Spray Applied CoatingsSummaryDevelopment of these high temperaturespray applied coating systems suitablefor immersed service conditions atelevated temperatures has now beencompleted although there are stillfuture opportunities to improve applicationcharacteristics as well as performance.The range of products currently available is summarized as follows :-Coating for immersion service conditions up to 50C ( 5811 )Coating for immersion service conditions up to 95C ( 5891 )Coating for immersion service conditions up to 120C ( 1391S )Coating for immersion service conditions up to 150C ( 1521 )
Developments in Spray Applied CoatingsCoating CharacteristicsSprayabilitySuitable for application using single componentof dual component heated airless spray systems.Temperature ResistanceImmersion temperature resistance up to 150C in aqueous aand hydrocarbon service and resistant to steam out conditionsat temperatures up to 210CChemical ResistanceGood resistance to hydrocarbons / aqueous solutions as well asamines ( MEA / MDEA etc ) used for the removal of acidic gases at elevated temperatures.
Developments in Spray Applied CoatingsLimitations Not suitable for dry heat conditions where nomoisture is present in the process Application thickness needs to be strictlycontrolled to avoid over-stressing the coating.NOTE :ANY COATING IS ONLY AS GOODAS THE APPLICATORS APPLYING THEPRODUCTS AND THE INSPECTOR / SUPERVISORCONTROLLING THE JOB
Developments in Spray Applied CoatingsApplication Controls and Training Fully documented procedures available
Developments in Spray Applied CoatingsApplication Controls and Training Factory Training available for Coating Supervisors
Developments in Spray Applied CoatingsApplication Controls and Training On-Site Project Supervision and Inspection Services availablefrom NACE level 1 to NACE Level 3 manufacturers personnel On-Site training available
DEVELOPMENTS IN SPRAY APPLIEDCOATINGS FOR THE PROTECTIONOF PROCESS VESSELSPresented By :Mr. Ron CampbellSenior Vice PresidentBelzona Asia PacificNACE Jubail MeetingOctober 2009THANK YOU FOR YOUR ATTENTION
Equipment - Process vessels for new Major Offshore Platform Location - Singapore Material of - Carbon Steel Construction Service Conditions - Variable depending on well conditions between 60 and 110 C and pressures up to 75 bar. Coating System - 1391 Application Date - 2004 Specification - Grit blasting to SA 2.5 with a 75 micron profile after .
Spray finishing can be conducted in a spray booth, spray room, or spray area. Tuesday, February 14, 2017 Definitions Tuesday, February 14, 2017 Spray room: A spray room is a room in which spray-finishing operations not conducted in a spray booth are performed separately from other areas. 1910.94(c)(1)(iii)
Introduction to Thermal Spray Processing / 5 Thermal Spray Processes and Techniques Members of the thermal spray family of processes are typically grouped into three major categories: flame spray, electric arc spray, and plasma arc spray, with a number of subsets falling under each category. (Cold spray is a recent addition to the familyFile Size: 793KB
intumescent coatings and spray-applied fire resistive materials. The most common form of insulation for a structural steel assembly is a spray-applied fire resistive material. Spray-applied fire resistive materials use a binder, generally gypsum or Portland cement, that is mixed with insulating materials to form a slurry or mixed at a
a properly selected spray angle, will tend to make more effective use of the spray as well as help minimize the dis-turbance effects of wind/draft condi-tions on the water spray patterns. Spray Patterns. The Design Spray Profiles for the nozzle spray angles of 65 to 180 degrees
coverage of spray patterns as calculated from the included spray angle of the spray and the distance from the nozzle orifice. Values are based on the assumption that the spray angle remains the same throughout the entire spray distance. In actual practice, the tabulated spray angle
VANSIL W is an excellent extender pigment for powder coatings as well as solvent-thinned and latex paints. VANSIL W-50 disperses to a to egman fineness at three pounds per gallon. This grade is suitable for liquid industrial and corrosion resistant coatings, powder coatings, and semi-gloss architectural coatings. n powder coatings, this grade
The Toro Company Residential & Commercial Whole Goods Irrigation Products 2019 Suggested List Prices – U.S. & Canada Effective October 15, 2018 Table of Contents SPRAY HEADS 1 LPS Series Low-Profile Spray Heads 1 570Z Series Low Pressure Spray Heads 1 570Z Series Spray Heads 1 570Z-XF Series Spray Heads 1 570Z-PR Series Spray Heads 2
applications for thermal spray coating [13-16]. Thermal spray processes are grouped into three major categories: flame spray, electrical arc spray, and plasma arc spray. These energies sources are used to heat the coating material (in powder,
