Selecting and Sourcing Coatings for Offshore Structures · The Use of Coatings for Corrosion...

23
Selecting and Sourcing Coatings for Offshore Structures A JPCL eBook

Transcript of Selecting and Sourcing Coatings for Offshore Structures · The Use of Coatings for Corrosion...

Page 1: Selecting and Sourcing Coatings for Offshore Structures · The Use of Coatings for Corrosion Control 1 ... of steel and attached to the seabed with piles ... of corrosion control

Selecting and SourcingCoatings for Offshore Structures

A JPCL eBook

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i

Selecting and Sourcing Coatings for Offshore Structures

A JPCL eBook

Copyright 2011 byTechnology Publishing Company2100 Wharton Street, Suite 310

Pittsburgh, PA 15203

All Rights Reserved

This eBook may not be copied or redistributed without the written permission of the publisher.

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Contents

iiContents

Introduction iii

The Use of Coatings for Corrosion Control 1

on Offshore Oil Structuresby Peter Ault

Coating Systems Guide for Offshore Platforms 5

Coatings Company Profiles 12

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iii

Introduction

Introduction

This eBook consists of a recent JPCL article on selecting and using

coatings for protecting offshore oil structures, followed by JPCL Buying

Guide material on coating systems for offshore platforms.

The Buying Guide is organized, first, by coating systems for

particular exposure types, such as for “Jacket Immersed Area” and

“Splash Zone.” Then, coating manufacturers are listed in alphabetical

order and their preferred system is named in both proprietary and

generic terms. Finally, contact details are given for all the companies.

This collection is designed to provide general guidance on selecting

and specifying coatings for offshore structures, and then to give

sources for acquiring the appropriate systems.

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oatings are critical to protecting offshore oil structures from corrosion. Factorsunique to the oil industry drive the use of coatings on offshore structures. This arti-cle will provide an overview of the offshore oil and gas industry, the types of struc-tures coated, the coatings used in different zones of the structures, and the pragmaticand, in the U.S., the regulatory criteria that influence the coating process.

The Offshore Oil and Gas Industry

According to the Mineral Management Service (MMS), approximately 30% of the U.S. domestic oilproduction and 20% of the domestic gas production is generated from the outer continental shelf(OCS). The majority of that production is in the Gulf of Mexico. The remainder of U.S. domesticproduction is in the Pacific and Alaska regions (which have similar produc-tion levels) and the Atlantic region (which is a distant fourth in termsof production). Beyond the current production, OCS resourcesare projected to contain the majority of undiscovered gas andoil in the U.S. The OCS Lands Act (Title 43, Chapter 29 ofthe US Administrative Code) required the Departmentof the Interior to manage federal offshore lands usedfor oil and gas production. The DOI determines thesize, timing, and location of areas to be used andensures that the U.S. government is fairly com-pensated for acreage made available throughleases. Importantly, the DOI is also chargedwith responsibility to protect the environmentand ensure that the offshore activities operatesafely. The DOI carries out these operationsthrough the MMS. The MMS Offshore programcoordinates the extensive offshore productionactivities. Requirements are communicatedthrough Notices to Lessees and Operators (NTL)as well as the Federal Administrative Record(FAR). These documents are publicly available.To put the U.S. offshore industry in perspective,

consider this. There are more than 6,500 offshore oiland gas installations in some 53 countries around theworld. More than 50% of these installations are in the U.S.Gulf of Mexico. After the U.S., the next five regions with themost offshore installations, in descending order, are Asia, the MiddleEast, the North Sea, the West African coast, and South America. These sixregions account for the majority of the existing offshore oil and gas installations.

The Use of Coatings for Corrosion Control on Offshore Oil Structures

CoatingOffshore

Structures

C

1

By Peter Ault,

Elzly Technology

Corporation

Editor’s note: This article appearedin JPCL in April 2006.

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The Structures To Be Protected

Extensive infrastructure is required to support the offshore production industry. The offshore in-stallations are built for exploration (drilling) and production (including preparing water or gas forinjection, processing oil or gas, cleaning produced water for disposal, and various accommoda-tions). There are several types of drilling rigs, including the following.• Jackups—usually towed to a location where the legs are lowered to the seabed and the hull isjacked above the sea surface• Drill Ships—look like ordinary ships with a derrick on top that drills through a hole in the hull.They can be anchored or positioned with computer-controlled propulsion systems.• Submersibles—can be floated to shallow water locations and ballasted to sit on the seabed.• Semi-submersibles—have the superstructure supported on a hull or pontoons that are ballastedbelow the water surfaceOnce the drilling rigs have completed their work, they are generally replaced by production

platforms. Production platforms vary in size and shape, but generally contain accommodations forlarger crews and the various production processes required to extract oil or gas and render it suit-able for transport. Sometimes satellite platforms will be situated around a larger production plat-form. Production platform types include the following.• Fixed production platforms—typically constructed of steel and attached to the seabed with piles• Floating Production Storage Offloading (FPSO) and Floating Storage and Offloading (FSO) ves-sel—either anchored or tethered• Tension Leg Platform (TLP)—typically used in deepwater applications, these platforms are builtfrom steel or concrete and anchored to the sea floor with vertical “tendons”Other supporting infrastructure for the offshore oil and gas industry includes the ships and aircraft

that transport people and supplies to the platforms and pipelines which, in turn, transfer the productback to refineries and other users on shore. The remainder of this article will focus on coatings usedfor the offshore structures themselves.

Considerations for Corrosion Control

Perhaps the most obvious consideration for corrosion control of offshore structures is the marineenvironment in which they operate. An offshore platform has significant exposure in seawater im-mersion, splash zone, and salt air. Corrosion of steel in these environments can be greater than100 mils per year. Corrosion rates are highest in the splash zone, as illustrated in Fig. 1. In additionto the marine environment, offshore platforms have areas subjected to severe abrasion and highlycorrosive water chemistries. For floating structures, ballast tank interiors comprise a significantportion of the coated surface.Because offshore platforms appear similar in many respects to ships, it might be anticipated that

much of the corrosion control design would be similar. Indeed, most offshore platform coating sys-tems are heavy-duty epoxies, which are also common on ships. Inorganic zinc pre-constructionprimers are used in new construction, and may be repaired and kept, depending on the design phi-losophy of the owner. Cathodic protection is typically used below the waterline. However, there are substantial differences between the operating environments for ships and

offshore platforms. For example, once located at sea, offshore platforms rarely come back to portfor maintenance, whereas a ship is frequently drydocked. Offshore platforms do not usually havethe same weight consideration as ships, allowing the use of sacrificial cathodic protection as thesole method of corrosion control for the underwater portions in some instances. Even among off-shore platforms, different design considerations exist. Weight reduction is a more important issuefor FPSOs than for fixed structures.Although this article focuses on the use of coatings, corrosion control on offshore structures

commonly includes the following five approaches. • No Protection (wastage allowance)• Protective Coatings• Cathodic Protection of Bare Steel• Cathodic Protection of Coated Steel• Corrosion Resistant Metal or Plastic

2

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Corrosion Control Coatings

In the early days of offshore oil and gas production (1940s–1950s) protective coating systemstypically consisted of vinyl or chlorinated rubber coatings. The typical system for the atmosphericexposed areas was multiple coats with a total build of 250–300 microns (10–12 mils). With time,inorganic zinc silicate primers were incorporated into the systems, as well as epoxy intermediatecoats. These systems were used for several decades with good results—indeed, inorganiczinc/epoxy/urethane systems are still used today. Underwater and splash zones typically wereprotected with a thicker system, such as 12–20 mils of coal tar epoxy.Current technologies include the use of organic zinc-rich primers, higher build epoxies, and poly-

siloxane coatings. The transition to organic zinc-rich primers (predominantly epoxies but alsomoisture-cured urethanes) has been driven by cost and schedule considerations. Organic zincprimers are less expensive than zinc silicates and can be applied under a broader range of environ-

mental conditions. Higher build epoxy interme-diate coats have a number of environmental,production, and performance benefits. Thehigher build formulation typically had lowerVOC and HAPS than more solvent-laden coun-terparts. The high build requires fewer coats toachieve the required thickness and retains filmbuild around sharp edges. Polysiloxane coatingsare formulated to provide a durable surface thatis resistant to abrasion, wear, and weathering.

Recently, there has been some use of ther-mal spray aluminum (TSA) coatings on offshorestructures. TSA can be a high-performance coat-ing system, but does not appear suitable for allareas of the structure. Specifically, in immersionareas, the TSA will act as an anode and sacrificeitself to protect exposed steel. Even at thickbuilds of 10–15 mils, the sacrificial action willquickly consume the TSA coatings, leaving baresteel. The bare steel left behind increases thegalvanic reaction on the remaining TSA.

Coating Evaluation and Maintenance

Corrosion of offshore structures results in a significant operational cost to the operators and own-ers of the structures, especially as the structures age. An assessment of the relative effectivenessas well as costs is central to investment decisions concerning life extension and integrity manage-ment for older structures. MMS recognizes the importance of corrosion and corrosion control aspart of the overall maintenance effort. While MMS does not evaluate structures to the level of de-tail required for effective maintenance management, they regulate inspection through the require-ments outlined in API RP-2A, Recommended Practice for Planning, Design, and Constructing FixedOffshore Platforms. API RP 2A requires annual inspection of protective coatings, cathodic protec-tion, and other corrosion control systems. There are various programs to meet the requirements,but they typically contain the following characteristics.• Multiple levels of inspection, including basic visual inspections with more sophisticated testing(ultrasonic, radiographic) as required• An inspection effort sufficient to identify imminent safety hazards and critical areas of concern,and to prioritize maintenance needs on the remainder of the structure• Use of a relatively simple grading system with extensive visual and written documentation tosupport and archive the findings

3

Fig. 1: Steel Corrosion Rate Relative to Sea Level

Typical Steel Corrosion Rate (mils per year)

Elev

atio

n

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Maintenance of offshore structures includes a number of challenges unique to the physical envi-ronment in which the work takes place. Perhaps most significantly, the logistical requirements ofworking in confined quarters at a remote location place great pressure on highly visible operationssuch as coatings maintenance. If challenges arise on the job, the stresses placed on the relationshipamong the paint crew, inspector, and facility manager (owner) can be magnified by the fact that theymust live and work together for 24 hours a day for several weeks. The remoteness of the work loca-tion makes it extremely difficult to change out personnel, get additional supplies and equipment, ordefer decisions up the chain of command.Of course, platform operations and other maintenance activities are being conducted concurrently

with coatings work. This limits the accessibility,requires efficient sharing of resources, and mayrequire the work area to be isolated from otheractivities. As a result, planning and coordinationare critical to minimize wasted resources. Once awork crew and equipment are mobilized to theplatform, the owner will pay for those assetsuntil they return to shore. If the work cannot beexecuted as planned due to weather or othercomplications, contingency plans involving alter-nate work options should be executed. Note thatthese plans cannot be made on an ad hoc basis.Substantial planning is required to ensure thatthe proper tools and materials are available forthe contingency work.

Planning an offshore project begins during“load-out,” long before the crew arrives at thesite. It is tremendously helpful if the inspector,paint crew, and owner discuss issues early in the

mobilization process. If possible, they should agree that the equipment being taken to the platform issufficient and in working order before it leaves shore. Coating materials and other supplies sufficientfor the planned work and any contingency work should be inventoried during mobilization to mini-mize the downtime once work begins.

Conclusion

Offshore structures are unique environments in which to perform coating work. The critical natureof corrosion control requires that protective coatings be properly monitored and maintained. Be-cause much of the work is performed remotely, the cost of downtime and rework is considerablymore than might be found on other coatings projects. As a result, planning and coordination becomeeven more critical to successful, cost-effective projects.

4

J.Peter Ault, P.E., is a cofounder of Elzly Technology Corporation, a consulting firm thatworks with technologies related to material selection for corrosion control, including environmentally acceptable products and practices. He has wide experience in corrosionprotection, including laboratory testing, field inspection, and failure analysis.

JPCL

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Page 14: Selecting and Sourcing Coatings for Offshore Structures · The Use of Coatings for Corrosion Control 1 ... of steel and attached to the seabed with piles ... of corrosion control

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Page 15: Selecting and Sourcing Coatings for Offshore Structures · The Use of Coatings for Corrosion Control 1 ... of steel and attached to the seabed with piles ... of corrosion control

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