1 naval sea systems command performance update - high solids tank coatings mega rust – 2015...
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NAVAL SEA SYSTEMS COMMAND NAVAL SEA SYSTEMS COMMAND Performance Update - High Solids Tank Coatings Performance Update - High Solids Tank Coatings
Mega Rust – 2015Norfolk, VA
June 2015
Mr. Mark Ingle, P.E.
SEA 05P2
(202) 781-3665
Distribution A – Approved for Public Release
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Objectives
• Summarize evolving Naval Sea Systems Command (NAVSEA) organization and coating requirements:
•• Headquarters NAVSEA Organization & Objectives.
• Summarize history and background for extending tank coating service life through the use of high-solids, and rapid-cure, single-coat, tank coatings:
•• Business case or motivation for effort.•• SEA 05 policy & requirements.
• Discuss results to date on high-solids tank coatings.•• Ballast tanks.•• Other tanks.
Naval Systems Engineering Directorate (SEA 05)
Technical Domain Manager (TDM)Chief Systems Engineer (CSE)
Office of the CHENG
SEA 05B Deputy / COS(SEA 05B1)
Aircraft Carrier Design & Systems Engineering (SEA 05V)
Chief Finance Office(SEA 05B3)
Surface Ship Design & Systems Engineering (SEA 05D)
Integrated Warfare Systems Engineering (SEA 05H)
Cost Engineering & Industrial Analysis (SEA 05C)
Ship Integrity & Performance Engineering (SEA 05P)
Chief Workforce Office(SEA 05B2)
Special Projects(SEA 00U/05X)
Executive Director / CHENG Deputy / Chief Technology Officer (SEA 05B)
Littoral and Mine Warfare Design & Systems Engineering
(SEA 05L)
Submarine/Submersible Design & Systems Engineering
(SEA 05U)
Undersea Warfare Systems Engineering (SEA 05N)
(NUWCNPT TD)
Surface Warfare Systems Engineering (SEA 05W)
(NSWCDD TD)
Marine Engineering (SEA 05Z)
L&MW Warfare Systems Engineering (SEA 05M)
(NSWCPC TD)
Explosive Ordnance Engineering(SEA 05E) (NSWC IH TD)
Deputy Commander/CHENG (SEA 05)
Chief HR & Admin Office(SEA 05B6)
Draft: June 2015
SEA 05P2
Code Product Related SpecsAll All Technical Products, Managerial AllAF Antifouling Coating Systems MIL-PRF-24647TNK Tank Coatings, Epoxy Primers MIL-PRF-23236
MIL-DTL-24441PRM Primers, Single Component TT-P-645TOP Topside, Alkyds & Polysiloxanes MIL-PRF-24635INT Interior Coatings (SEA 08) MIL-DTL-24607
MIL-PRF-24596MIL-DTL-15090MIL-DTL-1115
HT High Temp Coatings, Metallic TT-P-28PWD Powder, Interior, Cosmetic MIL-PRF-24712NSK Nonskid MIL-PRF-24667DCK Deck Coverings MIL-D-3134
MIL-PRF-3135MIL-PRF-24613MIL-PRF-32171
SUR Abrasive blasting, surface prep MIL-A-22262SEL Sealants & Preservatives MIL-PRF-16173
NAVSEAINST 9360.1DOC Policy Documents NSTM 631, NSTM 634
Standard Item 009-32Standard Item 009-26
COR Corrosion/PCOE Policy/Design DODI 5000.67RSH Research & Development To be determinedUNDS Regulations, Underwater hull TBD
NAVAIR Aircraft Engines
TWH: Habitability
SEA 08R
TWH: Underwater Hull Husbandry
SDMs: Surface, Submarine,
Carrier
Technical Authority Pyramid - Coatings & Corrosion Control - ShipsDraft: June 2015
Navy Employee Navy Developmental Employee Contractor
Ingleall
Castle(EM)
All, COR
LemieuxLemieux(EA)
All, RSH
Vacant(EM)
NSK, All
Wegand(EM)
RSH, NSK
Lattner(EM)COR
Haslbeck(EM)
All, AF
J. Martin(EM)
TOP, TNK
Melhuish(EM)
All, NSK
Brinckerhoff(EM)All
Tagert(EM)
TNK, NSK
Kenney(EM)
VA-Class
Jones(EM)
NSK, DCK
Iezzi(EM)
RSH TOP
Smith(EM)
UNDS
Wigle(EM)
CCAT
Slebodnick(EM)
RSH,TNK, NSK
Merlino(LE)
DOCs
Ehrich(LE)COR
Thomas(LE)COR
Clayton(LE)
DOCs
Lawrence(LE)AF
LangasterTNK
HolmAF
Eppard(LE)
NSK, RSH
ChasseCOR
MiekleCOR
CisconAll
ParkDOCs
FosterAll
StankeRSH, All
F. MartinHT
BerghTNK, SUR
Needham(LE)
COR, All
WebbRSH
InternAll
EllorCOR
AultTNK, RSH
Steinberg(LE)AF
Ranero(EM)
All, NSK
EAs
EMs
LEs
KoglerSUR
TWH
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Delegated signature authority
Duckworth/Duckworth/DeloachDeloach
(EA)All
McKelvey(EM)
COR, DOC
Tank Coating History
• There are ≈ 9,4009,400 tanks on Navy ships that contain:- Fuel (ships & aircraft) - Ballast water - Cooling Water- Potable water - Wastewater
1997, tank recoating was largest cost item (~25%) in availability work packages with annual cost estimate of ~$244M to re-preserve tanks/voids.
• Modern ballast tank coating era began on 27 Sept. 1971 with implementation of MIL-P-24441, “Mare Island” Formula 150 epoxy.
•• Polyamide epoxy formulation that contains <340 gm/l volatile organic compounds (VOC), (still in service in U.S. Navy).
•• Product was intended for “universal” service including potable water.•• System effectively supports 3 to 5 year docking cycles.
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Poor performance on welds, corners, and edges – Not edge-retentive.
Mare Island epoxy is a good coating with long history of service on Navy ships.55
What is Edge Retention?
Edge retention of high-solids,rapid-cure, single-coat paint
Edge Retention Evaluation of MIL-DTL-24441
Old solvent-based epoxy pulls away fromthe edge.
New solvent-free, edge retentive epoxy
MIL-PRF-23236 Appendix A requires measurement of coating thickness on aluminum extrusion with 1/32-inch or 0.8mm corner radius
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Pain
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Edge-retentive coatings must have >70% of the coating thickness on the flat surfaces retained on the edge
1997 Business Plan for High-solids, Edge-retentive Coatings
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● 1997 plan to shift from a 3-5 year tank recoating periodicity for Mare Island to a 20 year service life (i.e., 80% of the population being in a EXCELLENT or GOOD condition at end of service period) by:
- Qualifying ultra-high solids, edge-retentive paints.
- Improving coating application process (e.g., surface cleanliness, profile, environment, and oversight).
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1997 Business Case Proving Accurate for Seawater Ballast Tanks
∙ Business case predicated on avoiding need to repaint tanks. - 60% to 80% Job cost associated with opening and preparing tank.
- Labor and QA required to spray paint, inspect paint, and touch-up regardless of type. - Higher priced high-solids paint cures more rapidly, saves time.
88Avoiding Tank Repaint Work Using High Solids is Lowering Total Ownership Costs
* 15 UHS tanks are blistered and are rated CCIMS 3 or 4
Ballast Tank Coating Performance on LHD 2
• LHD 2 seawater ballast tanks coated in 1998/1999 to support twelve year docking.
- Larger tanks, more challenging access.- One platform, one contractor, one system.
• Tank coating assessment by Naval Research Laboratory using camera and visual inspections in 2012/2013. Total of 35 ballast tanks assessed as follows:
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All Inspected Legacy Tanks in POOR Cond.
UHS coatings can support 12-year docking with minimal risk to material condition99
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Service Life of Fuel and Compensated Fuel Showing Blistering
∙ Compensated fuel, fuel, and JP-5 tanks include wide range of service and in-service history. - JP-5 sumps and drains (e.g., 36 month inspection).
- Fuel oil storage (e.g., 120 month inspection). - Corrosion, pitting, and “steel contamination” increase blistering risk.
1010Extended service life being achieved, but blistering is significant issue.
* 13 UHS tanks are blistered and are rated CCIMS 3 or 4
What To Do About Blistering?
∙ Paint Center of Excellence funded analysis to determine if blistering is a significant risk issue for tank service life. - Do blisters lead to tank corrosion, metal loss, and the repair “hockey stick”?
- Do blisters grow and lead to catastrophic coating failure (e.g., sheets)?
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Extended service life being achieved, but blistering may be avoided without appreciable corrosion risk.
What To Do About Blistering?
∙ Corrosion data indicate blisters are not a risk to structure. - Blistered panels show similar mass loss in abrasion testing (e.g., foot traffic).
- Tanks inspection could be completed even on blistered tanks.
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Blistering would not be a problem with tank inspection and tanks could be placed back in service.
Business Case for Potable Water Tanks Initiated After Ballast Tanks in 2002
1414Potable water system limited to two coat UHS, but shifting to single coat in 2016
Qualified a Class 9/18 in 2014. Adding Class 9/18 to nextStandard Item 009-32 Update
∙ Potable water UHS tank coatings are all qualified to MIL-PRF-23236D “COATING SYSTEMS FOR SHIP STRUCTURE” that includes all corrosion control performance tests and the following additional requirements:3.4.1 Class 9 coatings shall maintain NSF International to NSF Standard 61 for 500-gallon storage tanks.3.4.2 Color in water. Color units shall not be greater than 10. 3.4.3 Taste in water. Threshold taste values shall not be greater than 2. 3.4.4 Odor in water. Threshold odor values shall not be greater than 2. 3.4.5 Chlorine residual. Chlorine residual shall not decrease in excess of 50 percent of concentration.3.4.6 Phenol contamination. The cured coating shall not leach phenolic compounds in concentrations greater
than 1 part per million.
High Solids, Type VII
Class 5/18 and 7/18 Single CoatBallast & Fuel tanks, chain lockers, voidsClass 18 signifies single-coat Class 9
Potable Water
Class 19 and Class 19/18 Well Deck Overhead
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Business Case for Potable Water Tanks Initiated After Ballast Tanks in 2002
∙ Potable water tank performance history limited to thirteen years of data. - Qualification of coatings to MIL-PRF-23236, Type VII, Class 9 is complex.
- Coating manufacturers must commit to maintain NSF 61 listing.
1313Potable water system limited to two coat UHS, but shifting to single coat in 2016
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CHT / Sanitary Tanks are Providing Up to 15 Years of Service
∙ NAVSEA never predicted extended service life for CHT/waste tanks. - Fatty acids actually degrade epoxy coatings.
- Tanks small and difficult to coat. - Qualified coatings most frequently based on novolac chemistry.
1515Performance to date suggest qualified novolac epoxy coatings can support 12 year docking
Tank/Void Coatings in New Ship Acquisition
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Expanding applications on every hull
Added to ship specification
Rapid-cure, high-solids,
edge-retentive, single coat
tank coatings
Demonstration testing
Specification Development
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Conclusions
• UHS tank coating technology developed and fielded in late 1990’s is performing effectively as measured by 1997 NAVSEA Business Case:
- Ballast tanks on track to achieve 15-20 years of service.
- Tank coatings on USS ESSEX (LHD 2) supported 12-year docking.
- Fuel, CHT, and Potable water tanks exceeding expectations.
• Key issue is end of life tank performance.•• Blistering. •• Schedule driven recoating.•• Service life beyond 20 years?
• NAVSEA to continue efforts to support extended tank coating service life.
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