establishment of soluble salt criterion & salt...

Protective Coatings & Corrosion DepProtective Coatings & Corrosion Dep’’tt

NACE_ IMCS2008NACE_ IMCS2008

Establishment of Soluble Salt Criterion & Establishment of Soluble Salt Criterion & Salt Measurement Method for Coating PerformanceSalt Measurement Method for Coating Performance

M.K ChungM.K Chung**, , C.H. Lee,C.H. Lee, Y.H. Y.H. BaekBaek, B.D. , B.D. HeoHeo, and K. S. Kim, and K. S. Kim

Hyundai Heavy Industries Co. Ltd.Hyundai Heavy Industries Co. Ltd.

Oct. 30, 2008Oct. 30, 2008

-2- IMCS 2008IMCS 2008NACENACE

Major Concerns on Salt ContaminationMajor Concerns on Salt Contamination

1. Reestablishment of Criterion of Soluble Salt

2. Development of Cost-effective Soluble Salt Measurement Method


SaltSalt--induced Blisteringinduced Blistering

• Premature Coating Failure

• Underfilm Corrosion

Osmotic Blistering


General Painting & Inspection PracticeGeneral Painting & Inspection Practice

1.1. Welding beadsWelding beads, burnt and rusted areas, burnt and rusted areas shall be blasted or shall be blasted or

power tool cleaned to the specified grade.power tool cleaned to the specified grade.

2.2. The The contamination such as contamination such as zinc saltzinc salt, , etc. etc. shall be removedshall be removed

with appropriate method like power tooling or sweep with appropriate method like power tooling or sweep

blasting, etc.blasting, etc.

Surface Salt ControlSurface Salt Control

⇒⇒ Follow Owner Spec. Follow Owner Spec.

⇒⇒ Test Kit : SCM400Test Kit : SCM400TMTM & Others& Others

Source : Source : KoShipAKoShipA


Steel Storage

Primary surface preparation

Sub Assembly

Unit Assembly

Secondary surface preparation

Salt Control in ShipyardsSalt Control in Shipyards

Salt Measurement

Salt Measurement

* Washing, if necessary

* Washing, if necessary


Criterion of Salt LevelCriterion of Salt Level

Shipyard : HHI (after blasting)Shipyard : HHI (after blasting)

* Measurement Method SCM400

70mg/m2Immersion

(WBT)

160mg/m2

Criterion

Non-immersion(Deck)

Area


Criteria of Salt LevelCriteria of Salt Level

Coating Manufacturer (after blasting)Coating Manufacturer (after blasting)

*

Remark

320

80

100

100

160

Non-immersionImmersion

50C

70A

50E

50D

100B

Criterion(mg/m2)Manufacturer

* Measurement Equipment : SCM400


Literature SurveyLiterature Survey

DNV Technical ReportDNV Technical Report

*: no blistering, **: blistering

Search or Request

B

100*< value <200** mg/m2A

E

D

100*< value <200** mg/m2C

Expected CriterionManufacturer


Claim AnalysisClaim Analysis


Claim Analysis Claim Analysis

• The number of construction ships : 1300 (2008 year : 100)

• Ship construction experiences : abt. 30 years

• Market share : about 14%

Receiving A/S claim↓

Analysis

No SaltNo Salt--induced Failure (Blistering)induced Failure (Blistering)• HHI’s criterion of soluble salt before IMO PSPC regulation

: 70mg/m2 using SCM400


ExperienceExperience

• No Claim

• Relatively weaker

to blistering

Early 1990sEarly 1990s

Pure Epoxy

ModifiedTar Epoxy

• No Claim

• No problem due to salt


SteelSteelI.O.Z. (15 I.O.Z. (15 µµm)m)

Epoxy HB (160 Epoxy HB (160 µµm)m)

Epoxy HB (160 Epoxy HB (160 µµm)m)

IMOIMO’’s PSPCs PSPC

PPerformance erformance SStandard tandard for for PProtective rotective CCoatingoating

Water Ballast TKWater Ballast TK


IMOIMO’’s PSPC s PSPC RegulationRegulation

Primary/Secondary Surface ConditionPrimary/Secondary Surface Condition

4.4 Basic coating requirements4.4 Basic coating requirements

Table 1 Table 1 -- 3.1 Secondary surface preparation3.1 Secondary surface preparation

Water soluble saltsWater soluble salts limit equivalent to limit equivalent to NaClNaCl after after blasting/grinding shall be blasting/grinding shall be ≤≤ 50 mg/m50 mg/m22 of of sodium chloride (NaCl).sodium chloride (NaCl).

Conductivity measured in accordance with Conductivity measured in accordance with ISO 8502ISO 8502--99 :1998.:1998.


Salt Requirement ChangeSalt Requirement Change

PSPC 1st Draft : 30mg/m2

PSPC Final Version (MSC 82) : 50mg/m2

?


Issue of Sur. Salt CriterionIssue of Sur. Salt Criterion

IMO PSPC :IMO PSPC :• NaCl 50 mg/m2

• Bresle Method

• No Tech. Data

HHI Technical DataHHI Technical Data

• NaCl 70 mg/m2

(CORR06, 06014)

Surface Salt Con. Criteria for Coatings of ShipSurface Salt Con. Criteria for Coatings of Ship’’s s WBTkWBTk

Insufficient Insufficient Tech. DataTech. Data

Surface Preparation(Work Period, Cost, Productivity, Environment, Safety, …)


Measurement TimesMeasurement Times

105m X 68m = 7140m2

PSPC_6.2 Inspection ItemsPSPC_6.2 Inspection Items

large block : 6000m2


Research ActivityResearch Activity

Composition Analysis of Surface Soluble Salt on the ShipComposition Analysis of Surface Soluble Salt on the Ship’’ss

Surface (Corrosion 2008, No. 08020) Surface (Corrosion 2008, No. 08020)

Coating Performance with Soluble Salt Coating Performance with Soluble Salt

(In process, be presented, min. (In process, be presented, min. NaClNaCl 70 ~100 mg/m2)70 ~100 mg/m2)

Development of Soluble Salt Measurement EquipmentDevelopment of Soluble Salt Measurement Equipment

Estimation of Atmospheric Environment in the ShipyardEstimation of Atmospheric Environment in the Shipyard(2007)(2007)

Technical data to obtain reliable soluble salt criterion


HHIHHI’’ss OpinionOpinion

HHI’s salt criterion more higher than that of IMO PSPC

No problem about 20 yrs

IMO PSPC has much higher safety margin, more than 40%.

Salt criterion in IMO PSPC

The better, the best? High cost, Low efficiency

More understanding real ship yard situation.

Soluble salt criterion in IMO PSPC should be revised.


Major Concerns of SaltMajor Concerns of Salt

1. Reestablishment of Criterion of Soluble Salt

2. Development of Cost-effective Soluble Salt Measurement Method


IMOIMO’’s PSPC s PSPC RegulationRegulation

Primary/Secondary Surface ConditionPrimary/Secondary Surface Condition

4.4 Basic coating requirements4.4 Basic coating requirements

Table 1 Table 1 -- 3.1 Secondary surface preparation3.1 Secondary surface preparation

Water soluble saltsWater soluble salts limit equivalent to limit equivalent to NaClNaCl after after blasting/grinding shall be blasting/grinding shall be ≤≤ 50 mg/m50 mg/m22 of of sodium chloride (NaCl).sodium chloride (NaCl).

Conductivity measured in accordance with Conductivity measured in accordance with ISO 8502ISO 8502--99 :1998.:1998.


Measurement EquipmentMeasurement Equipment

BresleBresle Method (Method (BresleBresle Patch)Patch)

SCM 400SCM 400

ChlorChlor*rid Test (sleeve, Kitagawa *rid Test (sleeve, Kitagawa TitratorTitrator tube)tube)

SSM (SSM (Surface Salinity Meter, Soluble Salt Meter)


Shortcomings of Shortcomings of BresleBresle PatchPatch

Shopprimed Surface Removal work

Foam Residue


Needs for Improvement Needs for Improvement BresleBresle PatchPatch

BresleBresle PatchPatch

- High price

- Residual form removal work by power tool

- Poor durability of film

Improving performance of bresle patch

Development of Color PatchDevelopment of Color Patch

- Easier, faster, more convenient, practical method

- Color indicating patch


Salt Patch DesignSalt Patch Design

Glassine, kraft, PE filmEasy detachmentInner/outer Liner

Arcryl

Latex

Polyethylene(PE)

Material

No Leakage, No VOC

Elongation

Adequate Strength (soft/hard)

Requirement

Adhesive

Film (vinyl)

Foam

Component


Performance Test ResultsPerformance Test Results

- No Residue after foam removal

- Cost down up to 1/3


Color PatchColor Patch

- Color indicating patch

- Easy, fast, comfortable, field oriented method

- Not the exact salt value but the value range


Summary and Future worksSummary and Future works

1.1. Reestablishment of soluble salt criterion Reestablishment of soluble salt criterion

- Evaluation of coating performance with salt level.

- Addition of salt criterion test item in coating performance test

of IMO PSPC .

2. Development of cost2. Development of cost--effectively practical salt test methodeffectively practical salt test method

- Field application of advanced Bresle patch and color indicating patch

- Color indicating patch : salt value ranges

- Development of more reliable and practical equipment/kit needed


Thank you ! Thank you !

establishment of soluble salt criterion & salt...

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