jpcl_chempetro_ebook2.pdf

Selecting and Sourcing Coatings for Chemical andPetrochemical Plants

A JPCL eBook

Selecting and Sourcing Coatings for Chemical and Petrochemical PlantsA 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.

i

Introduction iii

From New Construction Through Plant Operation: 1

An Overview of Protecting Chemical Plants

by Luke Clark

Coating Systems Guide for Chemical and 10

Petrochemical Plants

Coatings Company Profiles 26

Contents

ii

1

10

Contents

Storage tank in optimum condition to be restored. Storage tank after minor surface preparation and overcoating.All photos courtesy of Carboline Company.

SPONSORED BY

iii

Introduction

Introduction

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

coatings for protecting chemical and petrochemical plants, followed by

JPCL Buying Guide material on coating systems for chemical and

petrochemical plant environments.

The Buying Guide is organized, rst, by exposure type, such as

Exterior Plant Exposure - Moderate to Severe Chemical, Weathering,

& UV, then by substrate type, rst steel, then concrete. 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 chemical and petrochemical plants, and

then to give sources for acquiring the appropriate systems.

hemical fumes and humidity create aggressive exposure conditions for metal struc-tures, concrete structures, and pipelines in chemical plants, adversely affecting oper-ating/maintenance costs, appearance, and safety. In most chemical plants, thechallenges are to understand the potential types of corrosion caused by processingconditions and environmental conditions and to then select suitably resistant coatingsystems. This article illustrates the main types of corrosion found in the exterior sur-

faces of chemical plants, and it discusses coating selection for carbon steel from the perspectives ofnew construction as well as maintenance.

Types of Corrosion in Chemical Processing Plants

In the chemical processing industry, corrosion takes many forms. The most common is uniformcorrosion, which normally affects the appearance of a structure first, and eventually weakens itsmetal surface as the structure loses thickness and later fails. This type of failure usually occurs onunprotected structures. Galvanic corrosion is often ultimately a result of the design of a chemical plant. It occurs where

two dissimilar metals are in contact and share a common environment. For example, if a processsystem is made of stainless steel components, and the process requires a secondary phase that ismade of painted carbon steel, two dissimilar metals will be in contact. The metals create two ofthree conditions needed for corrosion: the cathode (the stainless steel) and the anode (the carbonsteel). When an electrolyte, such as moisture is added, corrosion occurs, with the carbon steel cor-roding first. If the surfaces are coated, premature coating failure will also occur (Fig. 1). As will beshown in the discussion of zinc-rich primers, galvanic corrosion can also help protect steel.Crevice corrosion is also related to design (Fig. 2). Crevices are inaccessible areas that are diffi-

cult to protect. When chlorides, chemical salts, and other airborne contaminants collect in crevicesand combine with moisture, they create mild acids. These acidic solutions create a very reactiveelectrolyte that will increase the efficiency of the corrosion cell and concentrate corrosion at thecrevice. Normally, crevices are located in critical areas where coatings are already vulnerable topremature failure. Sealing the crevice opening with caulks or welding can help avoid crevice corro-sion.Pitting is one of the most destructive and insidious forms of corrosion (Fig. 3). Pinholes and holi-

days are isolated voids in a coating system. These voids enable the concentration of corrosion, andthe result is Pit Corrosion. Pitting causes steel loss and holes in metal. Structural failures causedby pitting often occur suddenly and unexpectedly. In a chemical plant, pitting will cause equip-ment failure, environmental disasters, and safety hazards. Chemical processing plants also create their own corrosion conditions. Erosion occurs with solid

chemicals in aqueous solutions. The production process will erode protective coatings from a surface,resulting in deterioration of the metal surface. Coating selection and maintenance are important toprevent this kind of failure. Although this failure is generally associated with internal surfaces, suchcoating failures are also found in exterior exposures as well.

From New Construction throughPlant Operation: An Overview of Protecting Chemical Plants

ProtectingChemical

Plants

C

1

By Luke Clark,

Carboline Company

Editors note: This article appearedin JPCL in August 2007.

Also common is stress corrosion cracking (SCC), caused by the simultaneous presence of tensilestress and a specific corrosive medium (Fig. 4). The caustic embrittlement of steel is an example ofSCC. Normally, differences in operating temperatures create the stress, and the chemical environ-ment provides the corrosive medium.

New Construction

The painting of a structure during new construction should be given the same consideration as avital component of the chemical process. The structure that supports the process equipment mustbe protected from the service environment. The operating conditions and chemical environmentwill determine the severity of the service environment. Once the service environment has been de-fined and the corrosion issues identified, the coating selection process may begin. New construction painting (in the fabricating or paint shop) has its benefits. Importantly, in these

settings, the substrate has not been exposed to the service environment, eliminating the need to re-move contaminants and corrosion products created in a chemical processing plant. In addition, thesteel can be prepared and coated under controlled and appropriate ambient conditions, ratherthan being subject to the elements when coating exterior surfaces. The methods of surface prepara-tion and application of the coating system also may be effectively monitored, measured, and con-trolled in a shop. And any surfaces that would become inaccessible after erection are available forcleaning and coating, and thus can be properly coated in the pre-fabrication stage. Ideally, all coatsshould be applied in a shop, with damage from construction repaired in the field. However, for eco-nomic reasons on many projects, the normal process is to clean and prime the surfaces in the shop,and, after construction and erection in the field, to make repairs and apply the rest of the coatingsystems.

Coating Systems for New Construction

When selecting coating systems for carbon steel in chemical plant exteriors, it is important to keep inmind the functions of each coating in a system. Here is a quick review of coating functions.

PrimersThe most common new construction primers for carbon steel are zinc-rich coatings. These primersoffer sacrificial or galvanic protection to the surface and have excellent adhesion properties. Thatis, when a zinc-rich coating is in contact with steel, the zinc will protect the steel from corrosive el-ements by corroding before (or preferentially to) the steel. Sacrificial protection is caused by theelectrochemical reaction of the galvanic couple of steel cathode and the zinc anode. These coat-ings will also allow the fabricator/applicator to incorporate some flexibility into the work sched-ule, because most zinc-rich coatings have an indefinite recoat period. They can be top coated longafter the initial application.Zinc-rich coatings are classified as either organic or inorganic. An organic zinc-rich coating in-

cludes zinc dust in an epoxy or a urethane coating. Organic zinc coatings, which are chemicallycured, provide barrier protection and sacrificial or galvanic protection. Inorganic zinc-rich coatings are applied by mixing the zinc dust with a silicate vehicle. Inorganic

zincs, which are moisture cured (ethyl silicates), are known for their superior sacrificial protectionproperties. Epoxies and alkyds are also commonly used primers in new construction. These primers can

provide excellent adhesion and barrier protection to a steel substrate.

Intermediate CoatsIntermediate coatsnormally epoxiesimprove the protective properties of the coating system,mainly by adding thickness, barrier protection, and enhanced chemical resistance. Appropriatecoating thickness in most cases will improve service life and reduce maintenance painting costs.Many types of coatings are used to expand the chemical resistance and abrasion resistance of the

2

Fig 1: Galvanic corrosion of stainless steel piping and carbon steel storage tank

Fig. 2 (Below): Crevice corrosion on exterior wallof a storage tank. The exterior wall is skip welded.

The environment includes H2S and constant moisture from steam.

Fig. 3: Pitting of steel cooling water pipe

coating system. Epoxies with lamellar type pigments are often used to increase moisture resist-ance and dielectric strength. Intermediate coats also provide cohesion, or a bond, between theprimer and the finish coat. The role of intermediate coats is elaborated in the sidebar, How effec-tive is the epoxy barrier in extending overall system life?Despite the benefits of the intermediate coat, it has been replaced recently in some systems with

a high-solids, thick finish coat. The main reasons for switching to two-coat systems have been costand time.

TopcoatsThe function of a topcoat in a coating system is resistance to the service environment. The basicenvironment generally includes air, moisture, sunlight UV rays, and wind, which carries airbornecontaminants. These factors will contribute to weathering, a natural mode of failure for a coatingsystem. Weathering will usually begin with the degradation (chalking) of the binder due to expo-sure to UV sunlight (Fig. 5). Chalking erodes coating thickness. The coating system then becomesporous and loses its barrier protective properties, allowing the migration of moisture through theintermediate coat to the primer. Primers are generally porous coatings, not barriers to moisture, sothey begin to swell and crack when moisture penetrates them. The moisture then reaches the steelsubstrate, causing corrosion of the steel and underfilm corrosion.The selection of the proper finish coat will control the migration of the moisture through the

coating system and perform as an effective barrier for protection. The box to the left

lists parameters for se-lecting finish coats forexterior surfaces in achemical processingplant. Table 1 (pg. 7) listsservice environments,generic types of coat-ings, and coating per-formance ratings. In thetable, the weather ratingis considered the evalua-tion for color and glossretention.

Surface Preparationand ApplicationThe quality of the coat-ing system applicationdepends on the environ-ment, workmanship, andinspection (QC/QA)controls. As much of thecoating work as possibleshould be completed inthe shop before installingthe structure, because ofthe advantages of shoppainting noted earlier.The surface prepara-

tion that is required for

3

COATING SELECTION/SErvICE CONdITION:

DurabilityHardnessFlexibiltyPlyabilityScratch ResistanceGouge Resistance

WeatheringUV ResistanceMoisture ResistanceTemperature Resistance

Chemical ResistanceAcid ResistanceAlkali ResistanceSolvent Resistance

Recoatability

Primary coating use

Fig. 4: Corrosion failure of stack due to stresscorrosion cracking

Fig. 5: Epoxy coating system chalking

How effective is the epoxy barrier

in extending overall system life?

Three-coat systems have a mid-coat epoxy barrier. Epoxies are tough, high-build,often high-solids coatings designed as additional barrier protection in three coatsystems. The longer the zinc primer can be protected from the elements, thelonger the last line of defense, sacrificial galvanic protection, can be postponed. Epoxies are not UV tolerant. They chalk rapidly in sunlight. Once the mid-coat

epoxy barrier has chalked, the epoxy will also begin to absorb the broth of waterand environmental contaminants. As the moisture evaporates off, and is replaced,the contaminants increase in concentration (acids, salts, chlorides). Corrosion isnow accelerating. Finally, blisters will occur between the epoxy and the zincprimer. When the blisters break, the systems primer will be completely exposed.

new construction should focus on removing mill scale from the steel sur-face and creating a profile, or surface roughness. Mill scale must be re-moved to prevent the galvanic action between the steel surface and themill scale. Mill scale is cathodic to steel, meaning that the steel will corrodebefore the mill scale and as a result, the mill scale will detach from the cor-roded steel surface. If coatings are applied to the mill scale, they also willdetach and expose the steel surface. Underfilm corrosion and subsequentcoating failure will occur. Compared to a smooth surface, surface profile or surface roughness pro-

vides more surface area, or anchor, to which a coating can adhere. Smooth,mirror-like surfaces will not provide a sufficient anchor for the coating andwill lead to adhesion failure of a coating.As discussed above, primers in new construction are normally zinc-rich

because they will provide sacrificial or galvanic protection to the steel, cor-roding before it. To provide galvanic protection, the zinc pigments must be indirect contact with the steel surface. Mill scale or other contaminants will in-terfere with the contact between the zinc and the steel surface. Therefore,

when a zinc-rich primer is used, the surface must be abrasive blast cleaned to an SSPC-SP 10 Near-White blast or SP 5 White Metal blast, the two most rigorous types of abrasive blast cleaning.Many times in new construction, the structural steel and other process components are consid-

ered off-the-shelf items and are painted by the original component or equipment manufacturerwith standard coating systemswhich are not necessarily selected or suitable for the severity ofchemical plant environments (Fig. 6). If these items are installed in the field with the original manu-facturers coating system, they may begin to fail very quickly, leading to premature corrosion ofparts that are critical to plant operation. Premature corrosion means costly downtime for repairand loss of production time. Although recoating them in the new construction phase adds to thetotal construction cost, the maintenance costs are ultimately reduced, as is the downtime thatwould otherwise be needed to take the items out of service for recoating.In summary, while the cost of careful design, shop application and rigorous quality control may

seem high, the investment pays off in considerably reduced long- term maintenance costs.

Maintenance Painting

Protective coating systems are as much a part of an initial investment as the cost of fabricationand installation. For a facility to implement a successful maintenance painting program, the exist-ing protective coating systems must be monitored, evaluated, and maintained with the same dili-gence as the pumps, motors, structural steel, storage tanks, and other components of a chemicalplant.

Maintenance painting programs, therefore, should be designed with theintention of managing the coating process from the initial application atnew construction to its current and future condition. The programshould include inspection procedures, record keeping, and condition mon-itoring of the coating systems. The goal of maintenance painting programsshould be to prevent deterioration of the protective coating to a conditionthat will require the replacement of the coating system. That is, mainte-nance programs should prevent coating failures by identifying the mostcost-effective condition for repainting. This practice will result in a lowercost per square foot per year and will provide the protection required bythe metal surface in the specific service environment.

4

Fig. 7: Typical failure process of an alkyd coating system

Fig. 6: The standard coating system for this motor was not suitable for the service environment.

Condition AssessmentOrganic coatings will lose their gloss, begin to chalk, and fail over time (Fig. 7). When they will faildepends upon the service environment and the quality of coating maintenance. The purpose ofmonitoring and assessing an existing coating system is to establish evaluation parameters that willhelp us grade and measure the basic properties of an in-service coating system to determine if itstill meets its performance requirements or if it needs to be restored (or replaced, although we tryto avoid this).

Evaluation Parameters Appearance: Most protective coatings applied to steel and other metals change in appearance asthey age and fail. We can make a basic visual evaluation by identifying gloss, chalking, rust/millscale, and pitting and other forms of corrosion. Once we have qualified the condition of the coatingvisually, we quantify the failure based on the percentage of the coated surface area that has failed.An industry-recognized standard, ASTM D610/SSPC-Vis 2, uses pictures and diagrams ofpainted steel surfaces to quantify the extent of coating failure. Once we evaluate the appearance ofa coating, we need to determine the following mechanical properties of the coating system. Adhesion: The most important property of any coating system is adhesion. The adhesion of theexisting coating system will affect the success or failure of the coating system used for restoration.There are several standards that are readily accepted by the coatings industry to determine adhe-sion. ASTM D3359, Standard Test Methods for Measuring Adhesion by Tape Test, is the mostcommon. The primary purpose of surface preparation is to promote the adhesion of the coating system tothe substrate. Since our objective is to minimize surface preparation costs, the better the adhesionproperties of the existing coating system, the less surface preparation is required forrepainting/restoration. Because some surface preparation will always be required, we should de-termine if manual surface preparation will be sufficient to repair and restore the existing coatingsystem. A technique used by many contractors is to simply use a scraper or a knife to remove thefailed coating (Fig. 8), at which point the remaining, tightly adhered coating can be feathered to anacceptable repair condition. Thickness: As coating systems age and lose their elasticity, they develop stress points. Coatingthickness will affect the ability of a coating system to tolerate the stresses and maintain its cohesiveproperties. Measuring the thickness of the existing coating system is necessary to select the bestcoating system for restoration. If the existing coating system is too thick, the application of morecoating may be self-defeating. In many cases, the coating thickness is a result of multiple layers ofalkyds and other thin-film coatings. The application of an epoxy and urethane coating system maycreate stresses within the aged coating system that will result in cracking and other forms of stress

failures. In these situations, the coating system will have to be removed, be-cause the stress condition will continue to manifest into premature failure.Thickness measurements are taken with Type I (pull-off) or Type II (electronic)dry film thickness gauges, in accordance with the procedure described inSSPC-PA 2, Measurement of Dry Coating Thickness with Magnetic Gages.The number of measurements taken will depend on the configuration andcondition of the random sample area selected.

Finding the Sweet Spot in Failure AnalysisFailure analysis of coatings has become efficient enough that we can nowcreate real environmental conditions by implementing exposure cycling.We have also documented enough information about actual field applica-tions to understand the performance of different coating types in specificenvironments. Therefore, we are able to predict the rate at which a coatingwill fail in a specific service environment. If we can identify the optimal con-

5

Fig. 8: Failed existing coating system removedto an adhered condition

Fig. 9: Gloss retention of urethanes

6dition for repair in the service life of a coating system, we will be able to restorethe existing coating system rather than replace it, and thus reduce our mainte-nance costs (per square foot). Generally, the condition best for coating mainte-nance is when the primer is well adhered to the substrate and the coating film isporous enough for topcoating with limited surface preparation and primer repair.

It is worth noting that chalking is the first indicator that a coating systemis about to begin an accelerating decline. As shown in Fig. 9, cyclic salt fog/UVtesting confirms the relationship between chalking and coating failure. The curveassociated with UV exposure and gloss loss is relatively steady as the gloss holds,but when the coating begins to chalk, the coating swiftly deteriorates and totalsystem failure occurs. The fulcrum point in Fig. 9 indicates the exact time the sys-tem begins to chalk.

The reason for the sharp decline in coating performance as it loses gloss isthat the permeability and porosity of the coating increase to the point at which itabsorbs and holds moisture. The water and contaminants begin to accelerate cor-rosion by penetrating through the porous (chalked) coating film, as shown by the

sharp drop in readings in Fig. 9. Once topcoat chalking has begun, system failure can be predictedwithin 35 years, depending on the coating system and the exposure.

Project-Specific ProceduresUnlike new construction painting, maintenance painting often is scheduled during plant operation.The unique working conditions in maintenance painting create challenges that must be identified andovercome. Hence, a successful maintenance painting project begins with a procedure for surfacepreparation, application, and inspection that is tailored to the specific structure and operating condi-tions of the particular project at hand. The procedure should be focused on restoring the existing coat-ing system to achieve the longest possible service life. The procedure must address how the surface will be decontaminated and prepared, how the coat-

ing system will be applied, and how the crew will proceed in the working conditions inherent to theprocess area where the painting will be performed. The scope of work will have to define workinghours; protection of the paint crew, the plant workers, and plant equipment; operating conditions;control of hazards created by the surface preparation and coating application, such as airborne con-taminants; and other conditions that will affect the successful application of the coating system.Along with the natural environment, chemical processing plants are exposed to mineral acids, or-

ganic acids, alkalis, corrosive salts, solvents, and gases. This environment creates a surface contamina-tion problem that can lead to premature coating failure.During new construction, testing for contaminants is done,depending on how much of the coating system is applied inthe field. When the chemical plant is operating, the testingrequirement is extensive because of the environmentaland processing conditions. The surface should be tested forcontaminants prior to any surface preparation. In fact, inmaintenance painting, the primary surface preparationconcern is removing the surface contaminants that haveaccumulated on the surface. (See sidebar, Surface Prepara-tion for Maintenance Painting in Chemical Plants.) Thesecontaminants are a direct result of the chemical processand natural environmental conditions (Fig. 10). Maintenance painting projects will often include sev-

eral coating systems, depending upon the condition ofthe existing coating system and the part of the facility to

Fig. 10: Surface contamination from caustic processing area

Fig. 11: Handrails, piping, and pumps in different stages of maintenance and repair

be painted (Fig. 11). For example, structural steelmight require a different coating system than isneeded for the operating equipment in the samearea, and the specification for a pump may be dif-ferent than the specification for the attached pip-ing. Careful testing for process contaminants isalso needed to determine maintenance systemsthat can withstand the processing conditions;thorough inspection of prepared surfaces is alsoneeded to assure that they are decontaminated.

Selecting Coating Systems for Maintenance When selecting an appropriate primer, the mainconsiderations are compatibility with the existingcoating system and the method of surface prepa-ration. Because of their inability to adhere to anexisting coating, inorganic zincs are not commonlyused for maintenance painting. Organic zincs aremore common, but require constant agitation dur-ing application, which is difficult for most mainte-nance painting projects at chemical plants becausebrushes and rollers are generally used for applica-tion. Other organic coatings such as alkyds, epox-ies, and urethanes are used more commonly thanzinc-rich coatings.

When the existing coating system is notknown, the application of a field sample is recom-mended. Field samples are easy to apply and willanswer many questions regarding adhesion andcompatibility. Surface-tolerant coatings are com-monly used for surfaces that have been cleanedmanually. Designed to adhere to marginally pre-pared surfaces, these coatings are usually high-solids products with effective barrier properties.

The intermediate coat in maintenance paint-ing has several functions, depending on the scopeof work. It may be used as a primer over the exist-ing coating system to improve the adhesion of thenew finish coat, to hide the color of the existingfinish coat, and to add depth to the color of thenew finish coat. In the restoration of an existingcoating system, a sealer may be applied, usually ata DFT of 1.5- 2.0 mils, before the topcoat.

The selection of the topcoat is the same forboth maintenance painting and new construction.However, the advantage we have for maintenancepainting is that we already know how the finishcoat has performed in the service environment. Ifthe coating system was properly applied at newconstruction, the finish coat should chalk anderode from the surface, exposing the intermediateor primer (undercoats).

7

Coating Type Cure Mechanism Acid Oxidizing Alkali Salt Solvent Weather MaxAcid Temp

Dry

Epoxy Polyamide Chemical Reaction E G E E VG G 250 F

Polyurethane Chemical Reaction VG G VG E VG E 250F

Silicone Aluminum Heat P P F G F G 1000F

Inorganic Zinc Hydrolysis E* E* E* E E E 750F**

Organic Zinc Chemical Reaction VG* VG* VG* VG VG VG 300F**

Rating Scale:(E) Excellent- No effect, best selection where performance and appearance retention desired.(VG) Very Good- No effect on performance, very little appearance degradation. (G) Good- Little effect on performance, some appearance degradation.(F) Fair- Performance and appearance affected by exposure.(P) Poor- not suitable, coating attacked

* Results indicate zinc rich coating performance when topcoated. Use of these coatings untopcoated in chemical environments is not recommended.

** Limited by topcoat in the system.

Table 1: Generic Coating Types and Their Performance in Chemical Environments

Surface Preparation for Maintenance

Painting in Chemical PlantsPressure washing with detergents and chemicals is commonly used to neutralize the surface and remove visible and non-visible contaminants. If chemicals and detergents areused in combination with water or steam, the surface should first be rinsed with potablewater to remove residue. When the surface has been decontaminated, we should then address the failed areas of

the coating system. Generally, the steel surface is exposed, and corrosion products are onthe surface. Maintenance Painting Objective-Avoid pitting of the surface.If the surface is pitted, the areashould be cleaned by abrasiveblast cleaning, which is themost effective method to cleana steel surface for coating application, as per the specified written standard and the visualstandard for abrasive blastcleaning SSPC-VIS 1. However,because of process equipmentor the extent of the failure,

abrasive blasting may not be practical. In such cases, manual cleaning methods, such ashand tool cleaning and different degrees of power tool cleaning, may be employed, as perthe specified written standard and the visual standard SSPC-VIS 3. In both of these situations, the cost of repainting will increase due to the amount of surface preparation thatwill be required to achieve the maximum service life.Regardless of the cleaning methods used, the failed existing coating system should be

removed to an adhered condition and feathered. Proper feathering techniques create a gradual transition from the tightly adhered coating to the exposed steel surface (photo above).The surface adjacent to the feathered steel surface should be abraded to a texture similar tofine/medium grade sand paper to provide a surface suitable for the primer to adhere to it.

The existing coating system, feathered in preparation for primer application

In some cases, the finish coat will delaminate or blister, exposing the undercoats. Blistering ordelamination may occur for several reasons, such as service environment exposure, contaminationbetween coats, incompatibility between coats, or the application of the top coat exceeded the re-coat window of the undercoat. In these cases, the procedure for restoring the coating system is torepair any areas of the exposed steel surfaces and the finish coat. When coating failure is limited to the finish coat, the entire coating system does not necessarily

need replacement. For example, suppose a urethane finish coat on the roof of an external floatingstorage tank has blistered and lost adhesion, exposing the epoxy intermediate coat. The roof sur-face is subject to ponding water conditions, and the urethane failed because of the immersion con-ditions created by the ponding water. In this case, the practical solution is to replace the finish coatwith an epoxy coating, because epoxy coatings perform better in water immersion. However, theepoxy will chalk in UV exposure. So we will have to adjust our service life expectations and ourrepaint cycle for the coating system. The new construction finish coat selection was correct for thewalls, windgirder, and platforms of the storage tank. But even though the roof has a drain system,experience has shown that we will have to make adjustments to the coating system to accommo-date the service conditions.

Summary

Contemporary economics has encouraged the outsourcing of many new construction and mainte-nance tasks, so the design and engineering of chemical processing plants is normally the task of a

hired firm that is assigned the goals and objectives of building astructure that will have the processing capability to produce a target amount of product. Once the design has been approved, thetask is to build the plant at the lowest cost. When the constructiontask is complete and the owner accepts the plant, the duties andresponsibilities of maintaining the operating plant are assigned toanother firm or group. Yet the cost to maintain the plant will depend on the original

design and construction. Usually, the impact of any cost concessionsmade during construction will be realized after the plant is operat-ing, and the ultimate costs will be borne during maintenance. Main-tenance painting of the plant must therefore take into account newconstruction coating work as well as coating requirements duringplant operation.

Sources

Process Industry Corrosion / An Official NACE Publication. Published by National Associationof Corrosion Engineers, Library of Congress Catalog Number 75-28636 Copyright 1975. Steel Structures Painting Manual Volume 1 Good Painting Practice Second Edition Copyright1982, by Steel Structures Painting Council Second printing 1983. Corrosion Protection by Protective Coatings Charles G. Munger / Louis D. Vincent, Ph.D. Revi-sion Author 1984, 1999 National Association of Corrosion Engineers Second Edition 1999 ISBN1-57590-088-2 Library of Congress Catalog Card No. 99-75864. Material Performance December 2005 Volume 44, Number 12 p. 30 Using Organic Coatings toProtect Mild Steel in a Viscose Industrial Atmosphere M, Natesan, M. Selvaraj, and K. Maruthan;P. Rajendran.

Luke Clark is the director of technical service for Carboline Company. He has more than 25 years of experiencein industrial and marine coatings, working previously for such companies as Du Pont and Sigma Coatings USA.He is a NACE Certified Coatings Inspector and Instructor and a SSPC Certified Protective Coatings Specialist.

8

THE MILESTONES FOR A SUCCESSFUL PROTECTIVE COATINGS PROGRAM

Select the best possible coating system for the specific service environment

Application and inspection procedures for new construction

New construction paint applicationDo it in the shop

New constructionHire a paint inspector for shop application and field repairs

Design a Maintenance Painting Program that is specific for your site

Monitor the performance of your existing coating systems, and update periodically

Identify the condition of your existing coating systems. Restoration is preferred

over replacement

Site specific application and inspection procedures for maintenance

Inspection of maintenance painting

Update maintenance painting program and service life expectations

JPCL

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Coating System Guide for Chemical & Petrochemical Plants

Exterior Plant ExposureModerate to Severe Chemical,Weathering, & UVSteel

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Photos courtesy Hempel

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.$Marseal 4000Sheet Lining, Thermoplastic

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"$*'*$/,8-&12*5*2*/./'!Rescrete RCCR/Elasto-Glaze CRUEpoxy (1-2 Coats)/Urethane

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4".34-1/40Precidium P-180D, 650D, and LS-1150DPolyurea Pure (1, 2, or 3 Coats)

)*./*.*.(2/10/1"3*/.Rhino ExtremePolyurea Pure (1, 2, or 3 Coats)

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/5", /10Roval R22 Cold Galvanizing CompoundZinc-Rich, Organic

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"4&1&*2&..$SauereisenEpoxy 100% Solids (1 or 2 Coats)

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0&$*",381/%4$32.$PTU, Polyshield HT-100F, AMP 100Polyurea Pure (1, 2, or 3 Coats)

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40&1*/11/%4$32Enamo GripUrethane/Urethane

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&2,"".//"3*.(23%TeslanZinc-Rich, Organic

)&)/13&71/40Chemi-TechEpoxy 100% Solids (1 or 2 Coats)

)&1-*/.ThermionThermal Spray

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.&-&$/-0".8.$Tneme-Zinc/Hi-Build Epoxoline II/FluoronarOrganic Zinc/Epoxy/Fluorourethane

/0&$1&3/"3*.(2Top SecretEpoxy (1-2 Coats)/Urethane

23&.3418/"3*.(2.$FPUWC15Organic Zinc/Epoxy/Fluoropolymer

/"3*.(2MasticGrip/UreGripEpoxy (1-2 Coats)/Urethane

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AN COMPANY

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%'$"!!""%!PolyArmor, WarriorPolyurea Pure (1, 2, or 3 Coats)

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Chem & Petrochem Plants

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10/7/11 2:23 PM Page 46

15

/,8$/"31/%4$32Polyeuro 8245Polyurea Hybrid (1, 2, or 3 Coats)

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/6&12.%4231*",DuromarEpoxy 100% Solids (1 or 2 Coats)

Linings for Steel Storage Tanks & Vessels Solvents, Jet Fuel,Diesel, Gasoline, Crude OilSteel

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)&-1&"3.%*"3%ChemtuffEpoxy Phenolic (3 Coats)

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.%41"".4'"$341*.(/3%ARCEpoxy Novolac (1 or 2 Coats)


2:23 PM Page 47

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-%#.-.1/.1!3).-Chemclad XCEpoxy Novolac (1 or 2 Coats)

-5)1.+)-%-3%1-!3).-!+!)-3EnvirolineEpoxy 100% Solids (1 or 2 Coats)

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3+!2)-%1!+2(%,)#!+2-#Carbo-AlkorBrick and Tile, Acid-Resistant

Linings for Steel Storage Tanks & Vessels Acid, Oxidizer, AlkaliSteel


10/7/11 2:24 PM Page 48

17

'! EnvirolineEpoxy 100% Solids (1 or 2 Coats)

! %# %! Versi-LineVinyl Ester/Vinyl Ester/Vinyl Ester

!(#$ &$%#DuromarEpoxy 100% Solids (1 or 2 Coats)

#! !" *PlasiteEpoxy Novolac (1 or 2 Coats)

!% %# %! %CeilcoteVinyl Ester/Vinyl Ester/Vinyl Ester

%!Perlastic SGCoal Tar/Asphalt

! %# %! %Epo-chem RW 500Epoxy/Epoxy Novolac/Epoxy Novolac

#% %ChemtuffEpoxy/Epoxy Flake Filled/Epoxy Flake Filled

&$%#$CIMUrethane Elastomeric (1 Coat)

! $%#&%! *$%$&""*Eco-Polymer SC3300Epoxy Novolac (1 or 2 Coats)

!#!#"!#%! Corchem 243/243/243Vinyl Ester/Vinyl Ester/Vinyl Ester

!#!! !% $!##!$! ! %#!Corolon 3000Polyurea Hybrid (1, 2, or 3 Coats)

!#!%#!# !% $CortechEpoxy/Epoxy/Epoxy

!% &$%#$ Durabak SmoothUrethane/Urethane

#!( !*#$CrownCote AcidShield No VOCEpoxy/Epoxy Novolac/Epoxy Novolac

" *! ApexiorOther

$!!#%#Archco/DensoVinyl Ester/Vinyl Ester/Vinyl Ester

!# HPL-4310 Epoxy 100% Solids (1 or 2 Coats)

&% !%ARCEpoxy Novolac (1 or 2 Coats)

! !#"!#%! Chemclad XCEpoxy Novolac (1 or 2 Coats)

'#! %# %! %EnvirolineEpoxy Novolac (1 or 2 Coats)

'#! %#!%%'!% $ E-4000 One CoatZinc-Rich, Organic

! !%EonCoatOther

!% $Liquid EPDMOther

"!)* %# %! HSO 98Epoxy/Epoxy Novolac/Epoxy Novolac

#! #!#NovocoatEpoxy/Epoxy Novolac/Epoxy Novolac

!) &$%#$ Fox FX-3110SW Chem Resist CtgEpoxy Novolac (1 or 2 Coats)

888.760.0369 www.foxind.com



10/7/11 2:24 PM Page 49

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%,)3%1.$4#32-#Gem-Cote EP CREpoxy/Epoxy 100% Solids

4+&.!23!)-3&'-#Poly ChemEpoxy/Epoxy Novolac/Epoxy Novolac

%,/%+-#85671/85671/85671Epoxy Phenolic (3 Coats)

%-*%+.1/.1!3).-9.11.2).--')-%%1)-'Penncoat 331Vinyl Ester/Vinyl Ester/Vinyl Ester

%1%2)3%1.3%#3)5%.!3)-'2Heresite P-403LOther

)'(+!-$-3%1-!3).-!+-#74 Chem-Temp Epoxy LiningEpoxy Novolac (1 or 2 Coats)

.,/.2)3%%#(-.+.')%2CarbonSealEpoxy/Epoxy Novolac/Epoxy Novolac

-$41.-.!3)-'2-#PermaSafe 100 Ceramic EpoxyEpoxy 100% Solids (1 or 2 Coats)



-3%1-!3).-!+!)-3InternationalEpoxy Phenolic (3 Coats)

2.+!3%*-3%1-!3).-!+Fendolite M-IIThermal Spray

.+8/%#4341!.!3)-'2PolySpec NovoRezEpoxy/Epoxy Novolac/Epoxy Novolac

.11.2).-.-31.+.3$Techni-Plus VE 62Vinyl Ester/Vinyl Ester/Vinyl Ester

%,!.!3)-'23$Kema 300PAEpoxy/Epoxy Novolac/Epoxy Novolac

)#.1.,/!-8-#Micorline 320/47Vinyl Ester/Vinyl Ester/Vinyl Ester


/%#)!+381.$4#32NSP-120 High Performance Epoxy CoatingEpoxy 100% Solids (1 or 2 Coats)


.+8#.!31.$4#32Polyeuro 8245Polyurea Hybrid (1, 2, or 3 Coats)

.+8#.1/3$Polycorp/PolymericSheet Lining, Rubber

.+8/%#().*.+PolySpec NovoRezEpoxy/Epoxy Novolac/Epoxy Novolac



1.3%#3)5%!1)-%.!3)-'2AmercoatEpoxy 100% Solids (1 or 2 Coats)

1%,)%1.!3)-'823%,2-#PCS-#1100Other

4%23.-2311.$28$1.3./-)3%$3'2ElastuffPolyurea Hybrid (1, 2, or 3 Coats)


()-.)-)-'2.1/.1!3).-Rhino TuffGripPolyurea Pure (1, 2, or 3 Coats)

.$$!!)-3.1/.1!3).-ClovaLinerEpoxy Novolac (1 or 2 Coats)


!4%1%)2%--#SauereisenEpoxy/Epoxy 100% Solids

(%16)- )++)!,2Epo-Phen Epoxy, Nova-Plate UHS EpoxyEpoxy Novolac (1 or 2 Coats)

/%#)!+381.$4#32-#PTU, Polyshield HT-100FPolyurea Pure (1, 2, or 3 Coats)

/1!81.0-#SpraywallUrethane/Urethane

3)1+)-'+.8$1.4/+#PermareOther


4/%1).11.$4#32Lining KoteUrethane/Urethane



(%,)#!+2ProdotexEpoxy Coal Tar/Epoxy Coal Tar

-%,%#.,/!-8-#Bridgeport Glass ArmorEpoxy 100% Solids (1 or 2 Coats)



.!3)-'2GripLineVinyl Ester/Vinyl Ester/Vinyl Ester



.+!3)+%1%%-#Volatile Free, Inc.Epoxy Novolac (1 or 2 Coats)

!22%1.1/.1!3).-WasserPolyurea Pure (1, 2, or 3 Coats)


.+5%1)-%.!3)-'2.1/.1!3).-ChemShieldEpoxy Flake Filled/Epoxy Flake Filled

(%23%13.-..,/.2)3%2ARC S1Epoxy/Epoxy 100% Solids

$5!-#%$.+8,%1.!3)-'23$ChemlineOther

1#.1/.78-#ArcorEpoxy 100% Solids (1 or 2 Coats)

3+!2)-%1!+2(%,)#!+2-#RezkladEpoxy 100% Solids (1 or 2 Coats)

5)+).--#EnvirolineEpoxy 100% Solids (1 or 2 Coats)

+.,%-3%1-!3).-!+Versi-LineVinyl Ester/Vinyl Ester/Vinyl Ester

+4% !3%1!1)-%!-$1.3%#3)5%.!3)-'2Marine AC80Epoxy/Epoxy/Epoxy

.6%12-$4231)!+DuromarEpoxy 100% Solids (1 or 2 Coats)

!1".+)-%.,/!-8PlasiteEpoxy Novolac (1 or 2 Coats)

%)+#.3%-3%1-!3).-!+!)-3CeilcoteEpoxy/Epoxy Flake Filled/Epoxy Flake Filled

%3#.Perlastic SGCoal Tar/Asphalt

(%,#.-3%1-!3).-!+3$Epo-chem RA 500MEpoxy/Epoxy Flake Filled/Epoxy Flake Filled

(%,1%!3-$)!3$ChemtuffEpoxy/Epoxy Flake Filled/Epoxy Flake Filled

-$4231)%2CIMUrethane Elastomeric (1 Coat)

.-2314#3).-823%,24//+8Co-Polymer SP2000REpoxy Novolac (1 or 2 Coats)

Linings for Steel Storage Tanks & Vessels Process Water, Brine,WastewaterSteel


Page 50

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&( $&('&(*!&%Corchem 204/204/204Epoxy/Epoxy/Epoxy

&(&%&*!%)&((&)!&%&%*( Corolon WEpoxy/Epoxy/Epoxy

&(&* ! (&($%&*!%)CortechEpoxy/Epoxy/Epoxy

&*%+)*(!)%Durabak SmoothUrethane/Urethane

(&-%/$()CrownCote No VOCEpoxy/Epoxy 100% Solids

$'%/&%ApexiorOther

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,&%*(%*!&%#!%*Devoe High Performance CoatingsEpoxy/Epoxy/Epoxy

+(&$(%HPL-2510 Epoxy 100% Solids (1 or 2 Coats)

%+(%+*+(!%&*Guardian - EX-2CEpoxy (1-2 Coats)/Urethane

%&%&('&(*!&%Chemclad SCEpoxy 100% Solids (1 or 2 Coats)

%,!(!%%*(%*!&%#!%*EnvirolineEpoxy Novolac (1 or 2 Coats)

%,!(&%$%*#(&**!,&*!%)%E-4000 One CoatZinc-Rich, Organic

&%&*EonCoatOther

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(&%($&(NovocoatEpoxy/Epoxy 100% Solids

!"(&**!,&*!%)FabickPolyurea Pure (1, 2, or 3 Coats)

#.(* %&!)*CemprotecEpoxy (1-2 Coats)/Acrylic (1-2 Coats)

&.%+)*(!)%Fox FX-70-9 Hydro Ester CoatingEpoxy 100% Solids (1 or 2 Coats)

&)*(%GacoFlex LM-60Urethane Elastomeric (1 Coat)

$!*(&+*)%Gem-Cote EP 100Epoxy 100% Solids (1 or 2 Coats)

#& %&!)Endura-FlexUrethane Elastomeric (1 Coat)

+#&)*!%*%Poly ChemEpoxy/Epoxy Flake Filled/Epoxy Flake Filled

$'#%85671/85671/85671Epoxy Phenolic (3 Coats)

%"#&('&(*!&%0&((&)!&%%!%(!%Penncoat 227Epoxy/Epoxy Novolac/Epoxy Novolac

()!*(&**!,&*!%)Heresite P-403LOther

! #%%*(%*!&%#%74 Chem-Temp Epoxy LiningEpoxy Novolac (1 or 2 Coats)

&$'&)!* %&!)CarbonSealEpoxy/Epoxy Novolac/Epoxy Novolac



2:25 PM Page 51

20

-$41.-.!3)-'2-#PermaSafe 100 Ceramic EpoxyEpoxy/Epoxy 100% Solids



-3%1-!3).-!+!)-3InternationalEpoxy 100% Solids (1 or 2 Coats)

.+8/%#4341!.!3)-'2PolySpec ThiokolEpoxy/Epoxy/Epoxy

.11.2).-.-31.+.3$Techni-Plus EN 25.3Epoxy/Epoxy Novolac/Epoxy Novolac

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.-%3!1/%#)!+3)%2Reilly Coal Tar EnamelCoal Tar/Asphalt

)#.1.,/!-8-#Micorline 320Epoxy/Epoxy 100% Solids


/%#)!+381.$4#32NSP-120 High Performance Epoxy CoatingEpoxy/Epoxy 100% Solids


.+8#.!31.$4#32Polyeuro 1050HUrethane Elastomeric (1 Coat)

.+8#.1/3$Polycorp/PolymericSheet Lining, Rubber

.+8/%#().*.+PolySpec ThiokolEpoxy/Epoxy/Epoxy



1.3%#3)5%!1)-%.!3)-'2Amercoat 253Epoxy Novolac (1 or 2 Coats)

1%,)%1.!3)-'823%,2-#PCS-#1100Other

4!-34,1.4/Precidium P-180D, Precidium 650DPolyurea Pure (1, 2, or 3 Coats)

4%23.-2311.$28$1.3./-)3%$3'2ElastuffPolyurea Hybrid (1, 2, or 3 Coats)


()-.)-)-'2.1/.1!3).-Rhino Extreme PWPolyurea Pure (1, 2, or 3 Coats)

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423+%4,.1/.1!3).-9100 SystemEpoxy/Epoxy/Epoxy

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(%16)- )++)!,2Dura-Plate UHS/Fast Clad EREpoxy/Epoxy 100% Solids

/%#)!+381.$4#32-#Polyshield HT-SL, Hi-E, HT-100FPolyurea Pure (1, 2, or 3 Coats)

/%%$.5%1%#!23.5%!2%823%,2SpeedCove Precast Cove Base SystemsOther

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%3!+)9)-'823%,23$TMS MetalizingThermal Spray



.!3)-'2GripLineEpoxy Novolac (1 or 2 Coats)



.+!3)+%1%%-#Volatile Free, Inc.Epoxy Novolac (1 or 2 Coats)

!22%1.1/.1!3).-WasserMCU Coal Tar/MCU Coal Tar/MCU Coal Tar

)+*.!)-3-#WilkoEpoxy Coal Tar High Build (1 or 2 Coats)


.+5%1)-%.!3)-'2.1/.1!3).-LiquaTileEpoxy 100% Solids (1 or 2 Coats)

(%23%13.-..,/.2)3%2ARC 791/CS2Epoxy/Epoxy 100% Solids

$5!-#%$(%,)#!+%#(-.+.')%2-#Sil-ActSiloxane/Siloxane

-$%*.1/.1!3).-Polafloor PURUrethane/Urethane

1#.1/.78-#ArcorEpoxy 100% Solids (1 or 2 Coats)

1)9.-!.+8,%1+..1)-'-#Epoxy Novolac 900Epoxy/Epoxy Novolac/Epoxy Novolac

1,.1()%+$PolymericaEpoxy/Epoxy Novolac/Epoxy Novolac

3+!2)-%1!+2(%,)#!+2-#ChemprufEpoxy/Epoxy Flake Filled/Epoxy Flake Filled

5)+).--#EnvirolineEpoxy Novolac (1 or 2 Coats)

+.,%-3%1-!3).-!+Versi-LineEpoxy/Epoxy Novolac/Epoxy Novolac

.6%12-$4231)!+DuromarEpoxy 100% Solids (1 or 2 Coats)

!1".+)-%.,/!-8SemstoneEpoxy 100% Solids (1 or 2 Coats)

%)+#.3%-3%1-!3).-!+!)-3CeilcoteEpoxy/Epoxy Flake Filled/Epoxy Flake Filled

%3#.Perslastic SGCoal Tar/Asphalt

(%,#.-3%1-!3).-!+3$Chem-tect RB 300Epoxy/Vinyl Ester/Vinyl Ester

(%,.823%,2CCS CSREpoxy/Epoxy Novolac/Epoxy Novolac

(%,!23%12-#Duraguard 500 SeriesVinyl Ester/Vinyl Ester/Vinyl Ester

(%,1%!3-$)!3$ChemtuffEpoxy/Epoxy Flake Filled/Epoxy Flake Filled

-$4231)%2CIMUrethane Elastomeric (1 Coat)

.-#1%3%.+43).-2)5.&()-.)-)-'2.1/Epoxy 700 PlusEpoxy 100% Solids (1 or 2 Coats)

.-2314#3).-823%,24//+8Eco-Polymer SC3300Epoxy/Epoxy Novolac/Epoxy Novolac

Secondary ContainmentConcrete


10/7/11 2:25 PM Page 52

21

#$# ,!%%#''#",&'!&ChemProof Polymers/PermaTecEpoxy/Epoxy 100% Solids

#$$&"(&'%&"Armorgard 500Epoxy/Epoxy 100% Solids

#%!#%$#%'#"Corchem 262/258/258Epoxy/Epoxy Novolac/Epoxy Novolac

#%# #"#'"%%#"#"'%# Corolon 3000 SeriesPolyurea Hybrid (1, 2, or 3 Coats)

#%%# "'%"'#" "Corro Hi-CoteEpoxy Novolac (1 or 2 Coats)

#'"(&'%&"Durabak/Durabak SmoothUrethane/Urethane

%*#%#%'#%&" #%#NovolacOther

%#&& %#('%$Dex-O-TexEpoxy (1-2 Coats)/Urethane

%#*"# ,!%&CrownCote No VOCEpoxy/Epoxy 100% Solids

"#%'!%Archco/DensoOther

$" ##%%#('&"Vaporseal DB, Remediate Moisture EmissionEpoxy 100% Solids (1 or 2 Coats)

!#"# "'#!$",Mult-E-Poxy 180/Multi-Thane 330 or 340Epoxy (1-2 Coats)/Urethane

(%#!%"DF-4301Epoxy 100% Solids (1 or 2 Coats)

'%',&'!&E100-NV5Epoxy/Epoxy Novolac/Epoxy Novolac

"(%"('(%"#'HiBuild - EX-2CEpoxy (1-2 Coats)/Urethane

"#"#%$#%'#"ChemcladEpoxy 100% Solids (1 or 2 Coats)

")%# ""'%"'#" "'EnvirolineEpoxy 100% Solids (1 or 2 Coats)

")%#"!"' %#'')#'"&"E-4000 One CoatSiloxane/Siloxane

#"#'EonCoatOther

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$#+,"'%"'#" HSO 98Epoxy/Epoxy Novolac/Epoxy Novolac

%#"%!#%NovocoatEpoxy Novolac (1 or 2 Coats)

( ! #!$",Duralkote 240Epoxy/Epoxy 100% Solids

%#'')#'"&FabickPolyurea Pure (1, 2, or 3 Coats)

+%'"# #&'CemprotecEpoxy (1-2 Coats)/Acrylic (1-2 Coats)

#+"(&'%&"FX-3110SW Chem Resist CtgEpoxy Novolac (1 or 2 Coats)

#'"&"Super UrethaneUrethane/Urethane

#&'%"GacoFlex LM-60Urethane Elastomeric (1 Coat)

%#"%#('&"NutracidEpoxy Novolac (1 or 2 Coats)

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#)'(&!$(#'$$!$&$Multiple brandsPolyurea Hybrid (1, 2, or 3 Coats)

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#(($#!$(#'#ICO Super GuardEpoxy Novolac (1 or 2 Coats)

#(($#!#(InternationalEpoxy Novolac (1 or 2 Coats)

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2(-, *-*7+$01,"Private LabelEpoxy/Epoxy Novolac/Epoxy Novolac

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"(%("-*7+$01(4(1(-,-%Rescrete RCCREpoxy/Epoxy 100% Solids

$*1$ *$"',-*-&($1Pelseal Liquid Viton FluoroelastomerOther

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-*7.$"'(-)-*PolySpec NovoRezEpoxy/Epoxy Novolac/Epoxy Novolac

-0,"Floor ArmorUrethane/Urethane

- 2(,&1PPC CoatingsOther

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0$+($0- 2(,&712$+1,"PCS-#1100Other

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0-2$"2(4$*--0(,(,&1(4'$12$02-,PF&L 3300CREpoxy/Epoxy Novolac/Epoxy Novolac

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4$,(,(,&712$+1Raven Lining SystemsEpoxy 100% Solids (1 or 2 Coats)

'(,-(,(,&1-0.-0 2(-,Rhino HybridPolyurea Hybrid (1, 2, or 3 Coats)

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3123**$2Rust Bullet StandardOther

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7.$6'$+(" *-0.ConcentrateOther

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