marine painting manual - gbv
TRANSCRIPT
Marine Painting Manual A. M. Berendsen TNO Paint Research Institute Delft, The Netherlands
Ш^м Netherlands Organization for Applied Scientific Research, Delft
CMIO National Foundation for the l € | M | 5 € Co-ordination of Maritime Research, = = = = Г Rotterdam
Graham & Trotman A member of the Kluwer Academic Publishers Group LONDON/DORDRECHT/BOSTON
CONTENTS page
CHAPTER I: THE PROTECTION OF DIFFERENT PARTS OF SHIPS UNDER CONSTRUCTION
1.1. Introduction 1
1.2. Protective methods 1
1.2.1. PAINTING IN SECTION BUILDING (BLOCK PAINTING) 5 1.2.1.1 Operations in the coating hall 5 1.2.1.2 Operations on the slipway and during final construction (fitting-out) 5 1.2.1.3 Summary of painting in section building 6
1.2.2. BUILDING IN THE SHOP-COAT 6 1.2.2.1 Operations in the section hall 6 1.2.2.2 Operations on the slipway and during final construction 6 1.2.2.3 Summary of building in the shop-coat 8
1.3. Paint systems for the separate parts of a ship in new construction 8
1.3.1. UNDERWATER PARTS 8 1.3.1.1 Requirements 8 1.3.1.2 Suitable paint systems 9 1.3.1.3 Procedures 10
1.3.2. THE BOOTTOP ZONE 10 1.3.2.1 Requirements 10 1.3.2.2 Suitable paint systems 11
1.3.3. TOPSIDES AND EXTERIOR PARTS ON DECK (SUPERSTRUCTURES) 11 1.3.3.1 Requirements 11 1.3.3.2 Suitable paint systems 12
1.3.4. MAIN DECKS AND GANGWAYS 13 1.3.4.1 Requirements 13 1.3.4.2 Suitable paint systems 13 1.3.4.3 Procedures 14
1.3.5. DRY-CARGO HOLDS 1.3.5.1 Requirements 1.3.5.2 Suitable paint systems
1.3.6. TANKS 1.3.6.1 Introduction 1.3.6.2 Procedures 1.3.6.3 Requirements 1.3.6.4 Suitable paint systems
a. Water ballast tanks b. Fuel tanks с Lubricating oil tanks d. Drinking (potable) water tanks e. Water tanks other than ballast water or drinking water tanks f. Cargo tanks
1.3.7. ENGINE ROOMS 1.3.7.1 Requirements 1.3.7.2 Suitable paint systems
1.3.8. 'WET' ACCOMMODATION AND SERVICE SPACES 1.3.8.1 Requirements 1.3.8.2 Suitable paint systems
1.3.9. DRY ACCOMMODATION SPACES 1.3.9.1 Introduction 1.3.9.2 Requirements 1.3.9.3 Suitable paint systems
15 15 16
16 16 17 21 22 22 23 23 24 24 25
27 27 27
28 28 28
28 28 29 29
APPENDIX I .A. : SUMMARY OF THE PROTECTION OF THE SEPARATE PARTS OF A SHIP UNDER CONSTRUCTION
APPENDIX l.B. : HULL ROUGHNESS
APPENDIX l.C. : PART OF A RESISTANCE (COMMODITY) LIST
30
36
39
CHAPTER II: THE PROTECTION OF DIFFERENT PARTS OF OFFSHORE STRUCTURES UNDER CONSTRUCTION
2.1. Introduction 50
2.2. Building/Painting of fixed offshore platforms 50
2.2.1. INTRODUCTION 50
2.2.2. PROTECTIVE METHODS 51
2.3. Protective systems for the separate parts of offshore platforms 54 in new construction
2.3.1.
2.3.2. 2.3.2.1 2.3.2.2
2.3.3. 2.3.3.1 2.3.3.2
2.3.4. 2.3.4.1 2.3.4.2
2.3.5. 2.3.5.1 2.3.5.2
2.3.6. 2.3.6.1 2.3.6.2
2.3.7. 2.3.7.1 2.3.7.2
2.3.8. 2.3.8.1 2.3.8.2
GENERAL
UNDERWATER (SUBMERGED) ZONE Requirements Suitable protective systems
TIDAL AND SPLASH ZONE Requirements Suitable protective systems a. Silica-filled (flint-reinforced) compounds b. Monel 400 (nickel-copper alloy) sheeting с Glass-flake reinforced epoxy coatings d. Thick rubber or neoprene (synthetic rubber) coatings e. Bituminous wrappings
UNDERDECK AREA Requirements Suitable protective systems
ATMOSPHERIC ZONE (TOPSIDE FACILITIES) Requirements Suitable protective systems
DECKS (WORKING DECKS AND HELIDECKS) Requirements Suitable protective systems
HIGH TEMPERATURE AREAS Requirements Suitable protective systems
TANKS Requirements Procedures
54
54 54 55
55 55 56 56 56 56 57 57
57 57 57
58 58 58
59 59 60
60 60 60
61 61 61
2.3.8.3. Suitable protective systems 62 a. Drinking (potable) water tanks 62 b. Tanks for crude oil/ballast water/drilling mud/drilling water/ 62
fresh water с Tanks for fuel oil/white petroleum products 62 d. Tanks for chemicals and solvents 62 e. Tanks for methanol (and other strong solvents) 63
2.3.9. RISERS 63 2.3.9.1 Requirements 63 2.3.9.2 Suitable protective systems 64
2.3.10. SEA WATER PIPING SYSTEMS 64 2.3.10.1 Requirements 65 2.3.10.2 Suitable protective systems 65
2.3.11. SUPPLIERS EQUIPMENT 65
APPENDIX 2.A. : PART OF NACE-STANDARD RP 0176-83, RECOMMENDED 66 PRACTICE, CORROSION CONTROL OF STEEL, FIXED OFFSHORE PLATFORMS ASSOCIATED WITH PETROLEUM PRODUCTION
APPENDIX 2.B. : BUILDING/PAINTING OPERATIONS FOR MODULES 70
APPENDIX 2.C. : WEIGHT LOSSES OF STEEL 37 DUE TO CORROSION IN 75 VARIOUS ENVIRONMENTS
APPENDIX 2.D. : EXAMPLES OF CURRENT SYSTEMS FOR THE ATMOSPHERIC 76 ZONE
CHAPTER III: SURFACE PREPARATION 3.1. General 77
3.2. Surface preparation of steel 77
3.2.1. DEGREASING 77
3.2.2. REMOVAL OF MILL SCALE BY WEATHERING 78
3.2.3. MECHANICAL SURFACE PREPARATION 79 3.2.3.1 Hand-cleaning 79 3.2.3.2 Mechanical-cleaning (power-tool cleaning) 79 3.2.3.3 Preparation grade 80
3.2.4. BLAST-CLEANING 82 3.2.4.1 Methods 83 3.2.4.2 Abrasives 87 3.2.4.3 Surface roughness 90 3.2.4.4 Preparation grade 91 3.2.4.5 Surface contamination by water soluble salts 95 3.2.4.6 Working conditions
3.2.5. FLAME-CUTTING 95
3.2.6. PICKLING 96 3.2.6.1. Sulphuric acid/phosphoric acid method 97 3.2.6.2. Hydrochloric acid/phosphoric acid method 97 3.2.6.3. Phosphoric acid/phosphoric acid method 97
3.2.7. THE USE OF RUST CONVERTORS 97
3.2.8. COMPARISON OF PRETREATMENT METHODS FOR STEEL 98
3.2.9. RECENT ISO STANDARDS 98
3.3. Surface preparation of galvanized steel 99
3.3.1. SWEEP-BLASTING (for hot-dip galvanized steel) 100
3.3.2. CHEMICAL PRETREATMENT 100
3.3.3. MECHANICAL CLEANING 100
3.4. Surface preparation of aluminium 101
APPENDIX 3.A. : PROFILES (ROUGHNESS) PRODUCED BY SOME ABRASIVES 102
APPENDIX 3.B. : SURFACE PROFILE (ROUGHNESS) OF ABRASIVE BLAST- 103 CLEANED SURFACES
APPENDIX 3.C. : GRADES OF SURFACE PREPARATION BY BLAST-CLEANING 105
CHAPTER IV: PAINTS AND PAINT SYSTEMS
4.1. Definitions; aims of painting 106
4.2. Paint systems 107
4.3. Composition of paints 109
4.3.1. BINDERS 109
4.3.2. PIGMENTS AND EXTENDERS 110
4.3.3. SOLVENTS AND THINNERS 110
4.4. Classification of paints 112
4.4.1. CLASSIFICATION OF PAINTS ACCORDING TO DRYING MECHANISM 113 4.4.1.1 Physically drying paints 113 4.4.1.2 Chemically drying paints 114
4.5. Important types of paint used in the building of ships 115 and offshore structures
4.5.1. 4.5.1.1 4.5.1.2
4.5.1.3
4.5.2. 4.5.2.1 4.5.2.2 4.5.2.3 4.5.2.4 4.5.2.5 4.5.2.6 4.5.2.7 4.5.2.8
PRIMERS Common primers for steel Special primers for steel a. Prefabrication primers b. Touch-up primers с Holding primers d. System primers e. Universal primers Primers for non-ferrous metals
PAINT MATERIALS, CLASSIFIED ACCORDING TO THE BINDER TYPE Paints based on drying oils Bituminous paints Alkyd resin paints Chlorinated rubber paints Vinyl paints Epoxy paints Coal-tar epoxy paints Polyurethane paints
115 115 117 117 118 118 118 118 118
119 119 120 121 122 123 124 127 128
4.5.2.9 Polyurethane tar paints 129 4.5.2.10 Zinc silicate paints 129 4.5.2.11 Acrylic paints 131 4.5.2.12 Unsaturated polyester resin coatings 132 4.5.2.13 Silicon resin paints 132 4.5.2.14 Dispersion paints 132
4.5.3. SPECIAL PRODUCTS, CLASSIFIED ACCORDING TO THEIR FUNCTIONS 133 4.5.3.1 Varnishes (clear coatings) 133 4.5.3.2 Anti-fouling paints 134
a Soluble-matrix anti-fouling paints 136 b. Contact-matrix anti-fouling paints 136 с Self-erodable (polishing, ablative) anti-fouling paints 137 d. Future anti-foulings 137
4.5.3.3 Non-slip/non-skid paints 138 4.5.3.4 Paints with laminar (flake) pigments 139 4.5.3.5 Heat-resistant paints 139 4.5.3.6 Fire-retardant and fire-resistant paints 140
4.5.4. DATASHEETS 141
4.5.5. TABULAR COMPARISON OF THE DIFFERENT PAINT TYPES 143
APPENDIX 4.A.
APPENDIX 4.B.
APPENDIX 4.C.
PIGMENTS AND EXTENDERS 145
SOLVENTS AND DILUENTS (THINNERS) 150
CLASSIFICATION OF PAINTS ACCORDING TO DRYING 151 MECHANISM
APPENDIX 4.D. : SPECIAL PRIMERS FOR STEEL 152
APPENDIX 4.E. : EXAMPLE OF A DATA SHEET FOR A COAL-TAR EPOXY PAINT 153
APPENDIX 4.F. : COMPARISON OF PAINT TYPES ACCORDING TO THEIR BINDER 156 COMPOSITION
APPENDIX 4.G. : FOULING AND ANTI-FOULING 160
CHAPTER V : PREFABRICATION (SHOP) PRIMERS 5.1. Introduction 167
5.2. Requirements for prefabrication (shop) primers 168
5.3. Blast-cleanliness and surface roughness 169
5.3.1. BLAST-CLEANLINESS 169
5.3.2. SURFACE ROUGHNESS 169
5.4. Dry film thickness of the prefabrication (shop) primer 170
5.5. Behaviour during automatic welding and flame-cutting 170
5.6. Common types of prefabrication (shop) primers 171
5.6.1. ZINC DUST CONTAINING PREFABRICATION PRIMERS 171 5.6.1.1 Composition 171 5.6.1.2 Dry film thickness, anti-corrosive properties, recoatability 172 5.6.1.3 Welding (flame-cutting) fumes 173 5.6.1.4 Comparison of zinc-epoxy and zinc silicate prefabrication (shop) 173
primers
5.6.2. ZINC-FREE PREFABRICATION PRIMERS 173 5.6.2.1 Composition 173 5.6.2.2 Dry film thickness, anti-corrosive properties, recoatability 174 5.6.2.3 Welding (flame-cutting) fumes 175 5.6.2.4 Comparison of zinc dust free epoxy prefabrication primers with 175
reinforced wash primers
5.7. Summary 175
APPENDIX 5.A. : PROPERTIES OF THE MAIN TYPES OF PREFABRICATION 177 (SHOP) PRIMERS
CHAPTER VI: STORAGE AND APPLICATION OF PAINTS
6.1. Storage 178
6.2. Preparation before application 179
6.3. Application methods 180
6.3.1. BRUSHING 180
6.3.2. ROLLING 181
6.3.3. CONVENTIONAL SPRAYING (AIR SPRAYING) 182
6.3.4. AIRLESS SPRAYING 183
6.4. Application conditions 185
6.4.1. ATMOSPHERIC HUMIDITY 185
6.4.2. TEMPERATURE 187
6.4.3. OTHER CONDITIONS 187
6.5. Supervision/Inspection 189
APPENDIX 6.A. : RELATION BETWEEN AIR TEMPERATURE AND MAXIMUM 190 WATER VAPOUR CONTENT
APPENDIX 6.B. : RELATION BETWEEN DEW POINT, AIR TEMPERATURE AND 191 RELATIVE HUMIDITY
APPENDIX 6.C. : GRAPH SHOWING THE RELATIONSHIP BETWEEN AIR 192 TEMPERATURE, RELATIVE HUMIDITY AND DEW POINT
CHAPTER VII: MAINTENANCE OF PAINT SYSTEMS
7.1. General 193
7.2. Maintenance operations on the various parts of ships 197
7.2.1. GENERAL 197
7.2.2. MAINTENANCE OF THE UNDERWATER HULL 198
7.2.3. MAINTENANCE OF TANKS 200
7.3. Offshore maintenance 201
APPENDIX 7.A. : RELATION BETWEEN THE DISTRIBUTION OF RUST SPOTS AND 203 THE AREAS TO BE REPAIRED
APPENDIX 7.B. : AREA INVOLVED WHEN TOUCHING-UP A RUST SPOT 204
APPENDIX 7.C. : DAMAGED AREA CAUSED BY SPOT-BLASTING 205
8.1. Introduction 206
8.2. The contract painting speciflcation (painting schedule) 207
8.2.1. BASIC CLAUSES 207
8.2.2. SUPPLEMENTARY CLAUSES 208
8.3. The paint list 210
8.4. The checklist 210
8.5. The maintenance painting schedule 210
APPENDIX 8.A. : EXAMPLE OF CONTRACT PAINTING SPECIFICATION 212 (PAINTING SCHEDULE) FOR A SHIP'S NEW BUILD
APPENDIX 8.B. : EXAMPLE OF A PART OF A PAINT LIST FOR SHIP'S 215 NEW BUILD
APPENDIX 8.C. : CHECKLIST OF A SHIP 217
CHAPTER IX : QUALITY ASSURANCE, QUALITY CONTROL, TESTING AND INSPECTION
9.1. Introduction 220
9.2. Quality plans 220
9.3. Quality control 221
9.4. Testing (inspection) methods 222
9.4.1. GENERAL 222
9.4.2. INSPECTION OF EQUIPMENT 222
9.4.3. SUBSTRATE INSPECTION PRIOR TO SURFACE PREPARATION 223
9.4.4. MEASUREMENT OF AMBIENT CONDITIONS AND SUBSTRATE 223 TEMPERATURES
9.4.5. ABRASIVES 224
9.4.6. STEEL SURFACE CONDITIONS 225 9.4.6.1 Surface cleanliness (finish) 225 9.4.6.2 Surface roughness 225 9.4.6.3 Water soluble salts 226 9.4.6.4 Grease 227 9.4.6.5 Dust 227
9.4.7. PAINTS 227 9.4.7.1 Film thickness 228
a. Agreements 228 b. Calculation of the quantity of paint 228 с Measurement of wet film thickness 229 d. Measurement of dry film thickness on smooth substrates 230 e. Measurement of dry film thickness on blast-cleaned steed 231
9.4.7.2 Cure 231 9.4.7.3 Adhesion 232 9.4.7.4 Holiday (pinhole) detection 233
9.4.8. ASSESSMENT OF COATING DEFECTS 234
APPENDIX 9.A. : CURRENT STANDARDS USED FOR THE ASSESSMENT OF 235 COATING DEGRADATION (DEFECTS)
APPENDIX 9.B. : SOME EXAMPLES OF (PARTS) OF STANDARDS USED FOR 236 THE ASSESSMENT OF COATING DEFECTS
CHAPTER X : CATHODIC PROTECTION 10.1. Corrosion 240
10.2. Galvanic corrosion 241
10.3. Other forms of corrosion 241
10.4. Principles of cathodic protection 242
10.5. Potential and current density 242
10.6. Cathodic protection systems 243
10.6.1. SACRIFICIAL (GALVANIC) ANODE SYSTEMS 244
10.6.2. IMPRESSED CURRENT SYSTEMS 245
10.7. Cathodic protection of ship's hulls 246
10.8. Cathodic protection of fixed offshore structures 248
10.9. Cathodic protection of tanks 249
10.10. Damage by stray currents 251
10.11. Control and adjustment of cathodic protection systems 252
10.12. Cathodic protection and paint 253
10.12.1. EFFECT OF CATHODIC PROTECTION ON PAINTS 253
10.12.2. PAINTS SUITABLE FOR USE WITH CATHODIC PROTECTION 254
APPENDIX 10.A. : CORROSION CELL (STEEL WITH BROKEN MILL SCALE IN 256 SEA WATER)
APPENDIX 10.B. : POTENTIAL OF METALS IN SEA WATER 257
APPENDIX 10.C. : PRINCIPLES OF CATHODIC PROTECTION 258
APPENDIX 10.D. : COMPARISON OF CATHODIC PROTECTION SYSTEMS 259
APPENDIX 10.E. : CHARACTERISTICS OF SOME ANODE MATERIALS 260
APPENDIX 10.F. : QUANTITY OF ANODE MATERIAL TO BE USED (GALVANIC CATHODIC PROTECTION SYSTEM)
APPENDIX 1 O.G. : AVOIDANCE OF DAMAGE BY STRAY CURRENTS 262
APPENDIX 10.H. : RELATIONSHIP BETWEEN TOTENTIAL, DEGREE OF 264 CORROSION AND SECONDARY PHENOMENA
CHAPTER X I : HEALTH SAFETY AND THE ENVIRONMENT
11.1. Introduction 265
11.2. Some important characteristics 265
11.2.1. FLASHPOINT 266
11.2.2. LOWER EXPLOSIVE LIMIT 266
11.2.3. UPPER EXPLOSIVE LIMIT 266
11.2.4. EXPLOSIVE RANGE 267
11.2.5. SELF-IGNITION TEMPERATURE 267
11.2.6. TLV(MAC) 267
11.3. Safety hazards 268
11.3.1. ELECTRICAL HAZARDS 268
11.3.2. MECHANICAL (PHYSICAL) HAZARDS 269
11.3.3. FIRE HAZARDS 270
11.3.3.1 Solvents, ready-to-use paints, etc. 270 11.3.3.2 Deposits in dry spray-booths 270 11.3.3.3 Waste materials 270
11.3.4. EXPLOSION HAZARDS 270 11.3.4.1 Mixtures of solvent vapour and air 270 11.3.4.2 Spray mist and air suspended combustible dust 271
11.4. Occupational health hazards 271
11.4.1. ASPHYXIATION 271
11.4.2. WORKING AT HIGH TEMPERATURES 272
11.4.3. EXPOSURE TO NOISE 272
11.4.4. EXPOSURE OF THE RESPIRATORY TRACT TO HARMFUL SUBSTANCES 272
11.4.5. EXPOSURE OF THE SKIN TO HARMFUL SUBSTANCES 272
11.4.6. EXPOSURE OF THE EYES TO HARMFUL SUBSTANCES 273
11.4.7. EXPOSURE OF THE DIGESTIVE TRACK TO HARMFUL SUBSTANCES 273
11.5. The prevention of risk 274
11.5.1. ORGANIZATION OF THE WORK TO BE CARRIED OUT 274
11.5.2. PROCEDURES 274
11.5.3. INSTRUCTION AND TRAINING OF THE WORKFORCE 274
11.5.4. SELECTION, MAINTENANCE AND USE OF EQUIPMENT 275
11.5.5. SELECTION OF SURFACE PREPARATION TECHNIQUES 275
11.5.6. SELECTION OF PAINTS AND THINNERS 276
11.5.7. SELECTION OF PAINT APPLICATION TECHNIQUES 276
11.5.8. ELIMINATION OF IGNITION SOURCES 276
11.5.9. VENTILATION 277
11.5.10. PROTECTIVE CLOTHING, GLOVES, RESPIRATORS ETC. 280
11.5.10.1 Clothing 280 11.5.10.2 Aprons 281 11.5.10.3 Gloves 281 11.5.10.4 Footwear 281 11.5.10.5 Respiratory protection 282 11.5.10.6 Eye protection 282 11.5.10.7 Noise protection 283 11.5.10.8 Skin protection 283 11.5.10.9 Protection of the head 283
11.5.11. CLOAK ROOMS AND SANITARY FACILITIES 284
11.5.12. PERSONAL HYGIENE 284
11.5.13. TOTAL ABSTINENCE AT WORK 284
11.6. Some activities characterized by enhanced risks 285
11.6.1. STORAGE OF FLAMMABLE PAINTS AND THINNERS 285
11.6.2. APPLICATION OF ANTI-FOULINGS 285
11.6.3. WORKING IN CONFINED SPACES 286
11.6.3.1 The main hazards 286 11.6.3.2 Organization 287 11.6.3.3 Accessibility 287 11.6.3.4 Procedures, measurements etc. before entering a confined space 287 11.6.3.5 Temporary lighting 288 11.6.3.6 Temporary heating 288 11.6.3.7 Equipment 288 11.6.3.8 Spot cleaning 289
11.6.4. WELDING AND FLAME-CUTTING OF PAINTED STEEL 289
11.7. Some environmental aspects 289
11.8. Some relevant dutch compulsory rules and regulations 290
11.8.1. SAFETY AND INDUSTRIAL HEALTH 291
11.8.2. PREVENTION OF ENVIRONMENTAL POLLUTION 292
11.9. International compulsory regulations and rules 293
APPENDIX H.A. : BOILING POINTS, FLASH POINTS, EXPLOSION LIMITS, 294 IGNITION TEMPERATURES AND TLV'S (MAC'S) OF VARIOUS SUBSTANCES
APPENDIX ll.B. : DEFINITIONS THRESHOLD LIMIT VALUES (TLVS) 295
APPENDIX 11 .C. : SAFE WORKING IN CONFINED SPACES 297