Best practices for coating and FRP inspections

Best Practices for Coating and FRP Inspections

Michael P. Yee [email protected]

NACE Coating Inspector Level 3 #50795

Richard Taraborelli P.E. [email protected]

RTConults PLLC AMI Conference: June 10, 2015

• Common issues with the longevity of coatings and FRP linings.

• Case Studies with successful FRP construction.

• The value of knowing what you are receiving.

Table of Contents

Industry Standards

• API- Applies mainly corrosion with steel and insulation.

• NACE/SSPC- the main publications for surface preparation and coating/lining application.

• ASME- Composites mainly with FRP

• ICRI- Concrete coatings and repair.

• ISO- International equivalent of NACE

Coating and Linings

In the realistic world:

Surface Preparation Issues (+50% failures easily)

Ambient Conditions/Application

Wrong specification for environment

50%

20%

30% 30%

Failures

Surface Prep. Wrong Spec. Bad Application

Common Operating Issues

• Chemicals and Concentration

• Presence of Trace Chemicals

• Ambient Conditions

• Upset Conditions

• Size of Solid Presents

• Temperature Cycling

Chemical Environment Vulnerabilities

Chlorine/Halogens

• Permeation and diffusion.

• Aggressive ion exchange (valence number).

• Lots of vulnerable compounds.

• Used to make many composites/elastomers

Sulfur/Sulfur Compounds

• Hardening and brittle effect on steel/rubber (N/L steel, cross-linkage).

• Permeation and diffusion.

• Localized chemical attack.

• Improper anchoring and supporting (no point loads)

• Physical damage (striking/improper installation).

• Qualified experienced installers.

Above Ground Installation

Steel Tanks Internally Lined w/ FRP

Resin: Epoxy Novolac Resin for Tanks &

EN Formulated Steel Lining Systems

Case Study: Spent Sulfuric Acid Tanks

Environment:

Up to 80% Sulfuric Acid w/ Dissolved Cl2

Design Expectorations:

@ Max Temp = 140F

Lining Life = 10 - 15 yrs.

Recommend 5-yr. inspect intervals

Case Study: Spent Sulfuric Acid Service

•

•11.

Storage Tank in 36% phosphoric acid

Temp= Ambient

Age = 35+ years

Pulp/Paper Manufacturing

Design Expectorations:

Case Study: Phosphoric Acid Used in Water Treatment

Still in Service

“You can expect what you inspect- nothing more.”

- John H. Mallinson

• You must know what you require and know how to identify it.

• Quality Inspections are necessary.

Let the Results Speak for Themselves

What Inspections Find

Viable Contractor QC Program?

• Not viable due to motivation.

• Same figurehead= production/time efficiency

• Quality costs money

• In our experience, 90% of FRP field jobs are not delivered on time.

10x magnification of coating while raining

What Price Offers Service Life 10 years Life 15 years Life 30 years+

Service Rating Oilfield Service

Chemical Service/Treatment

ASME RTP-1 Tanks

Cost to Steel Ratio

1.2 Ratio 1.5 Ratio 2.0 Ratio

ASME RTP-1 DOES NOT GUARANTEE QUALITY (Requires Verification)

Issues Affecting Laminate Performance

Examples:

Poor curing (initial)

Diffusion

Applied stress

Embrittlement

Micro-cracking

Swelling

Impact

Environmental cycling

Aging (Time) Lack of Fusion and Poor Fit

Nozzle Misalignment

Air Voids Defects

More Issues

Poor Workmanship

Compliance

• Drawings

• Design Specifications

• Materials (lot numbers)

• Ambient Conditions

• Standards (ASME RTP-1)

• Verify Quality Control

• Pass/Fail Criteria

Quality Assurance Through Inspections

FINAL INSPECTION

Documents Review

Non Conformance

Reports

Cutouts

Resin Cure

Peel Adhesion Test (picture)

Dimensions and thickness

Holiday Testing

Quality is What Will Last

• Proper Material Selection for Service

• Comprehensive and descriptive specifications

• Qualify experienced applicators

• Quality assurance throughout the process

• Budget for Inspection on Coating/nonmetallic projects

Lessons Learned Keys to a Successful Project

“You can expect what you inspect - nothing more.” - John H. Mallinson

“I prefer a composite bike to a steel one. “ - Michael Yee