Top Banner
Coating considerations for Asset Protection RINA Conference London Marine Renewable & Offshore Wind Energy 21 st - 23rd April 2010 Alan Guy / Rodney Towers Safinah Limited
32

Coating considerations for Asset Protection RINA Conference London Marine Renewable & Offshore Wind Energy 21 st - 23rd April 2010 Alan Guy / Rodney Towers.

Jan 15, 2016

Download

Documents

Junior Matthews
Welcome message from author
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
Page 1: Coating considerations for Asset Protection RINA Conference London Marine Renewable & Offshore Wind Energy 21 st - 23rd April 2010 Alan Guy / Rodney Towers.

Coating considerations for

Asset Protection

RINA Conference London

Marine Renewable & Offshore Wind Energy

21st - 23rd April 2010

Alan Guy / Rodney Towers

Safinah Limited

Page 2: Coating considerations for Asset Protection RINA Conference London Marine Renewable & Offshore Wind Energy 21 st - 23rd April 2010 Alan Guy / Rodney Towers.

Offshore Wind Energy UK

UK target 2020

15% of energy from renewables

Estimated that the UK has 33% wind resources in Europe

Offshore to be primary expansion zone. Wind is more constant and predictable

Jan 2010

UK govt awards Round 3 wind farm zones / 9 successful bidders

£75bn programme for offshore wind farm projectsSource: BWEA

UK Round 3 Wind farm zones

Page 3: Coating considerations for Asset Protection RINA Conference London Marine Renewable & Offshore Wind Energy 21 st - 23rd April 2010 Alan Guy / Rodney Towers.

Offshore Wind Energy UKMW Capacity Plan

MW Capacity 2010 ( Feb ) 2015 2020

Operational 688

Under construction & planned

6,000

Zones awarded 33,000

Number of turbine towers ( est )

228 2,000 ± 11,000

Total Operational Capacity 10 year plan 40,000 MW

Largest Offshore Capacity Plan in Europe

This is a major growth business sector

Source RenewableUK

Page 4: Coating considerations for Asset Protection RINA Conference London Marine Renewable & Offshore Wind Energy 21 st - 23rd April 2010 Alan Guy / Rodney Towers.

Offshore Wind Towers

Typical 3 MW Tower structure External m2

Internal m2

Totalm2

Painting area per tower 1250 1250 2500

Painting cost per tower

EP / PU multi layer @ € 5 / m2 € 6250 € 6250 € 12,500

Total cost Paint + Application

up to € 25 / m2 *

€ 31,250 € 31,250 € 60 – 70,000 per tower

* Source JPCL / Muhlberg March 2010

Painting Offshore Wind Towers

Page 5: Coating considerations for Asset Protection RINA Conference London Marine Renewable & Offshore Wind Energy 21 st - 23rd April 2010 Alan Guy / Rodney Towers.

Offshore Wind TowersStructural protection in relation to project costs

Installation cost per MW € 3.3 mill

Installation cost per tower / 3MW € 10 mill

Painting cost ( P+A ) per tower € 60 – 70,000

Paint + Application as % tower installation cost

0.6 – 0.7%

Typical Wind Tower Structure

Factory painting + site erection painting ˂ less than 1% of installed cost

Page 6: Coating considerations for Asset Protection RINA Conference London Marine Renewable & Offshore Wind Energy 21 st - 23rd April 2010 Alan Guy / Rodney Towers.

Offshore Wind TowersStructural protection in relation to project costs

Tower structures 2010 ( Feb ) 2015 2020

No. of Tower structures 228 2,000 11,000

Painting areas

2500 m2 per 100m tower 0.57 mill m2 5 mill m2 27.5 mill m2

Painting costs

Paint + Application€ 60 – 70,000 per tower

€14-16 mill €120-140 mill € 660-770 mill

If the build specification fails to performfailure repetition can multiply by the number of towers in the field

Overview Painting areas & costs

Page 7: Coating considerations for Asset Protection RINA Conference London Marine Renewable & Offshore Wind Energy 21 st - 23rd April 2010 Alan Guy / Rodney Towers.

Offshore Wind Tower Fieldsoffshore repairs

Coatings unfortunately can fail

Page 8: Coating considerations for Asset Protection RINA Conference London Marine Renewable & Offshore Wind Energy 21 st - 23rd April 2010 Alan Guy / Rodney Towers.

Offshore Wind Tower Fieldsoffshore repairs

Cost Problem

Access to offshore location

...not by road

....but

... by boat or barge

Page 9: Coating considerations for Asset Protection RINA Conference London Marine Renewable & Offshore Wind Energy 21 st - 23rd April 2010 Alan Guy / Rodney Towers.

Offshore Wind Tower Fieldsoffshore repairs

Cost Problem Access to repair the coated surface

Staging difficult to erect & dismantle

Page 10: Coating considerations for Asset Protection RINA Conference London Marine Renewable & Offshore Wind Energy 21 st - 23rd April 2010 Alan Guy / Rodney Towers.

Coating repairs

repeat

repeat

repeat

Offshore Wind Towers The coating repair cost multiplier

Operational cost problem

likely to be out of proportion

Page 11: Coating considerations for Asset Protection RINA Conference London Marine Renewable & Offshore Wind Energy 21 st - 23rd April 2010 Alan Guy / Rodney Towers.

Offshore Wind Towersoffshore repair costs

Tower structures 2010 ( Feb ) 2015 2020

No. of Tower structures 228 2,000 11,000

Total Painting area

2500 m2 per 100m tower 0.57 mill m2 5 mill m2 27.5 mill m2

Total Painting cost

Paint + Application€ 60 – 70,000 per tower

€14-16 mill €120-140 mill € 660-770 mill

Assume 3% area failure 17,100 m2 150,000 m2 825,000 m2

Offshore repair cost up to €1000/ m2 € 17 mill € 150 mill € 825 mill

To repair only 3% area failure could cost more than the total initial cost of painting

Page 12: Coating considerations for Asset Protection RINA Conference London Marine Renewable & Offshore Wind Energy 21 st - 23rd April 2010 Alan Guy / Rodney Towers.

Coating Breakdown

Coating performance failures can occur because of one or more of the following:– Design

– Product specification/selection

– Product quality

– Management processes

– Preparation/application

– Maintenance

– Repairs

– Climate/environmental control

– Worker skill

Product quality is rarely the cause of failure

Page 13: Coating considerations for Asset Protection RINA Conference London Marine Renewable & Offshore Wind Energy 21 st - 23rd April 2010 Alan Guy / Rodney Towers.

Coating breakdownproblems for Asset Owner / Field Manager

Design, applicationSpecification ? System selection ? Application issues ?

Page 14: Coating considerations for Asset Protection RINA Conference London Marine Renewable & Offshore Wind Energy 21 st - 23rd April 2010 Alan Guy / Rodney Towers.

Coating breakdownproblems for Asset Owner / Field Manager

Bad spray application

Sharp edges

Stress cracking in dry film

Photos ABS, Houston

Page 15: Coating considerations for Asset Protection RINA Conference London Marine Renewable & Offshore Wind Energy 21 st - 23rd April 2010 Alan Guy / Rodney Towers.

Considerations for achieving long term coating performance

Purpose of coating systemAdopt the Functional Specification concept in design phase

Key point – performance 15 - 20 years or 35 - 40 years

Choose between multi layer 3 – 5 coat epoxy / p/urethane system

thermally sprayed Zn/Al + sealer/epoxy topcoats

‘green’ product 2–3 coat solvent free epoxy system

Asset Owner / Field Manager undertake independent technical evaluation of Paint Specification in Contract proposal prior to Contract agreement

Page 16: Coating considerations for Asset Protection RINA Conference London Marine Renewable & Offshore Wind Energy 21 st - 23rd April 2010 Alan Guy / Rodney Towers.

Offshore Wind Towers three different environmental zones

Upper section - atmosphericblades, turbine, housings & structureCoating - durable, anti-corrosive

Lower section – splash / tidaltower structureCoating - durable, anti-corrosive

Bottom section– tidal/immersed/buried tower structureCoating - anti-corrosive, anti-fouling

Splash zone is the most critical

Page 17: Coating considerations for Asset Protection RINA Conference London Marine Renewable & Offshore Wind Energy 21 st - 23rd April 2010 Alan Guy / Rodney Towers.

Offshore Wind Towers Coating selection

Structures similar to rigs, platforms and

ships

Difference unmanned

difficult to monitor/assess

Requirementslong term performance

suitable for fabrication process

suitable for range of environment

ease of repair

Needscare in selection

quality application

Page 18: Coating considerations for Asset Protection RINA Conference London Marine Renewable & Offshore Wind Energy 21 st - 23rd April 2010 Alan Guy / Rodney Towers.

Offshore Wind Towers Coating selection

Principal methodology

ISO 12944-2

Defines corrosion category of site by rate of steel loss

Combine category with required durability to select generic coating schemes

– Non-immersed areas C5-M applies

– Immersed areas Im-2 applies

– ISO 20340 further defines requirements for high durability systems

Zone mm / yrSplash 0.4

Tidal 0.25

Immersed 0.2

Page 19: Coating considerations for Asset Protection RINA Conference London Marine Renewable & Offshore Wind Energy 21 st - 23rd April 2010 Alan Guy / Rodney Towers.

Offshore Wind Towers Coating selection

schemes selected should have proven track records in the field

C5 Category Im-2 Category

3-6 coats EP + PU Total 300-500 microns

1-2 coats of solvent free EP Total 800 microns

3-5 coats Zinc silicate + EP + PU Total 300-400 microns

2-3 coats high solids EP Total 800 microns

1-2 coats solvent free EP Total 800 microns

2 coats glass flake EP Total 1000 microns

Coastal / offshore areas with high salinity

sea or brackish water

Generic 15 year maintenance free systems

Page 20: Coating considerations for Asset Protection RINA Conference London Marine Renewable & Offshore Wind Energy 21 st - 23rd April 2010 Alan Guy / Rodney Towers.

Offshore Wind Towers Coating system for 30-40 years protection

Metallization has now achieved 30 – 40 years low maintenance protection on offshore oil & gas structuresThe cost and application speed for systems which include this process

are now close to or the same as for multi layer organic coating systems

The reasons are a combination of

New alloy materials

New technology spray equipment

Contractors improved ability to control the application environment

The current trend in Europe is to

thermally spray Zn / Al (first coat) 60 – 100 mic dft

+ sealer coat

+ 2 x EP topcoats

Full exterior surface and internally 6-8 m up from bottom

Page 21: Coating considerations for Asset Protection RINA Conference London Marine Renewable & Offshore Wind Energy 21 st - 23rd April 2010 Alan Guy / Rodney Towers.

Painting Wind Towersthe importance of quality application

Best Quality Application requiresSpecified Standards of secondary surface preparation for steel & appropriate QC

Trained and skilful spray painting personnel

Applicators to conduct own DFT & QC work for multi layer coating systems

Applicators to have control over environmental conditions during the application process

The application contractor controls about 75-85% of the costThe importance of good application is fundamental for success

Page 22: Coating considerations for Asset Protection RINA Conference London Marine Renewable & Offshore Wind Energy 21 st - 23rd April 2010 Alan Guy / Rodney Towers.

Painting Wind Towersfor long term coating performance

Photo Muehlhan Herning, Denmark

Optimum approach

Purpose built Wind Tower coating factory

Page 23: Coating considerations for Asset Protection RINA Conference London Marine Renewable & Offshore Wind Energy 21 st - 23rd April 2010 Alan Guy / Rodney Towers.

Painting Wind Towersfor long term coating performance

Series of blasting & coating cells

Auto blasting / more consistent Rz and surface cleanliness

Some robot painting / internals

Two component spray equipment

Dust free environment

Climate & temperature regulation

Relative Humidity control

Photo Muehlhan GmbH

Page 24: Coating considerations for Asset Protection RINA Conference London Marine Renewable & Offshore Wind Energy 21 st - 23rd April 2010 Alan Guy / Rodney Towers.

Painting Wind Towersfor long term coating performance

Spray application

epoxy / p/urethane multi layer

systems or topcoats

Photo Muehlhan GmbH

Page 25: Coating considerations for Asset Protection RINA Conference London Marine Renewable & Offshore Wind Energy 21 st - 23rd April 2010 Alan Guy / Rodney Towers.

Painting Wind Towersfor long term coating performance

Thermal spraying

Zn / Al alloy

metallization PhotoMuehlhan GmbH

Page 26: Coating considerations for Asset Protection RINA Conference London Marine Renewable & Offshore Wind Energy 21 st - 23rd April 2010 Alan Guy / Rodney Towers.

Painting Wind Towersfor long term coating performance

Finish painting internal areas

Photo Muehlhan GmbH

Page 27: Coating considerations for Asset Protection RINA Conference London Marine Renewable & Offshore Wind Energy 21 st - 23rd April 2010 Alan Guy / Rodney Towers.

Wave & Tidal devicesPrototype design - testing – scaling up

Some differing environmental conditionsBut same considerations for long term coating performance

Page 28: Coating considerations for Asset Protection RINA Conference London Marine Renewable & Offshore Wind Energy 21 st - 23rd April 2010 Alan Guy / Rodney Towers.

Offshore Marine Renewablesimpact of fouling

Wind Towerswill occur but impact on power generation and coating performance generally small

will be confined to tidal & immersed areas

Wave & Tidal devicesImpact could be significant. Issues may be

how to minimise fouling adhesion

differences between exposed surfaces

steel & composite materials

static or moving

possible impact of greater hydrodynamic loads on tethered devices from fouling build up

Page 29: Coating considerations for Asset Protection RINA Conference London Marine Renewable & Offshore Wind Energy 21 st - 23rd April 2010 Alan Guy / Rodney Towers.

Offshore Marine Renewablestidal devices

In locations of ‘useful’ tidal range and flow, abrasion resistance of coatings and materials may be an issue

Page 30: Coating considerations for Asset Protection RINA Conference London Marine Renewable & Offshore Wind Energy 21 st - 23rd April 2010 Alan Guy / Rodney Towers.

Coating Considerations for Asset Protection & Structural Integrity

Coating product quality failures are unusual. Specification failures are not

Three recommended actions for Client / Asset Owner / Field Manager

which can reduce risk

1. Apply the Functional Specification approach

Coating system suitability for performance requirement

Coating system suitability for the application process

Coating system suitability for the field environment

Coating system suitability for repair & maintenance

2. Make an independent technical evaluation of coating specification within

design phase and prior to Build Contract

3. Audit the coating process independently during construction phase

Post ISO 9000 wrong coating specification cases have doubled ! * * Source JPCL / K.Muhlberg Mar 2010

Page 31: Coating considerations for Asset Protection RINA Conference London Marine Renewable & Offshore Wind Energy 21 st - 23rd April 2010 Alan Guy / Rodney Towers.

Unmanned structures

...deserve wise protection !

Page 32: Coating considerations for Asset Protection RINA Conference London Marine Renewable & Offshore Wind Energy 21 st - 23rd April 2010 Alan Guy / Rodney Towers.

Sources & References

Sources of info & PhotosNaREC, Blyth, Northumberland

EMEC, Stromness, Orkney

Muehlhan GmbH, Hamburg

ABS, Houston

PapersK.Muhlberg / JPCL March 2010

‘ Corrosion Protection of Offshore Wind Turbines’

A. Momber / JPCL Apr 2008 & Apr 2009

‘ Investigating Corrosion Protection of Offshore Wind Towers Parts 1 & 2 ’

‘ Thank you ‘