Dr M Raouf Kattan FRINA C.Eng www.safinah.co.u k IMAREST/RINA09 1 Implementing The Paint Specification in the Performance Standard for Protective Coatings – The Challenge The North East Coast Joint Branch of IMAREST and RINA Newcastle upon Tyne 12 March 2009
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Dr M Raouf Kattan FRINA C.Eng IMAREST/RINA091 Implementing The Paint Specification in the Performance Standard for Protective Coatings.
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Dr M Raouf Kattan FRINA C.Eng www.safinah.co.uk IMAREST/RINA09 1
Implementing The Paint Specification in the Performance Standard for Protective
Coatings – The Challenge
The North East Coast Joint Branch of IMAREST and RINA
Newcastle upon Tyne
12 March 2009
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Objective
To provide a review of the requirements/challenges posed by the IMO PSPC and highlight some key issues.
Rust is a Must – a poem
…….All the ships upon the sea
Slowly turn to Fe203…….
T.B Watson
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High Technology shipbuilding
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Surface preparation
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Painting
Improvement is needed
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The Parties Involved at present
Productivity/
Environment
Shipyard Ship-owner
Performance
Coating supplier
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The Parties Involved
A paint specification is in many ways a compromise:
– It has to meet with the yards building procedures, environmental and productivity requirements
– The shipyard is the customer of the coating manufacturers and they have to be competitive on standards as well as price
– It has to match the paint suppliers product range.
The PSPC is in effect making the compromise redundant
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Coating Performance Standard Review
The Performance Standard for Protective Coatings (PSPC) provides the technical requirements for protective coatings in dedicated sea water ballast tanks of all types of ships of 500 gt and greater and double sided skin spaces on bulk carriers of 150m and greater in length.
It will be mandatory and is intended to be included as amendments to SOLAS regs II-1/3-2 and XII/6
It is also recommended to be applied where possible to items, not integral to the structure e.g. ladders, platforms – Permanent means of access
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Tip of the iceberg
A family of regulations– PSPC– Permanent means of access– Cargo tanks– Maintenance
These will change the current compromise solutions
SOLAS Regulation
All vessels now cannot be delivered without a compliant ballast tank coating systems
For Common Structural Rule vessels – this now becomes a condition of class!
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Why?
Structural failures
Chase for minimum standards
Use of high tensile steels
Paint as part of the solution – but was it part of the problem?
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Coating Performance Standard Review
Aims of the PSPC
– to provide a 15 year life for ballast tank coatings over which it is defined as in being ‘good’ condition.
– ‘Good’ condition is defined in resolution A.744(18) and is “ condition with only minor rust spotting”
– Better coating systems with reduced maintenance
– Improved safety at sea
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Coating Performance Standard Review
Aims of the PSPC
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Coating Performance Standard Review
Aims of the PSPC
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Coating Performance Standard Review
Entry into force
The proposals will apply to the aforementioned types of vessels:
– For which the building contract is placed on or after 1st July 2008, or
– In the absence of a building contract, the keels of which are laid or which are at a similar stage of construction on or after 1st January 2009, or
– The delivery of which is on or after 1st July 2012
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Coating Performance Standard Review
Entry into force
However IACS applied the proposals on ratification to tankers ( L > 150m) and bulkers (L > 90m) under the Common Structural Rules (CSR) for contracts signed from December 8th 2006
The first new building classed under the above rules were delivered in the second half of 2008
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The Parties Involved
Productivity
Performance
Shipyard Ship-owner
?
Coating supplier
Classification Soc.
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Coating Performance Standard Review
Main Elements of the PSPC:
– Design of a specification and coating system
– Coating System approval
– Definition of inspection procedures
– Production of a Coating Technical File (CTF) which records all aspects of the process
– Verification of compliance
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The Paint Specification
The paint specification is at the heart of the PSPC and covers:– Primary and Secondary surface preparation standards– Steel profile range– Cleanliness of surfaces prior to coating– Soluble salt limits– Steel condition– Thickness and number of coats– Environmental conditions allowed
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The Paint Specification
The paint specification applies to the coating system that has been selected
Selection of the coating system takes into account the service conditions and planned maintenance
All coatings to be epoxy based or equivalent and consist of multi-coat systems of contrasting colour
The top coat to be a light colour
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Type approval
All coatings to be pre-qualified by:– A method corresponding to a specified test procedure or
equivalent ( now Annex 1), cross test with shop primer or…– Documented field exposure with a final condition of “GOOD”
after 5 years
Non Annex 1 test must show equivalent testing procedures and needs.
A Statement of Compliance or Type Approval Certificate to be issued by a third party - independent of the coating manufacturer
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Inspection process
The inspection process covers all the processes and defines the standards from:
Shop Primer Application
Block Painting
Post Erection Repairs
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The inspection process
• The inspection processat each stage can be separated into the following simple processes:
between Owner/yard and paint company for this contract
– Paint specification as issued by yard including key criteria and data sheets
– A summary or full log of work carried out by yard/coating inspector - one for each tank and Non-conformity/repair summary log for each tank - including verified inspection reports
– Statement of conformance
– Copy of type approval certificate or statement of compliance
– Yard procedures (for inspection and repair) audit certificate from class (includes application ).
• Tri-party agreement• Type approval• Test results• Process audit• Inspection audit• CTF audit and sign off – currently cannot be complied
with
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The Paint Specification
• The main elements of the specification in the PSPC are already being carried out in many shipyards and have been for a number of years
• The main items that are new are :
– A Coating Technical File has to be produced by the shipyard
– All inspectors are to be qualified to a recognised standard
– Increased inspection and prescriptive inspection and data collection
– Audit by class
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Ambiguities
• There are many ambiguities in the standard:– Salt measurement– 90:10 rule– Area judgement and other subjective elements– CTF detail and content– Products approved through testing – will they last 15 years target life– What happens if they do not– Approved inspector
• There are some guidelines– PR34 from IACS– IACS guidance notes
• Maintenance requirements• Costs of implementation• IACS members not acting in harmony – adding costs• Conflict with other regulations
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Conclusions
• Added time and cost to the process• Needs a bedding in period• Needs a cool and calm interpretation• In the wrong hands is adding to costs.• Places a clear increased burden on yards• It is going to get worse before it gets better.• Will it bring with it improvements?• Is it needed?• Can we do better?
Do it soon
Thank you – but how does the poem end?
……Here’s to rust no doubt about it
Most of us would starve without it!…..
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Acknowledgement to Hyun- Kug Lee for some images (Korean Shipbuilders Assoc and Samsung Heavy Industry) for some images