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The U.S. Army maintains a global presence and is required to abide by environmental safety and occupational health regulations and restrictions in all operating environments. As a result, coatings technology advancements and improvements must stay ahead of ever increasing and changing requirements. The U.S. Army Combat Capabilities Development Command (DEVCOM) Safer Alternatives for Readiness (SAFR) program has funded efforts to formulate coatings free of ingredients including n-methylpyrrolidone/NMP, isocyanates, and chromium, while updating specifications to allow for new formulations and promoting their implementation Army-wide.
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It has become common practice for specification writers to require minimum tensile pull-off adhesion strength values as part of the acceptance criteria for protective coating work for concrete substrates. These values are convenient for specifiers because a minimum number provides a black and white basis upon which to define success versus failure. But there is much more to performing and evaluating adhesion testing than a hard and fast number.
Being proactive and performing scheduled coating condition assessments on above ground storage tanks to prevent corrosion is of utmost importance to protect assets. Undetected corrosion can result in product contamination, section loss, create compliance issues resulting in fines levied by governmental agencies, and increase costs of asset replacement. Planned and detailed coating/lining condition assessments can help a tank owner realize the current condition of their assets and maximize life expectancy.
Every day a new specification comes out naming coating manufacturers reps as performers of Coating Inspection duties on projects. These often include multiple scheduled job site visit commitments and having the manufacturers rep sign off on inspection hold points. I know that in some instances this is due to old outdated engineer and owners’ specifications where this stipulation has been in the documents for years and no one ever bothered to remove it, even though they may agree with me on this point.
The role of a Coating Inspector has evolved considerably over the past few decades, and the responsibilities have increased over what used to be a rather straightforward job: to verify that surface preparation and coating application meet the project specification requirements. Today there are week-long or multi-week basic and advanced coating inspection courses, specialty courses that are industry-specific (e.g., bridge, nuclear), courses that are substrate-specific (e.g., concrete coatings inspection) and even coating-specific (e.g., inspection of thermal spray coatings).
Third Generation Polysiloxane (TGPS) ambient curing CUI mitigation coatings have been used in the petrochemical industry for over five years since the “third generation” concept was introduced at NACE Corrosion 2017. These coating technologies have demonstrated positive results in both shop and field application for asset management in elevated temperature, cryogenic and cyclic applications across -196 to 650o C/ -321 to 1200o F operational temperatures. TGPS coatings have also demonstrated effective use of a two-step (primer-insulation) CUI mitigation coating approach operating up to 400o C/750o F, when compared to the traditional (CUI coating-fibrous insulation-cladding) systems.
Corrosion Under Insulation (CUI) is a very serious problem impacting the oil and gas, petrochemical, power and heavy industries. Due to the high costs associated with CUI, many industries have begun abandoning conventional jacket insulation. Recent advancements in trade association standards have helped engineers select, apply and inspect different types of insulative coatings in lieu of conventional jacket insulation.
CUI (corrosion under insulation) is a pervasive, difficult and high-liability issue for petrochemical, power, shipping, and other industries. Situational variations (meteorological, geographical, seasonal, etc.) can confound conventionally specified surface preparation attempts to achieve perfect or near-perfect metal hygiene, thus reducing expected coating life by 30 to 75 percent. Because conventional surface preparation processes have historically been unable to adequately relieve microcontamination of metal surfaces, organizations have settled for an uneasy balance between economic and physical feasibilities that exclude the possibility of achieving ideal surface preparation outcomes and rely more heavily upon barrier coatings to supply needed corrosion control.
The Offshore Oil and Gas environment is among the most corrosive in the world. It is also one of the mostdangerous. Providing safe working surfaces is a requirement of the Bureau of Safety and EnvironmentalEnforcement (BSEE) and is desired by asset owners and contractors alike. Balancing safety with production,downtime, and turn-around times is always a battle, but one coating manufacturer seems to have solvedthese issues through its development of a single coat zinc carbon nanotube (CNT) non-skid epoxy deck coatthat provides galvanic protection via the sacrificial metal’s electron transfer along the CNT quantum network.
A steel surface has been properly prepared to a white metal blast and it looks great … to the naked eye at least. But is it? Why is a surface that has the correct profile and appears to be perfectly clean typically not good enough? A standard abrasive blast will give you the profile and visible cleanliness, but how clean is it? Testing is the only way to determine. That is testing for conductivity, chlorides, and any other contaminants.
This summary is a look at implementable work and a gage of the value of future work. The strategic implementation of Surface Preparation and Coatings Automation, Standardization and Digitization of Visual Inspection, and Surface Preparation and Coatings Training Certification Program could provide cost and schedule savings. Optimizing Power Tool Surface Preparation potentially will increase Shipbuilders safety, while reducing material and labor costs.
Power tool cleaning has been a common method of surface preparation prior to coating application since the dawn of steel shipbuilding. Power tools are usually handheld pneumatic, or sometimes electric, devices that through impacting or abrasive action can remove coating and corrosion. Most commonly power tool cleaning has been used for re-work or coating repair associated with outfitting. Typically, power tools are limited to the touch up or repair of small areas or areas that cannot be accessed by bulkier equipment such as abrasive blasters.