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Since 1982, there has been a move to Thermal Sprayed Aluminum (TSA) coating in the “splash zone” of offshore structures. Our experience indicates that an experience applicator, good surface preparation and quality of wire combined to achieve required thickness and apply the sealer to seal the entire surface.
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Offshore coating systems have evolved over the past 50 years to allow for restrictions in raw material use and solvent emissions. This has meant that many tried and tested systems can no longer be used. This paper describes the industry in terms of attempts to generate suitable prequalification testing scenarios which will prevent premature failures of untried new systems
Offshore structures represent large capital investments. Structures are being placed in offshore areas worldwide and are being designed to withstand forces resulting from hurricanes, arctic storms, tidal currents, earthquakes, and ice floes. Moreover, platform structures are currently being placed in deeper waters and, therefore, have become larger, more complex, and more expensive. Control of corrosion on structures is necessary for the economic development of oil and gas production, to provide safe support for working and living areas, and to avoid potential harm to the environment. Corrosion on offshore structures can be divided into three major areas: the submerged zone, the splash zone, and the atmospheric zone. The submerged zone also includes that portion of the structure below the mudline. For the purposes of this standard, offshore structures are stationary structures (platforms or subsea facilities) that are fixed to the sea floor by gravity, pilings, or mooring cables.
Optimizing power generated from wind needs bigger improved designs and windy conditions, thus increasing installations offshore. As component costs decrease and processes improve, it can be profitable for farm developers to go further from shore into deeper waters and high-risk areas. In addition, the lifecycle expectancies of a coating system have developed along the way, moving from a typical >15 years expected lifetime in a given environment, to now >25 years.