Professional Documents
Culture Documents
Abstract
Among the general information in this section is a description of the coatings and
coating systems, which includes the advantages, disadvantages, and uses. Coatings
are also described in the individual sections for special surfaces such as: concrete,
downhole tubulars, and pipelines.
Note This manual does not contain information about coatings for architectural
surfaces.
Quality control is essential for any project. Among the key elements of quality
control for coatings are inspections, monitoring progress, and protecting the
Companys equipment. For assistance with specific questions about coatings, see
the listing of the Companys specialists and coating manufacturers in the Quick
Reference Guide.
Contents Page
111 Acrylics
Acrylic ester resins are polymers and co-polymers of the esters of acrylic and meth-
acrylic acids. As thermoplastics, they soften at high temperatures.
Advantages:
Good moisture and mild chemical resistance
Either fast-drying solvent evaporation or coalescence
Disadvantages:
Poor resistance to aromatic solvents
Uses:
Solvent acrylic: truck and machinery finishes
Latex emulsions: stucco, wood, and masonry
By Company: as architectural coatings
112 Alkyds
Alkyd resins are basically modified polyesters. An alkyd is the reaction product of a
polyhydric alcohol and a polybasic acid. A common alkyd resin uses glycerol as the
alcohol and phthalic acid as the polybasic acid.
Oxidation in the air cures alkyd coating resins. Adding drying oils to pure alkyd
modifies the alkyd into alkyd coating resins.
These resins are classified by oil length (long, medium, and short). The alkyd resin
without oil modification is hard and brittle. As the oil length increases (more oil
added), the film becomes softer and more flexible.
Advantages:
Perform well in moderate environments
Easy-to-handle, single-component coatings
Inexpensive
Fair-to-good performance in most of the Companys environments
Amine-cured & Cross Linked Chalks Excellent 1. Good 1. Excellent 1. Limited 1. Excellent
Amine Adduct Yellow 2. Fair 2. Excellent 2. N/R 2. Excellent
Epoxy
Coal-tar Epoxy Cross Linked Chalks, N/R 1. Excellent 1. Excellent 1. Excellent 1. Poor
Polyamide Cracks 2. Good 2. Good 2. N/R 2. N/R
Epoxy Phenolic Cross Linked N/R N/R 1. N/R(1) 1. N/R(1) 1. N/R(1) 1. N/R(1)
(1) (1) (1)
2. Good 2. Very Good 2. N/R 2. Very Good(1)
Baked Phenolic Heat Cured N/R N/R 1. Good(1) 1. Good(1) N/R(1) 1. Poor(1)
(1)
2. Lid 2. N/R 2. Out-
Mineral standing(1)
Acids(1)
Moisture-cured Cross Linked Aromatic Very Good 1. Good 1. Good 1. Poor 1. Excellent
Urethane (II) Yellows; 2. Fair 2. Fair 2. N/R 2. Good
Aliphatic
Excellent
Silicone Heat Cured Excellent Very Good 1. Good 1. Good 1. Very 1. Fair
Cross Linked 2. Poor 2. Poor Good 2. Fair
2. Poor
Silicone Alkyd Oxidation Excellent Very Good 1. Good 1. Good 1. Good 1. Good
2. Poor 2. Fair 2. Poor 2. Good-Poor
Amine-cured & Very Good N/R Good Good Very hard Chalks to Flat Full
Amine Adduct
Epoxy
Polyamide Very Good Solvents Good Good Hard Chalks to Flat Full
Epoxy Water
Coal-tar Epoxy Excellent Water Limited Excellent Very Hard Flat Black, Red
Polyamide
Chlorinated Very Good Water Fair-Poor Poor Good Semi to Flat Wide
Rubber
Epoxy Phenolic Very Good Wide- Good Outstanding Very Hard High Dark
range
Solvent
Baked Phenolic 1. Excellent(1) Wide Good Excellent Excellent Excellent Clear Dark
2. Very Good Resis-
tance
Silicone Alkyd N/R N/R Good Very Good Good High Full
Vinyl Very good Water Fair-Poor Poor Good Semi to Flat Wide
Organic Good(3) N/R Good Good Very Good Semi to Flat Some
Zinc-rich
Solvent-based Good(3) Fuels Excellent Excellent Very Good Flat Earth Tones
Self-cured Solvent
Inorganic Zinc
Not suited to highly alkaline surfaces such as fresh concrete, galvanized steel,
and inorganic zinc
Chalk in sunlight
Usually fail within a few years on piping and structural components
Not VOC-compliant
Uses:
In external primers and finish coatings
113 Epoxies
The most common epoxy resins are formed by the reaction of epichlorhydrin and
bisphenol-A. This reaction can be controlled to produce resins ranging from liquids
of low-molecular weight to solids of high-molecular weight.
Complete curing gives epoxies their chemical and water resistance. Curing time
increases at temperatures below about 70F, essentially stopping below about 50F
unless it is a specially formulated low-temperature epoxy.
Epoxies have very good resistance to bases and many solvents. Epoxies have poor
acid resistance unless modified with a phenolic.
Advantages:
Resist water and chemicals, especially caustics, superbly
Resist weather well
Adhere well, particularly to concrete
Apply easily
Disadvantages:
Do not retain color and gloss as well as alkyds
Tend to chalk rapidly
Do not have good acid resistance
Need surfaces between layers of epoxy roughened by solvent or blasting when
applying multiple coats as many epoxies cure with a hard, slick surface
Need successive coats of epoxy applied as soon as possible to obtain satisfac-
tory adhesion between coats. Manufacturers normally recommend a maximum
time between coats.
Need long cure time. For epoxy linings at 70F, curing may take one week. In
the field, coatings applicators often accelerate the curing of an internal coating
with a low-temperature bake (100 to 150F).
Caution Do not put internal coatings into service until they are fully cured.
Uses:
Epoxy resins are the most popular resin for thin-film coatings on concrete.
There are six groups of epoxy coatings in this section: amine cured, amine adduct,
polyamide, coal tar, epoxy mastics, and epoxy novolac.
Amine-cured Epoxies
These coatings are epoxy resins cross-linked with one of several amine compounds.
Caution Because the amines can present a health hazard, apply them according to
manufacturers safety recommendations.
Advantages:
Same properties as liquid amines, but much less hazardous
Very good resistance to oils, solvents, and chemicals
Disadvantages:
Ultraviolet degradation causes rapid chalking
Uses:
Lining gasoline storage tanks, chemical tanks
Corrosion-resistant primer under polyurethane foam insulation
Polyamide Epoxies
Polyamide resins are produced from polyamines and fatty acids. Epoxy coatings for
atmospheric exposures are usually polyamides. Mastic coatings which adhere to wet
surfaces and which will cure under water are formulated with polyamide epoxies.
Advantages:
Good surface-wetting properties
Longer pot life, more flexibility and better water resistance than amine or
amine-adduct cured epoxies
Good resistance to alkalies, petroleum products, and salt water
Disadvantages:
Not quite as chemically resistant as amine adduct epoxies.
Uses:
Topcoats and tiecoats in severe exposures
Coal-tar Epoxies
As the name suggests these coatings are blends of epoxy resins and coal tar.
Note Coal tar is a suspected carcinogen but is tied up sufficiently in the polymer
so that manufacturers consider the cured film safe.
Coal-tar epoxies can be either polyamide- or amine-adduct cured. Usually applied in
two heavy coats of eight mils each, these coatings are normally self-priming.
Advantages:
Outstanding for water-immersion service
Disadvantages:
Chalk rapidly and fail in (ultraviolet) sunlight
Uses:
Underwater, in water tank linings (except potable water tanks), and on buried
structural steel
Note Although coatings manufacturers continue to use them for municipal water-
tank linings, the Company prefers FDA-approved polyamide or amine-adduct
epoxies for potable-water tank linings.
Epoxy Mastics
Advantages:
Perform better than alkyds
Adhere to a variety of surface preparations, including tightly adhered rust
Adhere to any old coating firmly attached to the substrate
VOC compliant
Disadvantages:
More expensive than alkyds
Uses:
For less-than-perfectly prepared surfaces
Epoxy Novolac
Epoxy novolac resins are second-generation epoxies with greater cross-linking
density.
Advantages:
Greater resistance to chemical attack and high temperatures than standard
epoxies
Disadvantages:
More expensive and less flexible than standard epoxies
Uses:
Common coating for concrete
114 Elastomers
An elastomer is a polymeric substance with more than 100 percent elongation in a
tensile test. Included in this category are natural- and synthetic-rubber products
(which also have the physical characteristics of natural rubber). The chemical, oil,
and water resistance of elastomers vary widely.
Coatings applicators can apply modified elastomers as coatings. The Company uses
many elastomeric coatings, such as chlorinated rubber and hypalon, alone over steel
and other surfaces or, as required, with special primers such as inorganic zinc.
Air-drying Elastomers
Chlorinated rubber, an air-dried formulation of hypalon, and butadiene-styrene are
the most popular elastomers for air-drying coatings.
Chlorinated Rubber. Chlorine and natural rubber latex produce chlorinated rubber
resins. When suitably plasticized and pigmented, these resins exhibit outstanding
resistance to a broad range of corrosive chemicals and environments.
Advantages:
Shows outstanding resistance to severe chemical environments such as acids,
alkalies, salt fog, water, oxidizing agents, bleaches, and cleaning compounds
Dries rapidly, allowing application of several coats in one day
Produces excellent bond between old and new coats as the solvents in the new
coat penetrate the old coat
Disadvantages:
Does not resist sunlight damage as well as alkyds and acrylics
121 Phenolics
Phenolic resins, formed by the reaction of phenol with formaldehyde, produce a
range of coatings from hard plastics (Bakelite) to oil-soluble resins and from heat-
reactive varnishes to air drying oils. The Company uses two phenolic resins in coat-
ings: a baked pure phenolic and an air-drying epoxy phenolic.
Baked Phenolics
Baked phenolics are almost exclusively shop-applied due to a complicated baking
procedure. They contain resins which are polymerized by being heated above 300F.
The reaction time and temperature depend on the modifying oils and resins.
Note The Company uses baked phenolics only in the most severe immersion
services where no other material will work, such as container inner-coatings and
tank car linings.
Advantages:
Excellent chemical and water resistance
Withstand immersion in almost all petroleum products
Good abrasion resistance
Disadvantages:
Poor wetability (the ability of a coating to flow over a surface)
Require maximum surface preparation
Poor adhesion
Embrittles
Note To overcome poor adhesion and brittleness, some formulas are modified with
epoxy resins, giving them better caustic resistance than pure phenolics but not equal
resistance to strong solvents.
Epoxy Phenolics
Catalytic setting (non-baking) phenolics are usually composed of phenolic resins
and epoxies.
Advantages:
Better chemical and solvent resistance than pure epoxies
Disadvantages:
Lower resistance to chemicals and solvents than pure baked phenolics
Uses:
Lining tanks, vessels, containers, etc.
122 Polyesters
While there are two major classes of polyester resins, the Company uses only isophthalic.
Isophthalic polyesters, the resin preferred for corrosion protection, is also the main
resin in laminate-reinforced systems.
While the chemical and temperature resistance of polyester is usually poorer than
any of the other resins, they are also the least expensive.
123 Polyurethanes
Polyurethane resins are formed by the reaction of isocyanates with polyols and are
used for a variety of purposes from foam insulation to air-drying coatings and
varnishes. The isocyanate may be either aromatic or aliphatic.
There are literally thousands of polyurethane formulationsfrom hard roller skate
wheels to elastomeric materials that stretch like rubber bandswhich have many
different properties. Some of these properties are:
Abrasion resistance
Chemical resistance
Elasticity
Impact resistance
Tensile strength
Caution Remember that increases in one property result in decreases in another.
Because of this, many elastomeric polyurethanes are not as chemically resistant as
the more rigid polyurethanes.
The most common polyols are acrylics and polyesters, although there are epoxies,
vinyls, and alkyds.
Advantages:
Highly resistant to abrasion and impact
Catalyzed urethanes are highly chemical resistant
Better performance than alkyds
AliphaticFor atmospheric coatings, usually as easy to overcoat as epoxies
AromaticMore chemically resistant than aliphatic urethanes
Disadvantages:
More expensive than alkyds
AromaticNot designed for external exposure as they chalk and yellow; diffi-
cult to overcoat because adhesion is poor
Uses:
AliphaticNon-fading, non-chalking external finishes
AromaticTank linings, chemically resistant coatings, flexible elastomeric
coatings for polyurethane foam insulation coverings
Classifications. Urethane coatings cure by a variety of mechanisms as classified by
ASTM D16-75 types. Types II, IV, and V are considered high performance and are
described below. Most of the Companys experience has been with Type V, the two-
package polyol-cured urethane.
Type II, One-package Moisture-cured. The Company has limited experience with
these urethanes which cure by reacting with moisture in the air. The moisture reacts
with a prepolymer containing isocyanate so that the isocyanate is released for cross-
linking. The reaction also releases CO2 which must migrate to the surface before the
film sets up.
Caution In high humidity areas, such as offshore, the reaction can occur so
rapidly that the CO2 cannot escape; and the film is filled with gas bubbles and
pinholes.
Type IV, Two-package Catalyzed. These urethanes cure by reacting with a low-
molecular-weight-reactive catalyst. They cure in a similar way not only to moisture-
cure (although the catalyst is in a separate package), but also to epoxy coatings.
Type V, Two-package Polyol-cured. These urethanes are the Companys most
common choice for high-performance coating systems such as for offshore plat-
forms and chemical plants. To cure, polyol-cured coatings react with pre-reacted
(adduct) hydroxyl-bearing polyols. They require no additional curing agent;
however, coatings applicators may add an agent to promote low-temperature curing.
124 Silicones
Silicones are a group of various organo-silicon-oxide polymers available as fluids,
elastomers, and resins. Because of their chemical composition, silicones have excel-
lent resistance to heat, weathering, and moisture.
Note Repairing silicone coatings is very difficult because almost nothing will
adhere to them. For small repairs, sand the failure and apply fresh silicone coating
with a brush. For large repairs, remove the coating by abrasive blasting and recoat.
The Company uses both classes of silicone coating resins: heat-reactive and modified.
Heat-reactive
Silicone resins are cross-linked polymers which require a high-temperature cure to
produce heat-stable films. Catalyzed formulations which cure at room temperature
are now available. Non-catalyzed formulations remain tacky until heated above
about 300 to 400F. For this reason, most field applications use the catalyzed, room-
temperature cure.
The film thickness of baked silicone coatings is low compared to that of other coat-
ings. A self-primed two-coat application usually produces only 1 to 2 mils dry
film thickness (DFT).
Advantages:
Excellent sunlight resistance
Good durability at high temperatures
Disadvantages:
Apply only on abrasion-blasted surfaces
Uses:
Furnaces and stacks up to 600F (up to 750F for aluminum and black colors)
Note The color and gloss retention of baked silicones depends on the pigments.
Modified or Air-drying
Modified or air-drying silicones are produced by reaction with organic resins such
as alkyds or acrylics.
Advantages:
Excellent gloss and color retention
Good weather and sunlight resistance
Many resist temperatures up to 300F
Disadvantages:
Tend to cure quite slowly even at ambient temperature, taking weeks to harden
and resist damage in cool weather.
Note Topcoat inorganic zinc with an epoxy or silicone acrylic.
125 Vinyls
Vinyl resins are formed from the reaction of acetylene with acetic or hydrochloric
acids. Varying this process produces resins consisting of 100 percent vinyl chloride, or
100 percent vinyl acetate. The resins in protective coatings are usually co-polymers
containing 80 to 90 percent vinyl chloride and 5 to 15 percent vinyl acetate.
Vinyl resins are hard and brittle and must be combined with plasticizers and
dissolved in solvents to form vehicles for coatings. Vinyl solutions contain only
15 to 40 percent solids depending on the co-polymers.
The various vinyl-resin solutions are compatible and may be blended to emphasize
desired properties. Some blends adhere very well to concrete and metal and are used
in formulating primers. Other blends are pigmented and plasticized to produce high-
build films. Used for finish coats, some blends have low solids and adhere poorly to
steel but have very good chemical and weather resistance.
The Company uses vinyls for many services, often where water exposure is
expected such as on floating tank roofs, docks, and on offshore platforms near the
water.
Advantages:
Excellent chemical, water, and aliphatic oil resistance
Excellent shelf life
Ready bond to weathered vinyl films
Removable with a solvent wash when desired
Easy to patch old coatings without blistering or wrinkling
Easy to apply by spray
Disadvantages:
May lose their plasticizer over time and embrittle, a problem with vinyl as a
weathercoat over polyurethane-foam insulation
Do not have good gloss retention or stain resistance
Dissolved by ketones, esters, chlorinated solvents, and some aromatics
Need good ventilation to avoid prolonged (solvent evaporation) drying
Tend to lift and blister because of the strong solvents
Difficult to brush or roll because of their rapid drying
Tend to bubble and pinhole when applied over porous inorganic zinc
Uses:
With alkyds or epoxy esters to improve film build, gloss, and adhesion which
are excellent as vehicles:
In rust-inhibiting primers for ferrous metals
In seal or tiecoats over inorganic zinc primers to improve adhesion of
vinyl, alkyd, chlorinated rubber
In epoxy ester topcoats
In formulae ranging from thin-bodied, air-drying coatings to semi-mastic
putties and air-drying, baking plastisols
To formulate a wide variety of latex materials in glues, paper sizes, and emul-
sion coatings
In vinyl-emulsion-latex coatings for both internal and external services. The
retention of deep colors by vinyl latexes is superior to that of most other coatings.
Vinyl Ester
Vinyl ester resin is a reaction product between polyesters and epoxies and shares
many of the attributes of polyesters.
Advantages:
Resistance to acid, solvent attack, and high temperatures
Disadvantages:
More expensive than an isophthalic polyester or normal epoxy
Uses:
Coating concrete
Inorganic-zinc Coatings
Inorganic-zinc coatings consist of two components:
A pigment composed solely or principally of zinc powder
Any of a variety of patented and proprietary inorganic or semi-inorganic vehi-
cles to form the matrix of the coating
Post-cured inorganic zincs have a third component: a curing agent such as phos-
phoric acid.
Among the vehicles are ethyl and sodium silicate, phosphates, and other complexes.
When properly mixed, applied to blasted steel surfaces, and allowed to cure, the
resultant coatings have outstanding resistance to weathering, humidity, elevated
temperatures, organic solvents, animal and vegetable oils, both fresh and salt water,
and most petroleum products. In addition, these coatings (especially post-cured) have
excellent abrasion resistance. The corrosion resistance of the cured film is similar to
that of galvanized iron; the weather resistance is superior to galvanized iron.
Two types of inorganic zinc coatings are self-cured and post-cured.
water-soluble film to an insoluble film. Conversion time depends on the vehicle and
the relative humidity and temperature.
Some of these coatings undergo a color change as they cure, indicating when they
are completely cured.
Caution Do not topcoat or place these coatings in water-immersion service until
they are thoroughly cured.
Advantages:
Excellent water and weather resistance
Better wetting ability, because of their organic vehicles, than inorganic zinc
Usable over a broader range of surface preparation conditions than inorganic zinc
Disadvantages:
Not as oil resistant as the inorganic coatings
Uses:
Touch up for inorganic-zinc-primed systems
Subsea equipment primers
As primers under other coatings
Note Often one coat of IOZ alone gives excellent performance. For higher perfor-
mance or aesthetics, topcoat with epoxy or epoxy plus urethane.
Example: One coat of IOZ has lasted 15 plus years on a Richmond Long Wharf line.
Pascagoula successfully used a two-coat system of Carboline Coating Companys
IOZ with Carboline high-build urethane.
cannot recommend them for severe exposure environments (ie: offshore or indus-
trial environments). Refer to the System Number Selection Guide in the Coat-
ings Manual Quick Reference Guide for a listing of the acceptable brands of
water-based coatings for both new construction and maintenance systems.
Life Expectancy
The expected life of a thin-film internal coating is approximately ten years. After
ten years, the coating commonly blisters, and corrosion at holidays is usually occur-
ring over enough of the surface that blasting and replacing the entire coating are
required.
Note Early failure due to blistering often indicates either a problem with the
surface preparation or an incorrect coating selection.
Periodic inspection and repair (touch-up) of the internal coating may extend its life.
As the Company inspects tanks on a ten-year cycle, periodic inspection and touch-
up is usually not possible.
These factors also vary from product to product within a category, so it is difficult to
make general statements. Coal-tar epoxies are, however, usually very easy to apply
and relatively inexpensive, but the black color makes them difficult to inspect.
Straight epoxies (polyamides or amine adduct) are also fairly easy to apply and only
slightly more expensive than the coal tars. Epoxy-phenolics are often significantly
more expensive and more difficult to apply.
Life Expectancy
Expect glass-flake-reinforced coatings to last at least ten years before inspection.
Depending on the condition of the coating and the service, making necessary repairs
may allow the coating to last another ten years. Frequently, however, it will be
necessary to replace the coating after only ten years, especially for sprays. Trowel
applications have a better chance of lasting through a second decade.
Note The veil prevents any glass fibers from protruding through the resin surface,
which could allow wicking or chemical attack of the glass itself.
After the completed laminate is inspected, the coatings applicator applies a final
coat of resin. For epoxy resins, this gel coat simply provides additional protection
from chemical attack.
For polyester resins, the coatings applicator adds a wax to the final resin coat to
obtain full curing. Without the wax coat the surface of a polyester coating always
remains slightly tacky and lacks its optimum chemical resistance, and the body of
the laminate cures very slowly.
Advantages:
A laminate-reinforced coating provides the best protection against severe corrosion.
Laminates should not require cathodic protection as they should not contain any
holidays.
A laminate is the only type of internal coating which has significant structural
strength by itself.
Because it does not need to be as thick, epoxy-resin laminates are less expen-
sive than polyester or vinyl ester laminates.
Disadvantages:
Compared to thin-film and glass-flake-reinforced coatings, laminates are the
most expensive coating.
Laminate-reinforced coatings are the most difficult and time consuming to
apply.
Uses:
Laminates are generally used for stockside corrosion only when there is severe
corrosion or when underside corrosion is expected or has occurred.
Life Expectancy
Laminate reinforced coatings will last for 20 years, but inspect and repair them after
10 years. Eventually, the laminate will start to crack and lose its adhesion to the
steel, especially if the tank bottom flexes or settles significantly.
If underside corrosion occurs, remove the coupons to check the condition of the
steel bottom. Replace the laminate and the bottom if the bottom is essentially
corroded through.
Caution Never apply a second laminate over a failed laminate.
weeks. Laminates are also expensive. The total cost per square foot is equal to or
higher than that of trowel-applied glass-flake coatings.
Because it does not need to be as thick, epoxy-resin laminates are less expensive
than polyester or vinyl ester laminates. Polyesters and vinyl esters require a final
wax coat to obtain full surface curing; however, as they remain fluid longer before
starting to cure, they are easier to use.
Note The time between mixing and cure is called the gel time.
The coatings applicator can adjust the gel time by mixing different amounts of cata-
lyst and promoter into the resin. After the resin sets, it will reach 90 percent of full
cure in a short time. As epoxy resins do not have a gel time, they cure at a relatively
constant rate, starting immediately after mixing, and therefore do not remain as fluid
for as long as laminates.
Offshore
Achieving high-quality coatings is more difficult offshore than onshore due to some
of the following conditions:
Adverse weather
Simultaneous operations with other platform activities
Congested platform areas
Limited availability of transportation
Existing substrate surfaces that can be deeply pitted and contaminated with
soluble surface salts
Inaccessible items
Careful design and planning help to minimize the effects of these conditions.
A major component of quality for offshore coatings includes cure and recoat times
before returning a facility to service. Critical areas are the +/- 10-foot splash zone,
work decks and helidecks, and sweating equipment and piping. See detailed infor-
mation about quality control for offshore coatings in Section 800 of this manual.
Specifications
Caution Avoid the pitfall of writing specifications so vague and general that they
confuse everyone and allow the contractor to provide substandard work.
A well-written specification includes:
Requirements for the pre-job conference
Coating schedule for all items
Work schedule
Materials, including coatings and abrasive
Minimum standards for equipment
Example: Equipment such as moisture traps on coating and blast pots, coating gun
types and hose sizes, and quality of compressed air.
Note These records are extremely important in case of litigation and provide the
engineering team with daily work updates and recommendations.
See also the sections below on Inspections and Inspectors.
alternative would be a high alloy coupling welded through (not set-on) the
equipment wall with the appropriate high alloy electrode, with the coating
extending from the equipment surface continuously to the bore of the high
alloy coupling; this alternative can be considered where thin film coatings
are used but should never be used with elastomeric linings.
Flanged nozzles should be short and straight; long nozzles and nozzles
that have weld ells are more difficult to effectively coat internally; small
diameter nozzles are also difficult to coat internally. Internal coat-
ings/linings that require surface rolling (elastomeric, glass flake, FRP)
require that nozzles be short, straight, and at least 3" diameter.
Clips used for bolting in vessel internals are typically carbon steel with
drilled (and sometimes threaded) holes with an attempt made to coat the
clips to a holiday-free condition. Even if the clips are coated to a holiday-
free condition, the coating is usually damaged down to bare carbon steel
the first time that the internals are bolted in place after coating. Clips can
be high alloy material welded to the shell with the appropriate high alloy
electrode at little added cost. The required blast cleaning and internal
coating would include the high alloy clips, with a holiday-free condition
required that extends from the vessel surface at least 1" onto the high alloy
clip (for elastomeric linings, high alloy clips are still recommended but
must be completely enveloped by the lining).
Vortex breakers should always be bolted to clips and never be welded in
place; when they are welded in place, neither the nozzle bore nor the
breaker can be adequately blasted or coated. Vortex breakers, outlet
strainers, and similar small parts should be fabricated from high alloy
material rather than carbon steel that is blasted and coated after fabrica-
tion; any cost difference is minimal and some of these small parts are virtu-
ally impossible to coat holiday-free.
Designers
The fabricators design engineer frequently does not recognize the details that
are needed to result in an effective coating application, and is sometimes under
the additional constraints of being given Company required construction details
that cannot be effectively blasted and coated.
Coating Contractors
They are rarely given the opportunity to provide input in the equipment design
stage as to what details will be difficult or impossible to coat. They are usually
given a completely fabricated piece of equipment and are stuck with doing the
best they can with what they have been given, while still trying to make a
profit. A coating Pre-Inspection Meeting should be held with the coating
contractor by the Company inspector after the equipment detail drawings have
been completed but preferably before fabrication has begun; that will give the
coating contractor the opportunity to identify problem areas before the equip-
ment is fabricated and permit equipment design changes to be made more
easily.
Holiday Testing
Unless holiday testing is watched closely by the Company inspector, it is typi-
cally done on a random basis on some flat, exposed areas that are easy to coat
to a holiday-free condition, and not the areas that are likely to have holidays.
The fabricators inspector (if involved in the coating at all) just goes along with
this cursory inspection; the coating contractor has a vested interest in not
exposing defective coating areas that are difficult/impossible to repair. Every
square inch of the internal coating must be holiday tested (it is not very time
consuming) and should be witnessed by the Company inspector. Even when a
careful design review has been made or the vessel has simple internals, careful
inspection will almost always reveal some holidays.
Complete Inspections
A complete inspection requires a full-time, qualified inspector. The most conserva-
tive and costly of the three programs, a complete inspection is recommended when a
coatings reliability is critical.
The complete inspection checklist (Figure 100-2) is a compilation of items the
inspector should examine to ensure that the work satisfies all requirements of the
specification. While all items are important, they are ranked in terms of relative
importance: ccritical, nnecessary, and aapplies. Missing an a item has
lower potential effect on the life of the coating than missing the others.
Partial Inspections
The Company has two levels of partial inspection, Level 2 being the more limited.
Partial Inspection Level 1. Partial Inspection Level 1 (Figure 100-3) differs from
a complete inspection not only in the inspectors qualifications and time on the
project, but also in the number of tests required.
The inspector examines or tests particular itemshighlighted on the checklist
during and on completion of the work. Time and cost permitting, the inspector may
also verify the critical and necessary items on the Checklist For Complete Inspec-
tion (Figure 100-2) as any extra inspection improves the coatings reliability.
Partial Inspection Level 2. Partial Inspection Level 2 (Figure 100-4) is the
minimal inspection for any tank or vessel coating project and is recommended only
if the Company is willing to accept the risk of premature failure of the coating
Caution Select Level 2, the lowest recommended level, only after evaluating the
project carefully and considering the risks of a premature failure.
164 Inspectors
To carry out a thorough inspection, the inspector may be a Company employee or a
contractor but must be trained, experienced, and familiar with a variety of coating
methods and equipment.
Whether full- or part-time, the inspector should participate in all inspections at the
completion of the coating contract and must inspect the finished project before the
end of the contractors guarantee.
Qualifications
Full-time Inspector. A qualified, full-time coatings inspector must have one of the
two backgrounds below:
Certified and experienced.
National Association of Corrosion Engineers (NACE)-certified Level III
Experience inspecting tank and vessel coatings
Uncertified, trained, and experienced.
No certification
Some industry-accepted training
At least five years of verifiable experience inspecting coatings on tanks and
vessels
Example: Industry training coating courses are offered by KTA-Tator, S.G.Pinney,
or Bechtel.
Responsibilities
Full-time inspector. The full-time inspector reviews the project prior to start up and
is present whenever the fabricator is working offsite or the contractor onsite and
during hold points in the project, normally:
Prior to starting work
After preparing the surface
Prior to applying each coating
Following application of the final coating
Following the final cure
Part-time inspector. The part-time inspector must be available to examine the
coating during the projects hold points.
Evaluation Reports
The Companys representative should prepare an evaluation report about the
inspectors work.
Transition Times
Transition time may demonstrate the foreman and crews effectiveness and the
overall organization of the operation.
Example: If an eight-man crew has one hour of excessive transition time, the effect is
equal to an additional eight-and-a-half manhours for the project. See Figure 100-5.
Daily
The following should be completed on a daily basis:
Conduct pre-inspection of work area before blasting and coating, checking for
protection of equipment, inaccessible areas, and hazardous areas
Meet with the foreman of the coatings applicators to plan daily work schedule,
discuss positive aspects and potential problem areas of project, compare paper-
work
Coordinate work with production activities
Order materials on timely basis
Check contractors equipment
Check work and safety practices for compliance
Ensure that work area is square and clean
Prepare and submit reports; report to the Companys representative, as required
Air Compressors for Blasting. Air compressors for blasting should supply oil-
and water-free air at the correct pressure. The inspector should check the compressor
regularly (daily, unless tests show the equipment to be in good working order) by
releasing air into a white cloth and checking it for moisture or contamination.
If surface cleaning is poor or proceeding slowly, the inspector should:
Test the nozzles air pressure by inserting a hypodermic needle air-pressure
gage into the hose as close to the nozzle as possible
Check the nozzle with a nozzle-throat gage to ensure that the orifice is the
proper diameter
Not rely on pressure readings at the compressor as these differ from nozzle
pressure due to pressure loss in the hose. Typically, 100 psig is required at the
nozzle to obtain adequate cleaning and productivity.
Abrasive material. Abrasive material should be clean, dry, and the correct type and
size for the specific work. The inspector should ensure it meets these criteria.
The correct thinners are available for thinning the coating material, if required,
and for cleaning equipment
Storage conditions are adequate
Method of Application. The coating contractor is usually free to choose the method
of application; however, it must comply with one of the manufacturers recom-
mended procedures.
If there is doubt, the Companys representative should require the contractor to run a
test, proving that the coating film of the proposed method complies with the specifi-
cation. The inspector should be present during tests and should judge the results.
Mixes, Proportions, Incubation. Before the coating is applied, the coating
inspector should ensure that:
All coatings are properly mixed
Multi-component coatings are in the correct proportions
Proper incubation periods are met
Note Inadequate mixing or improper proportioning of multi-component coatings
can cause soft spots which may dry a slightly different shade of color.
During Coating
The inspector should check that each layer of a coating system meets the specifica-
tions for:
Coating thickness
General quality of the coating, such as hardness, freedom from pinholes, or sags
Dry film thickness (DFT)
The coatings applicator should:
Thin the coating according to the suppliers data sheets
Check viscosity before applying thinned coatings
Check the coatings film thickness with a wet film thickness gage immediately
after applying it
The coating contractor must know the thickness of films specified by the manufac-
turer. The specifications usually give normal DFT and place a limit on maximum
thickness; some give maximum and minimum values.
Although coating manufacturers specify only DFTs, inspectors should:
Use wet film measurements for control during actual application
Multiply wet film thickness by the volume percent solids of the coating; the
result gives the actual DFT of the coating
Measure the thickness of wet-coating films with comb gages
A representative from the Company, not the contractor, should approve gages
for measuring dry film thickness. The coatings applicator should calibrate
the gage daily according to the National Bureau of Standards Calibration
Standards.
If films are not the correct thickness, the coatings applicator must adjust both
the technique and equipment appropriately to meet the specification and to
avoid rework.
Note Refer to industry standard SSPC-PA2, Measurement of Dry Paint Thick-
ness With Magnetic Gages.
Internal Coatings
In addition to the general inspection procedures, the following items apply to
internal coatings.
Temperature and Humidity. Weather conditions are critical to the application and
curing of coatings. The inspector must make sure the surface is dry and tempera-
ture is above the dew point to avoid condensation. Almost all internal coatings cure
by a chemical reaction which produces heat and will not cure properly if the
ambient temperature is too low. The guidelines for temperature and humidity in
COM-MS-4738 are acceptable for most internal coatings, but always check the
manufacturers instructions too.
The inspector must read and then record atmospheric conditions in the daily reports
to verify that no moisture is present on the surface to be coated.
Film Thickness. Inspectors measure dry film thickness (DFT) with a magnetic film-
thickness gage or a Company-approved equivalent. They should check film thickness
of each coat and the final thickness of the coating. Each coat should be within the
specified range because an extra heavy coat (applied to correct another coats insuffi-
cient thickness) may crack or cure improperly. The inspector should ensure that the
coatings applicator repairs any defects after applying each coat.
Caution Using a subsequent coat to cover defective areas is unacceptable.
Pinholes and Holidays. The inspector must examine 100 percent of the finished
coating for pinholes and holidays.
Check thin films (1 to 20 mils) with a low-voltage (67-volt), sponge holiday
detector, which sounds an alarm if the fluid in the sponge comes in contact with
the underlying steel.
Check thick-film coatings (20 to 200 mils) with a high-voltage (nondestructive
voltages of usually 100 to 150 volts per mil) holiday detector. This voltage
gives the spark enough energy to jump across the gap between the coating
surface and the underlying steel if a holiday exists, but not enough energy to
break through the coating.
Most coating resin materials (epoxies, isopolyesters, vinyl esters) have a dielectric
strength of 300 to 350 volts per mil. It is important to have sufficiently high voltage
to bridge the pinholes air gap to the steel substrate without burning through the
solid coating. The voltage recommendations of the coating suppliers are normally
acceptable.
Note If a final wax or gel coat is required, the inspector should carry out the
holiday test and require coatings applicators to make any repairs before the final
coat is applied. This requirement prevents the wax or gel coat from covering up
possible holidays in the underlying coats. If the coatings applicators make any
repairs after applying the wax or gel coat, they must remove that coat and re-apply
it after completing the necessary repairs.
Water Test. Scheduled after the voltage test, the water test involves filling the tank
with water (sometimes salt water) and leaving it for several days. After the tank is
drained, rust spots on the coating reveal pinholes. The test is more complete than the
voltage test because water touches all surfaces of the tank; the low-voltage sweeper
may miss some parts.
Note The Company runs the water test infrequently as it is expensive and time
consuming.
Testing for Final Surface Cure. The inspector must test the final surface cure of
laminates with a Barcol hardness tester and an acetone wipe test. This requirement
is particularly important for isopolyester and vinyl ester resins which will not fully
cure without a wax coat.
Note The coatings applicator must sand off the wax layer to obtain an accurate
test because full surface curing is essential for the coating to have its optimum
chemical resistance.
Offshore Coatings
The inspection process for offshore coatings is detailed in specification COM-MS-4771.
Those who need assistance with interpreting the specifications or have other questions
pertaining to the specification should contact the Companys coating specialist (see the
Quick Reference Guide).
Pipeline Coatings
There are many different types of pipeline coatings, each with many completely
different properties and application procedures. The Company therefore recom-
mends following the inspection procedures written as part of the various specifica-
tions for each type of coating system. Those who need assistance with interpreting
the specifications or have other questions pertaining to the specification should
contact the Companys coating specialist.
Caution Due to the environmental risk associated with the failure of a pipeline
coating, the Company recommends following the most complete inspection program
available, which includes having a full-time, qualified inspector.
Wrapping Lights
Problem: Protective light lenses are sensitive to overblast and overspray.
Solution: Wrap in plastic sheeting and duct tape.
Problem: Sheeting melts on the protective lenses.
Solution: Wrap lenses in chicken wire before wrapping in the sheeting. This
will prevent sheeting from melting and provide more permanent
protection for the entire job.
Plugged Drains
Problem: How to prevent sand from clogging drains while allowing small
amounts of water to drain through when raining or when washing area.
Solution: Stuff filter media (woven polyester fibers, and adhesives for filtering
air intakes on engines) into the drain and tie to the cover with a piece
of manila twine.
Problem: Drains surrounded by troughs. Can coatings applicator remove sand
without shoveling out each trough?
Solution: Lay a sheet of filter media over the trough in addition to plugging the
drain.
outer layer only; leave the inner layer to filter dust during the several-minute
changeout process.
4. Monitor the filtration closely to ensure that it is adequate and installed properly.
Containment Screens
Problem: Isolate particular areas to keep the remainder of a facility clean
during blasting (reduces cleaning time).
Solution: Strategically position containment screens, usually square or rectan-
gular polypropylene solid or mesh screens of various sizes from
40 ft. 40 ft., to collect spent blast abrasive, dust, and airborne parti-
cles of coating.
Note Items in square work area include the tops and bottoms of all piping, braces
and stiffeners, the interior of the wide flange beam webs and flanges, and the
bottom side of the beam flanges.
Solution 2 Re-sweep before squaring work area after carrying out several days
Blasting of rough blasting with appropriately sized blast nozzles and abra-
Procedures: sive. Proper blasting technique ensures the blast nozzle is pointed
away from previously coated surfaces and toward the surfaces to
be blasted, especially during touch-up feathering and spot blasting.
Note Rough or high-productivity blasting calls for larger nozzles, orifice sizes of
5/16 inch or larger venturi; spot and touch-up blasting require smaller nozzles, 3/16
inch or smaller, with straight-bore orifices.
Solution 3 During blasting and coating, wrap to protect all items that will
Protective Wrap-neither be blasted nor coated. The cost of the labor and materials
ping: necessary to add protective wrapping results in a far superior job
and minimizes costs for rework of prematurely failed areas.
Common Shielding
Plastic sheeting, tarpaulins, and burlap sacks are some of the more common
shielding materials.
Problems:
Plastic sheeting is susceptible to overblast damage.
170 References
1. Chevron Corporation. Corrosion Prevention Manual. Chevron Research and
Technology Company. Richmond, CA, January, 1994.