Wigle

Corrosion Control
Assistance Team (CCAT)
Program – Mega Rust 2014
Program Manager – Mark Lattner, NAVSEA 05PF
[email protected] Phone #: (202) 781-1298
Project Engineering Lead - Jim Wigle, NSWC CD
[email protected] Phone #: (301) 227-8976
CCAT Operations Manager – John Soeder
[email protected] Phone #: (757) 621-2947
Distribution A: Approved for Public Release, distribution unlimited.
CCAT Mission & Objectives
Mission: Educate and Assist Fleet Sailors in
Ship Preservation & Corrosion Control
Objectives:
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Increase Efficiency & Effectiveness of Ship’s
Force Corrosion Control Efforts
Enhance Ship’s State of Material Readiness
Improve Ships Force Self Sufficiency
Reduce Ship Total Ownership Cost
Enhance Ships’ Capability to Perform Preservation
2
CCAT Capabilities
 Tools
• Pier-side Preservation Tool Complement & Issue (Tool Depot)
• Air Compressor Support
• Maintenance of Ship-Owned and CCAT Tools
 Training
• Ship Force Corrosion Control and Tool Use Training – Classroom and OJT
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Basic Corrosion Control, Coatings and Tool Training
C5I Corrosion Control Training
Ship Supervisory (Officer and CPO) Corrosion Control Training
Polysiloxane Maintenance and Application
• Proper Corrosion Control Material & Coating Selection
 Technical Expertise
• HM&E & C5I Corrosion Control Experts on the Deck plates providing Technical Guidance
and Oversight to SF
• Support in Planning of Ship Corrosion Control Maintenance
 Technology Introduction
• Introduce Sailor-Friendly State of the Art Technology
The Four “T’s”
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CCAT 4T’s
Tools / Training / Tech Assist / New Technology
Before
4
After
Current/Planned CCAT
Deployment
Everett
Yokosuka
Sasebo*
Norfolk
(CRUDES)
Little Creek
San Diego
(AMPHIB)
Pearl Harbor – FY15
Mayport
Current
Planned
* Full Sasebo CCAT stand-up in progress
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CCAT Team Composition
and Qualifications
 Typical Configuration is 5 Team Members
• Team Lead/Head Technical Expert
 NACE CIP Level III (w/ peer review) and min of 10 years
experience working on Navy ships.*
• (2) HM&E Technical Experts
 NACE CIP Level III (w/peer review) and min of 5 years
experience.*
• (1) C5I Technical Expert
 NACE CIP Level I and min of 5 years experience.*
 Extensive knowledge maintaining Navy C5I equipment.
• (1) Tool Technician
 NACE CIP Level I and min of 5 years experience.*
 Extensive knowledge of tool maintenance and repair.*
* Note: CCAT requirements per NAVSEA ltr 9630 Ser 05P/212 dtd 12 May 11
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CCAT Team Composition
 San Diego Team (8 personnel)
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Team Lead
(5) HM&E Techs (Added 1 – Sep 13)
(1) C5I Tech
(1) Tool Tech
 Everett / PNW Team (4 personnel)
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•
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Team Lead
(1) HM&E Tech U/I (Added for CVN 74)
(2) Tool Tech (Added 1 for CVN 74)
 Yokosuka Team (5 personnel)
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Team Lead
(2) HM&E Techs
(1) C5I Tech (Added – Sep 13)
(1) HM&E Tech / Tool Tech
 Sasebo Team (3 personnel) – (Apr 14
start-up)
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•
•
 Norfolk Team (6 personnel)
Team Lead
(1) HM&E Tech
(1) HM&E Tech / Tool Tech (July 14)
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•

Team Lead
(3) HM&E Techs (Added 1 – Mar 14)
(1) C5I Tech
(1) Tool Tech
LCRK Team (5 personnel)
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•
•
•
Team Lead
(2) HM&E Techs
(1) C5I Tech
(1) Tool Tech
 Mayport Team (5 personnel)
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•
•
•
Team Lead
(2) HM&E Techs
(1) C5I Tech
(1) Tool Tech
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Project Developments and
Technology Introduction
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Aircraft Carrier CCAT Support
2012-14
•
USS RONALD REAGAN (CVN 76) FY12 DPIA (PSNS):
– Flight Deck Overhangs (Port/Stbd) Preservation
– Island Superstructure Preservation
– Training on Freeboard Maintenance Post Dry-Docking (Polysiloxane)
•
USS CARL VINSON (CVN 70) FY12 PIA (San Diego)
– Spot preserve, clean, scuff sand and top coat with Polysiloxane
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Main Mast
SPS-49 Tower
Island Superstructure
– 62 Water Closets / Washrooms (Heads) Refurbished
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USS CARL VINSON (CVN 70) Aug 13 Upkeep (San Diego)
– Training and Tech Assist for Bilge Preservation in MMR 1
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USS JOHN C STENNIS (CVN 74) FY13 DPIA (PSNS)
– CNAP Tool Depot Operations & Maintenance
– Spot preserve, clean, scuff sand and top coat with Polysiloxane
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•
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Main Mast
SPS-49 Tower
Island Superstructure
– Vent Plenum and Fan Room team assist (9 condition 2/3/4 worked)
– CAT #3 Wing Voids
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USS CARL VINSON (CVN 70) Mast , Island and
SPS-49 Tower Preservation with Polysiloxane –
July to Sept 12
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USS CARL VINSON (CVN-70)
ISLAND 12 MONTH INSPECTION – OCTOBER 2013
ALL AREAS ON BULKHEAD AND
OVERHANG IN GOOD CONDITION
NO SIGNS OF CORROSION.
ALL AREAS ON BULKHEAD AND
OVERHANG IN GOOD CONDITION
USS CARL VINSON (CVN-70)
MAST 12 MONTH INSPECTION – OCTOBER 2013
MAST STRUCTURE IN
GOOD CONDITION
NO SIGNS OF CORROSION AND GLOSS IS
HIGHLY VISIBLE.
YARD ARM SHOWING NO SIGNS OF
CORROSION
AREA IN GOOD CONDITION NO
CORROSION FOUND.
USS CARL VINSON (CVN-70)
SPS-49 TOWER 12 MONTH INSPECTION – OCTOBER 2013
NO CORROSION FOUND.
NO STAINING OR CORROSION RUN OFF
FOUND
ALL AREAS IN GOOD CONDITION
USS JASON DUNHAM (DDG 109)
Mast - Oct 2013 Scuff Sand/Spot Preserve (INTERBOND
998 Red)/Top coat (PSX 700 Haze Gray)
USS JASON DUNHAM (DDG 109)
Mast - Oct 2013 Scuff Sand/Spot Preserve (INTERBOND
998 Red)/Top coat (PSX 700 Haze Gray)
Mast 06 Level
USS JASON DUNHAM (DDG 109)
Mast - Oct 2013 Scuff Sand/Spot Preserve (INTERBOND
998 Red)/Top coat (PSX 700 Haze Gray)
Mast 07 Level
USS JASON DUNHAM (DDG 109)
Mast - Oct 2013 Scuff Sand/Spot Preserve (INTERBOND
998 Red)/Top coat (PSX 700 Haze Gray)
Mast 08 and 010 Level
USS JOHN S MCCAIN (DDG-56)
MT 21 FWD CIWS 03-112-0-W – May 13
INTERBOND 998, Silicon Alkyd Deck Gray, Peel & Stick
USS SAMPSON (DDG-102)
FIRE CONTROL SYSTEM (FCS #3) – FEB 2013
CORROSION THROUGHOUT DECK
AFTER APPLICATION AND CURE OF
PRIMER
AFTER PREP AND WIPE-DOWN OF DECK
AFTER APPLICATION OF 3M PEEL
AND STICK AND DECK GREY TRIM
USS CARL VINSON (CVN-70)
MMR1 Bilge Pocket Preservation – JULY 2013
CORROSION
THROUGHOUT DECK
FIRST COAT OF PRIMER INTERBOND 998
HAZE GRAY
SURFACE PREPARATION SSPC SP-11
TOP COAT INTERBOND 998 RED
USS JOHN C STENNIS (CVN-74)
Vent Plenum 01-235-4-Q November 2013
Initial Condition 4
USS JOHN C STENNIS (CVN-74)
Vent Plenum 01-235-4-Q November 2013
Surface Prep SP3/11
Over Head Insulation
Prime Coated with
Interbond 998 Red
USS JOHN C STENNIS (CVN-74)
Vent Plenum 01-235-4-Q November 2013
Top Coated with
Interbond 998 Haze Gray
USS ROOSEVELT (DDG-80)
PORT OVERBOARD DISCHARGES - July 2012
July 24, 2012 CUSTOM
VERSA TOOL TO REACH
INSIDE DISCHARGE
July 24, 2012 PRIME
COAT 998
July 24, 2012 SP-11
July 25, 2012 Haze gray
Topcoat
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USS BATAAN (LHD 5)
ATG ANTENNA – MAY 2013
WEATHER SEALING
AS-2815 Fleet Broadcast Antennas
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USS PELELIU (LHA-5)
AFT RAM LAUNCHER INTERBOND 998 Primer /PSX 700
Polysiloxane Topcoat – March 2014
SPOT CORROSION THROUGHOUT LAUNCHER
AND LIGHT GRAY TOP COAT TURNING GREEN
AFTER PREP AND WIPE-DOWN OF RAM
LAUNCHER
AFTER APPLICATION OF INTERBOND 998
PRIMER
APPLICATION OF POLYSULFIDE
COMPLETED
USS PELELIU (LHA-5)
AFT RAM LAUNCHER INTERBOND 998 Primer /PSX 700
Polysiloxane Topcoat – March 2014
APPLICATION OF INTREPID PRIMER TO
BATHTUB AND AREAS OF NON-SLIP
INTREPID NON-SLIP APPLICATION
COMPLETED
PSX-700 POLY SILOXANE HAZE
GRAY COMPLETED
AFTER APPLICATION AMERON PSX-700 POLY
SILOXANE LIGHT GRAY TO TOP OF LAUNCHER
Difficult Projects and Corrosion
Problem Areas
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USS JOHN S MCCAIN (DDG-56)
Bridge Windows 04-130-0 – May 13
INTERBOND 998 DG, Silicon Alkyd Haze Gray
USS CURTIS WILBUR (DDG-54)
RAS #4 02-113-2-W – March 13
USS FITZGERALD (DDG 62)
Port Side Vent Louvers
INTERBOND 998 Red/Silicone Alkyd Haze Gray LSA
USS FITZGERALD (DDG-62)
Amidship’s Bulkhead (behind PCMS)
USS JOHN S MCCAIN (DDG-56)
Aft Mixing Room Deck 02-242-0 – Jul12
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USS SAMPSON (DDG-102)
2B Gas Turbine Dirty Side Intakes – (Feb 13)
PRIOR TO START – CORROSION
THROUGHOUT DECK
SPOT PRESERVATION WITH 1ST COAT OF
PRIMER
SPOT REPAIR – SP-11 SURFACE PREP
AFTER APPLICATION OF FULL 2ND
COAT OF PRIMER
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USS SHOUP (DDG-86)
2A GTM ACCESS LOUVERS INTERBOND 998 Primer /
Silicone Alkyd Haze Gray LSA – March 2014
CORROSION THROUGHOUT
LOUVER AND ACCESS
AFTER APPLICATION OF INTERBOND 998
PRIMER RED
SURFACE PREPARATION SSPC SP11 BEING COMPLETED
TOP COAT LSA HAZE GRAY
USS TRUXTUN (DDG 103)
RAST Track - Nov 2013
INTERBOND 998 Red / LSA Deck Gray
Making a Difference – Projects
After 12-24 months
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USS FARRAGUT (DDG 99)
NR 3 GTG DOG HOUSE (1 of 2) – Feb 12
USS FARRAGUT (DDG 99)
NR 3 GTG DOG HOUSE (2 of 2) – Feb 12
July 1, 2013
July 1, 2013
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USS SAN ANTONIO (LPD 17)
Fan RM 03-46-1-Q; 2+ years in service without maintenance
SP-11 entire deck/AMERON 240 Dk Gray & 240 Terracotta
Before & After
USS John S. McCain DDG-56
Sonar Skid
1 November 2011
10 January 2013
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Before & After
USS John S. McCain DDG-56
Starboard Break
21 October 2011
14 January 2013
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Shipboard Corrosion Control Technical
and Practical Issues
(SF or O-Level)
• Bilge Coating Application at <50oF steel temps. In cold water ports SF
cannot apply bilge paint at steel temps <50oF per NSTM 631. Allow use of MILPRF-23236 Ty VII Cl 17 coatings down to Manufacturers PDS min temp as an
interim (18-24m) fix. Update NSTM 631 and issue ISE Advisory.
• Smoke Pipe and Bliss Cap black color requirement. NSTM 631 coating
table do not permit black coatings on Bliss Caps. Most ships paint these areas
black using BBQ paint or Silicone Alkyd LSA. (practical issue – actual fleet/ship
maintenance practice). Allow use of black high temp paint (Amercoat PSX 892HS
or TT-P-28 Type I) black coatings. Require ship to get authorization from
CNSL/CNSP.
• Ship’s Force application of AF coatings to boot top. Due to fouling
residue, mechanical damage and fading, Ships routinely overcoat the boot top
area with unapproved coatings (i.e. black Silicone Alkyd LSA). Initiate project to
develop containments (or utilize existing COTS) that will prevent paint and paint
chips from falling into the water. Allow SF to apply AF black to boot top areas
utilizing containments and update SHML (CCAT oversight). Develop “sailor
friendly” black AF coating that the ships can use to touch-up boot top areas.
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Shipboard Corrosion Control Technical
and Practical Issues
(SF or O-Level)
• AFFF station deck coatings for Ships Force application. AFFF deck
coatings (MIL-PRF-32171 Ty V; Cl 1/2) cannot be applied by SF and can be
expensive to have shipyards install. Allow SF to apply MIL-PRF-23236 Ty VII Cl17
coatings to AFFF station decks as a maintenance (18-24m) coating. Conduct SF
demo with surface prep to SP-11. If successful, update NSTM 631 tables and PMS
to allow SF application of MIL-PRF-23236 Ty VII Cl 17 coatings to AFFF decks and
issue interim ISE Advisory.
• Update PMS to allow use of MIL-PRF-23236 Ty VII Cl 17 Coatings. PMS
for gas turbine intakes (MIP 2513 MRC U-2) and interior/exterior maintenance
painting (MIP 6300 MRC U-2) require use of MIL-DTL-24441 series primers and
topcoats. Contradicts NSTM 631 tables that allow use of MIL-PRF-23236 Ty VII Cl
17 coatings as the primary coating choice and creates confusion onboard ships and
with port engineers. Change PMS MRCs to reflect NSTM 631 tables and issue ISE
Advisory.
• Bliss Cap deck coating requirements. DDG 51 class (DDG 51-88) Bliss Cap
decks are corroding and deteriorating requiring significant structural repairs. New
construction and maintenance coating systems are inadequate and NSTM 631 and
NAVSEA SI 009-32 coating tables do not specifically address these areas. Allow
MIL-PRF-23236 Ty VII Cl 5 or 17 primers (2 coats with stripe) and top coat with an
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appropriate exterior topcoat.
Shipboard Corrosion Control Technical
and Practical Issues
(SF or O-Level)
• Severe Corrosion under PCMS tiles. Can cause significant structural
damage on ships. SF needs better repair and maintenance guidance to provide
long term corrosion control. Update PMS and NSTM 631 to reflect use of MILPRF-23236 Ty VII Cl 17 coatings as a primer system under PCMS tiles.
Emphasize sealing PCMS tiles with approved caulk.
• Develop SF Touch-Up procedure for DDG Gas Turbine intake
louvers. Poor installation practices and excessively thick coatings cause minor
cracks that lead to spot corrosion and running rust. Develop SF T/U procedure
using MIL-PRF-23236 Ty VII Cl 17 coatings as a primer with MIL-PRF-24635 TY
V and VI top coats that extend life of fluidized bed coating.
• Ship Application of Non-skid Color Topping on Non-Critical Decks.
SF will color top non-skid decks with unapproved products for cosmetic and slip
resistance issues (practical issue – actual fleet/ship maintenance practice). Allow
use of INTERCRYL 588 or similar product on a one time “fix” at the ship’s CO
discretion for non-critical non-skid decks. Update NSTM 631/634 and issue ISE
Advisory.
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Additional CCAT Identified
Waterfront Issues
• Advanced Coating Procurement by Ships
– NAVSUP / GSA process is slow
– Ship SUPPOs will not purchase due to cost (despite advantages)
– Supply System issues (MIL-SPEC and generic NSNs)
• Single Maintenance Pier at Naval Stations (Increase CCAT ship support
efficiency)
• Increasing Fleet Demand (supporting 4-5 ships at one time)
• Lack of Ship Preparation for CCAT Visits (No work list or 2Ks)
• Large Back-Log of Corrosion Maintenance on Ships (COSMOS –
INSURV and Corrosion Surveys)
• Improper Paint Mixing by Ships (when CCAT not onboard)
• Paint Locker Disarray
• Environmental Compliance by Ships (containment and dust collection)
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CCAT Summary & Way-Ahead
 Educate and Assist SF to Increase Efficiency and
Effectiveness of Corrosion Control Efforts
• Improved/efficient tools, abrasives and processes for surface prep and
increase coating longevity with better processes and materials.
 Tools, Training, Technical Expertise, and New Technology
• Not a labor force or assessment team.
 Focus on Doing
• SF completing 2-Kilos.
 Funding
• Painting Center of Excellence Program is funded via SEA05P.
 CCAT Expansion
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New CCAT location in Sasebo (started April 14).
Increased capacity (manning) in Norfolk, San Diego and Yokosuka.
Aircraft Carrier support (expanded in 2013 and 2014).
Pearl Harbor CCAT start-up (early FY15 start planned).
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