Protective Coatings Offshore Corrosion Corrosion protection and the cost of failure Navigating Deepwater – 26 February 2014, Houston Lasse Isaksen: Global Concept Director - Offshore INTSOK Navigating Deepwater Opportunities and Challenges, 26 February 20114, Houston Offshore Corrosion Protective Coatings Did you know? INTSOK Navigating Deepwater Opportunities and Challenges, 26 February 20114, Houston Protective Coatings Offshore Corrosion 5 metric tons of steel is degenerated every second dW World ld Wid Wide INTSOK Navigating Deepwater Opportunities and Challenges, 26 February 20114, Houston Protective Coatings Offshore Corrosion That 40% of all produced steel is used to replace corroded steel INTSOK Navigating Deepwater Opportunities and Challenges, 26 February 20114, Houston Protective Coatings Offshore Corrosion The estimated cost of corrosion is 1 8 trillion 1,8 t illi USD annually ll World W ld Wide Wid INTSOK Navigating Deepwater Opportunities and Challenges, 26 February 20114, Houston Offshore Corrosion Protective Coatings H How much h iis a trillion t illi dollar? d ll ? 100 USD 1 BILLON USD 10,000 USD 1,000,000 USD Here I am INTSOK Navigating Deepwater Opportunities and Challenges, 26 February 20114, Houston 1 Trillion USD 100,000,000 USD Protective Coatings Agenda Why things go wrong The cost of offshore maintenance Critical areas INTSOK Navigating Deepwater Opportunities and Challenges, 26 February 20114, Houston Offshore Corrosion Protective Coatings Offshore Corrosion Experience show • 95% coating failures occur due to: – – – – To incorrect specification choice Poo s Poor surface fa e p preparation epa ation Poor application Climatic conditions • 85% of coating failures appear within the first 1 1-3 3 years Image: Ballast tank INTSOK Navigating Deepwater Opportunities and Challenges, 26 February 20114, Houston Protective Coatings Offshore Corrosion Lessons learned - Norway • All Norwegian N i FPSO’s FPSO’ have h suffered ff d from f inadequate i d t paintwork i t k • The underlying problems are; – Lack L k off priority i it and d ti time allocated ll t d tto this thi activity ti it – Quality control of preparation and finishing has been mixed – Painting in Singapore has been particularly poor due to humid conditions • Painting of FPSOs is critical area to ensure low maintenance facility • Work often conducted late when the pressure for sail away is high Source: Norwegian oil and gas association INTSOK Navigating Deepwater Opportunities and Challenges, 26 February 20114, Houston Protective Coatings Agenda Why things go wrong The cost of offshore maintenance Critical areas INTSOK Navigating Deepwater Opportunities and Challenges, 26 February 20114, Houston Offshore Corrosion Offshore Corrosion Protective Coatings CAPEX versus OPEX the balancing act Spend money up up-front, front, save on maintenance Save money up up-front, front, spend on maintenance OPEX CAPEX INTSOK Navigating Deepwater Opportunities and Challenges, 26 February 20114, Houston Offshore Corrosion Protective Coatings A large ageing offshore infrastructure • 6000 fixed platforms • 184 floating production units “More than 50% of the DNV classed mobile units is above 20 years of age” • 650 offshore drilling rigs • 2900 subsea wells operating • 60% of the world offshore fleet are past their theoretical design age of 20 years • Lifetime extension programs on-going and being planned Source: Douglas-Westwood INTSOK Navigating Deepwater Opportunities and Challenges, 26 February 20114, Houston Protective Coatings Offshore Corrosion Offshore maintenance 15-20 times more costly compared to performing work at yard Source: Douglas-Westwood INTSOK Navigating Deepwater Opportunities and Challenges, 26 February 20114, Houston Offshore Corrosion Protective Coatings “ DVN-RP-C302: Coatings are the only cost-effective means to control atmospheric corrosion “ Corrosion can account for 60% of offshore maintenance cost Source: P. Cavassi and M. Cornago: "The Cost of Corrosion in the Oil and Gas Industry", JPCL, May 1999 INTSOK Navigating Deepwater Opportunities and Challenges, 26 February 20114, Houston Protective Coatings Maintenance Challenges • Delay and backlogs on fabric maintenance work due to lack of bed capacity • Scaffolding will provide best work efficiency and result • Inspection p p program g for integrity g y of p passive fire protection often lacking • Inspection program for corrosion under insulation often lacking INTSOK Navigating Deepwater Opportunities and Challenges, 26 February 20114, Houston Offshore Corrosion Protective Coatings Agenda Why things go wrong The cost of offshore maintenance Critical areas INTSOK Navigating Deepwater Opportunities and Challenges, 26 February 20114, Houston Offshore Corrosion Protective Coatings The Water Ballast Tank challenge • Ballast tanks pose a high corrosion risk due to contaminants in seawater and various water levels in tank. • Complex geometry where application errors easily can occur • CP only works when submerged • Offshore units using ballast tanks for storage, risk SRB corrosion SRB= Sulphate Reducing Bacteria INTSOK Navigating Deepwater Opportunities and Challenges, 26 February 20114, Houston Offshore Corrosion Protective Coatings Offshore Corrosion Crude oil tank environment • • • • Upper deck plate exposed to general corrosion due to sour environment Bottom B tt plating l ti exposed d to t pitting itti corrosion. i Typical caused by a defect in the coating Double hull more exposed p to p pitting g corrosion due to elevated temperature that will activate the Sulphate Reducing Bacteria (SRB) Sour crude and elevated temperatures will increase risk of pitting corrosion in bottom of tank Inert Gas: H₂O O₂ SO₂ CO₂ Crude Oil: H₂S H₂O Inside Tank: H₂S H₂S+ O₂ O₂+ H₂O Upper deck plate (Dew occurs under upper plate) Sour Gas Crude Oil Sludge, Drainage Bottom plate g occurs Pitting INTSOK Navigating Deepwater Opportunities and Challenges, 26 February 20114, Houston Protective Coatings Offshore Corrosion C a hidden CUI hidd time i b bomb? b? • Potential major accident and a growing concern for an aging fleet • Studies show over 60% of leaks on HC systems are caused by ageing processes such as fatigue, fatigue and corrosion • Fire and explosions, usually a consequence of a HC leak • Factors accelerating corrosion under insulation (CUI): – – – – Availability of moisture Availability of oxygen High temperature High concentration of dissolved aggressive species INTSOK Navigating Deepwater Opportunities and Challenges, 26 February 20114, Houston Protective Coatings Offshore Corrosion The coating advisor a curtail role • Good technical support is critical for a good result • The coating advisor inspect, log and report – Surface preparation – Environmental monitoring – Paint application • Coating advisor should have FROSIO or NACE certification INTSOK Navigating Deepwater Opportunities and Challenges, 26 February 20114, Houston Protective Coatings FPSO example – not including PFP • FPSO cost 800 MUSD • Cost of paint 1% of total investment = 8 MUSD • Cost of surface preparation 4% = 32 MUSD • Cost of scaffolding 3% = 24 MUSD T t l paint Total i t related l t d cost: t 64 MUSD INTSOK Navigating Deepwater Opportunities and Challenges, 26 February 20114, Houston Offshore Corrosion Offshore Corrosion Protective Coatings LCC example – FPSO conversion 13 year design life • Same paint system different surface treatment 50% lower maintenance cost 2 maintenance cycles during lifetime 1 maintenance cycles during lifetime Water jetting, corroded areas spot blasting INTSOK Navigating Deepwater Opportunities and Challenges, 26 February 20114, Houston Full blast Sa 2,5 Protective Coatings LCC example - Condition after 3 years INTSOK Navigating Deepwater Opportunities and Challenges, 26 February 20114, Houston Offshore Corrosion Protective Coatings Offshore Corrosion Pictures from construction phase – CA report Example of typical challenge Remark: Blasting and painting at workshop good quality however, but after back to yard, a lot of mechanical damage and dirt. S l i Solution chosen h by b yard: d one layer l off topcoat INTSOK Navigating Deepwater Opportunities and Challenges, 26 February 20114, Houston Protective Coatings Offshore Corrosion Summary • Specify suitable coating systems for the design life on the asset • Take care during surface preparation and application stage, stage make sure you have qualified technical personnel to follow-up • Coating advisors from paint manufacturer often have a good relationship with the yard and can be helpful in getting the best possible result • It makes good economy to get it right during CAPEX stage INTSOK Navigating Deepwater Opportunities and Challenges, 26 February 20114, Houston Offshore Corrosion Protective Coatings Lasse isaksen@jotun com [email protected] INTSOK Navigating Deepwater Opportunities and Challenges, 26 February 20114, Houston
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