ABS 49-2017 GUIDANCE NOTES ON THE APPLICATION AND INSPECTION OF MARINE COATING SYSTEMS.pdf

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1、 Guidance Notes on the Application and Inspection of Marine Coating Systems GUIDANCE NOTES ON THE APPLICATION AND INSPECTION OF MARINE COATING SYSTEMS JANUARY 2017 American Bureau of Shipping Incorporated by Act of Legislature of the State of New York 1862 2016 American Bureau of Shipping. All right

2、s reserved. ABS Plaza 16855 Northchase Drive Houston, TX 77060 USA Foreword Foreword (1 January 2017) The steel structure of a vessel is prone to corrosion throughout its service life. Due allowance should be made at the new building stage and by periodic maintenance to provide effective corrosion p

3、rotection that contributes to the continued structural integrity of the vessel. Given the emphasis on protective coatings in the various mandated Rules and Regulations and the unprecedented acceleration of coating technology, personnel involved with coatings should have factual knowledge of coating

4、systems and the applicable standards. It is the intent of these Guidance Notes to meet this need in a straight-forward and practical manner. The Performance Standards for Protective Coatings (PSPC) from IMO are intended to standardize the requirements for protective coatings for ballast tanks, cargo

5、 oil tanks and void spaces for a target of 15 years of useful life. A good quality protective coating can delay the onset of corrosion of the structure. The mandated standards represent the latest in the line of many regulatory actions taken to enhance vessel longevity and thereby enhance safety. Th

6、ere has been an increased industry focus placed on the consequences of corrosion and an increased demand for better coating performance as primary corrosion control. This has led to adoption of ballast tanks PSPC for SOLAS Chapter II Part A-1 Regulation 3-2 on December 8, 2006, and adoption of PSPC

7、for cargo oil tanks of all crude oil tankers per SOLAS Chapter II Part A-1 Regulation 3-11 on May 21, 2010. Those mandated PSPC standards specify requirements for coating application processes during various stages of new construction. To help industry to understand the major elements of PSPC requir

8、ements, ABS has produced and maintained this publication since 2007. As a direct response to the needs of industry personnel involved with the PSPC implementation, a complete revision has addressed the fundamentals of coating technology as applied to ship structures for the regulatory requirements f

9、or coatings in ballast tanks, void spaces, cargo tanks, cargo holds and outer hull anti-fouling systems. Figure 1 gives a brief timeline of requirements or recommendations from IMO and IACS. These Guidance Notes start with the basics of the chemistry, and mechanics of corrosion to understand protect

10、ive coatings as a barrier to corrosion. The coating application process technology and coating inspection for surface preparation, environmental controls, film thickness measurements and the methods of coating application are included. Once a vessel is in-service, the coatings are subject to various

11、 conditions. To aid in the assessment of the coatings in service, coating assessment methods and typical failures are illustrated as guidance. For ballast tanks PSPC of ABS classed vessels only, ABS provides the Guide for the Class Notation Coating Performance Standard (CPS) and a detailed procedure

12、 to obtain the ABS CPS notation. ABS also provides the optional notations Environmental Protection (ENVIRO) or Environmental Protection Plus (ENVIRO+) for vessels and antifouling systems are as part of the ENVIRO or ENVIRO+ Notation requirement. Please note that the adoption of ballast water exchang

13、e practices (as per IMO Resolution A.868(20) may potentially have a negative effect on the longevity of the coatings. NACE has developed a test standard (NACE TM0112-2012) to determine the potential corrosion effects of Ballast Water Treatment Systems on Ballast Tanks. These Guidance Notes become ef

14、fective on the first day of the month of publication. Users are advised to check periodically on the ABS website www.eagle.org to verify that this version of these Guidance Notes is the most current. We welcome your feedback. Comments or suggestions can be sent electronically by email to rsdeagle.or

15、g. ii ABSGUIDANCE NOTES ON THE APPLICATION AND INSPECTION OF MARINE COATING SYSTEMS .2017 FIGURE 1 Timeline of Development 1992 1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014IACS UR Z9 (Rev.1 1992, last Rev. 1996), Corrosion Protection Coatings for Cargo Hold Spaces on Bulk Carriers. IMO Res

16、. A.744(18) (adopted on 4 November 1993), IACS Z10.1 to 10.5 (1992/1992/1996/2001/2003, last 2009), Guidelines on ESP during surveys of bulk carriers and oil tankersIMO Res. A.798(19) (adopted on 23 November 1995), coating guidelines for dedicated seawater ballast tanksSOLAS Ch II-1/3.2 (amended on

17、8 Dec. 2006), IACS PR34 (effective 8 Dec. 2006) for CSR BC/OT, PSPC (IMO MSC. Res. 215(82) requirement on dedicated seawater ballast tanksSOLAS Ch II-1/3.2 (amended on 4 June 1996), IACS UI SC122, coating requirement on dedicated seawater ballast tanks. Effective on 1 July 1998IMO Res. A928(22) (ado

18、pted on 29 Nov 2001), AFS Control. Effective 17 September 2008 for flag signatory to AFS Convention. For EU, effective 1 January 2008. SOLAS Ch II-1/3.2 (amended on 8 Dec. 2006), IACS UI SC223/IMO MSC./Circ.1330 , PSPC (IMO MSC. Res. 215(82) requirement on dedicated seawater ballast tanks. Effective

19、 on 1 July 2008SOLAS Ch II-1/3.11 (amended on 21 May 2010), PSPC (IMO MSC. Res. 288(87) / CRS (IMO MSC. Res. 289(87) requirement on cargo oil tanks of crude oil tankers. Effective on 1 Jan. 2013Note: See applicable regulations for details of the above dates ABSGUIDANCENOTESONTHEAPPLICATIONANDINSPECT

20、IONOFMARINE COATINGSYSTEMS.2017iiiTable of Contents GUIDANCE NOTES ON THE APPLICATION AND INSPECTION OF MARINE COATING SYSTEMS CONTENTS SECTION 1 Corrosion 1 1 General . 1 2 Uncoated Steel and the Corrosion Reaction 2 3 Factors Influencing Corrosion Rates 4 3.1 Oxygen 4 3.2 Temperature 4 3.3 Conduct

21、ivity of Electrolytes 4 3.4 Type of Ions . 5 3.5 Acidity and Alkalinity (pH) 5 3.6 Electrochemical Potential 5 4 Types of Corrosion 5 4.1 Uniform Corrosion 5 4.2 Pitting Corrosion 6 4.3 Crevice Corrosion 7 4.4 Galvanic Corrosion 8 4.5 Deposition Corrosion . 10 4.6 Impingement Corrosion . 11 4.7 Micr

22、obiologically Influenced Corrosion (MIC) 11 FIGURE 1 Corrosion Cell . 2 FIGURE 2 Anodic and Cathodic Areas Form on the Uncoated Steel Surface 3 FIGURE 3 Diffusion Pathways near Anodes and Cathodes 4 FIGURE 4 Pitting Corrosion on Uncoated Steel, Showing Layers of Iron Oxides . 6 FIGURE 5 Different Pi

23、t Shapes 6 FIGURE 6 Crevice Corrosion . 7 FIGURE 7 The Galvanic Series of Metals with the Most Noble Metals at the Bottom . 9 FIGURE 8 Flow of Electrons in the Iron/Copper Couple 10 PHOTOGRAPH 1 Undercut Pits 7 PHOTOGRAPH 2 Pits Forming as a Result of Crevice Corrosion between the U Bolt Support and

24、 the Pipe 8 PHOTOGRAPH 3 Deposition Corrosion 10 PHOTOGRAPH 4 Impingement Corrosion 11 iv ABSGUIDANCE NOTES ON THE APPLICATION AND INSPECTION OF MARINE COATING SYSTEMS .2017 SECTION 2 Protective Coatings 13 1 General . 13 2 Factors Affecting Coating Lifetime 13 2.1 Oxygen Permeability . 13 2.2 Water

25、 Vapor Permeability 13 2.3 Liquid Water Uptake 13 2.4 Ionic Permeability 13 2.5 Coating Porosity 13 2.6 Surface Contamination 15 2.7 Surface Profile . 15 3 Types of Coating Breakdown 16 3.1 Blistering via Osmosis . 16 3.2 Blistering via Electro Osmosis . 16 3.3 Rust Jacking 17 3.4 Calcareous Deposit

26、 Jacking 17 4 Protective Coatings . 18 4.1 Barrier Effect . 18 4.2 Galvanic Effect 18 4.3 Inhibitor Effect . 19 4.4 Surface Tolerant Coatings . 19 5 Coating Compatibility 19 FIGURE 1 Schematic Coating Porosity in Single Coatings of Different Thickness 14 FIGURE 2 Schematic Coating Porosity in a Two

27、Layer System 14 FIGURE 3 Schematic Showing the Need for Stripe Coatings 15 FIGURE 4 Schematic Osmotic Blister Formation . 16 FIGURE 5 Schematic Electro Osmotic Blister Formation 16 FIGURE 6 Rust Jacking 17 FIGURE 7 Calcareous Deposits . 17 FIGURE 8 Complex Pathway Produced by Lamellar Pigments . 18

28、FIGURE 9 Residual Contamination in Pits . 19 SECTION 3 Coating Types and Their Uses 20 1 General . 20 2 Paint Composition . 20 3 Binders 21 4 Cross-linked (Thermoset) Coatings 21 4.1 Epoxy Resins 21 4.2 Polyurethane Resins . 21 4.3 Alkyd Resins 22 4.4 Inorganic Resins 22 5 Thermoplastic Coatings 22

29、5.1 Chlorinated Rubber Resins . 22 5.2 Vinyl Resins . 22 ABSGUIDANCE NOTES ON THE APPLICATION AND INSPECTION OF MARINE COATING SYSTEMS .2017 v 6 Pigments and Extenders . 23 6.1 Anti-corrosive Pigments . 23 6.2 Barrier Pigments 23 6.3 Coloring Pigments . 24 6.4 Extender Pigments 24 7 Solvents 24 7.1

30、True Solvent 24 7.2 Latent Solvent 24 7.3 Diluent Solvent 24 8 Anti-corrosion Paints . 24 8.1 Pure Epoxy 25 8.2 Modified Epoxy 25 8.3 Coal Tar Epoxy 25 8.4 High Solid Content Epoxy 25 9 Impact and Abrasion-resistant Coatings . 26 10 Shop Primers 26 SECTION 4 Surface Preparation . 27 1 General . 27 2

31、 Surface Cleanliness 28 3 Surface Cleaning 29 3.1 Solvent Cleaning 31 3.2 Abrasive Dry Blasting 32 3.3 Hydro Blasting/Waterjetting . 35 3.4 Power Tool Cleaning . 36 3.5 Hand Tool Cleaning . 37 3.6 Pickling 37 4 Preparation of Non-ferrous Metals 38 4.1 Galvanized steel with Zinc . 38 4.2 Aluminum . 3

32、8 4.3 Stainless Steel . 38 5 Steel Work before Surface Preparation 39 5.1 Weld Preparation . 39 5.2 Edge Preparation . 41 FIGURE 1 Surface Profile . 27 FIGURE 2 Schematic of Feathered Edges . 33 FIGURE 3 Contamination Trapped in the Blast Profile is Over-coated 34 FIGURE 4 Schematic Fillet Weld Show

33、ing Typical Defects that Form Voids under the Coating . 41 FIGURE 5 Types of Edge Profile 41 PHOTOGRAPH 1 Salt Contamination Testing 28 PHOTOGRAPH 2 Outer Hull Showing Application of Primer after Localized Spot Blasting 29 PHOTOGRAPH 3 Oil and Grease Stains during Block Assembly Show as Dark Stains

34、on the Shop Primer 31 vi ABSGUIDANCE NOTES ON THE APPLICATION AND INSPECTION OF MARINE COATING SYSTEMS .2017 PHOTOGRAPH 4 Poor Removal of Oil Contamination using Solvent and a Brush 32 PHOTOGRAPH 5 Abrasive Blasting . 32 PHOTOGRAPH 6 Sander Paper Grinder 37 PHOTOGRAPH 7 Abrasive Grinder 37 PHOTOGRAP

35、H 8 Pipes Undergoing Pickling . 38 PHOTOGRAPH 9 Weld Fume (Brown Stains) and Spatter 39 PHOTOGRAPH 10 Blistering where a Stiffener was Welded on the Other Side of the Plate . 40 PHOTOGRAPH 11 Complex Structure, with Lower Welds Only Accessible Through the Hole . 40 SECTION 5 Coating Application . 42

36、 1 General . 42 2 Surface Preparation 42 3 Coating Application Methods 42 3.1 Brush Application 42 3.2 Roller Application 44 3.3 Conventional Air Spray 44 3.4 Conventional Airless Spray . 44 3.5 Plural Component Airless Spray 45 4 Film Thickness 45 5 Coating Application Conditions . 45 5.1 Condition

37、 of the Substrate . 45 5.2 Temperature 46 5.3 Relative Humidity and Condensation 46 5.4 Weather Conditions . 47 5.5 Ventilation 47 5.6 Ultraviolet light (UV) 47 PHOTOGRAPH 1 Brush Applied Touch-up Paint on a Forepeak Stringer . 43 PHOTOGRAPH 2 Stripe Coating on Welded Details 43 PHOTOGRAPH 3 Airless

38、 Spray Application of Paint to Vessel Topsides . 44 PHOTOGRAPH 4 Amine Bloom 46 SECTION 6 Cathodic Protection . 48 1 General . 48 2 Cathodic Protection Systems 48 2.1 Sacrificial Anodes 48 3 Impressed Current Cathodic Protection 52 4 US EPA VGP Requirement on Cathodic Protection Systems 54 FIGURE 1

39、Sacrificial Cathodic Protection Schematic 49 FIGURE 2 Schematic Diagram of an Impressed Current System 53 ABSGUIDANCE NOTES ON THE APPLICATION AND INSPECTION OF MARINE COATING SYSTEMS .2017 vii PHOTOGRAPH 1 Normally Working Anode . 50 PHOTOGRAPH 2 Overworked Zinc Anode . 50 PHOTOGRAPH 3 Overworked A

40、luminum Anode . 51 PHOTOGRAPH 4 Heavy Calcareous Deposits . 51 PHOTOGRAPH 5 Poorly Sited Anode 52 PHOTOGRAPH 6 An Example of a Zinc Reference Electrode on a Ship 53 PHOTOGRAPH 7 An Example of an ICCP Anode on a Ship . 54 SECTION 7 Anti-fouling . 55 1 General . 55 2 Fouling 55 3 Anti-fouling System (

41、AFS) . 57 3.1 General 57 3.2 AFS 2001 Convention 57 3.3 Self-polishing Anti-fouling Coatings . 58 3.4 Insoluble Matrix (Controlled Depletion) Coatings . 58 3.5 Foul Release Coatings 58 3.6 Coating Compatibility . 59 PHOTOGRAPH 1 Light Plant Fouling . 55 PHOTOGRAPH 2 Early Stages of Barnacle Fouling

42、on an Area Where the Anti-fouling Paint had been Damaged 56 PHOTOGRAPH 3 Mussel Fouling in a Sea Chest 57 SECTION 8 IMO Performance Standards for Protective Coatings . 60 1 SOLAS Requirements on Corrosion Prevention of Ships 60 1.1 Introduction 60 1.2 Performance Standard for Protective Coatings for

43、 Dedicated Seawater Ballast Tanks in all Types of Ships and Double-side Skin Spaces of Bulk Carriers . 60 1.3 Performance Standard for Protective Coatings for Cargo Oil Tanks of Crude Oil Tankers (IMO PSPC-COT) . 61 2 IMO Performance Standard for Protective Coatings (PSPC) for Void Spaces 62 2.1 Int

44、roduction 62 2.2 Void Spaces for IMO PSPC-VOID . 63 2.3 Void Space Recommended for IMO PSPC-SWBT 63 2.4 Void Spaces with no IMO PSPC-VOID Requirement 64 3 Inspection Agreement . 64 3.1 Areas to be Coated 64 3.2 Selection of Coating System and Coating System Type Approval 64 3.3 Coating Inspector. 65

45、 3.4 Primary Surface Preparation . 71 3.5 Secondary Surface Preparation . 73 3.6 Coating Application 79 viii ABSGUIDANCE NOTES ON THE APPLICATION AND INSPECTION OF MARINE COATING SYSTEMS .2017 4 Coating Technical File (CTF) 80 5 Verification Requirements . 82 6 In-service Maintenance and Repairs 84

46、6.1 Survey Recommendations 84 6.2 In-service Condition Monitoring by the Crew . 84 6.3 Recommended Maintenance . 84 6.4 Recommended Repair 84 6.5 Coating Technical File (CTF) . 84 FIGURE 1 Illustration of IMO PSPC Spaces of Oil Tanker 62 FIGURE 2 Typical Automated Shop Primer Line . 72 FIGURE 3 ISO

47、8501-3 Weld Preparation Standard . 75 FIGURE 4 Coating Process Flow . 83 PHOTOGRAPH 1 Dry Film Thickness Gauge . 66 PHOTOGRAPH 2 Wet Film Thickness Gauge 66 PHOTOGRAPH 3 ISO 8503-1/2 Surface Roughness Comparators . 67 PHOTOGRAPH 4 Keane-Tator Surface Profile Comparator 67 PHOTOGRAPH 5 Testex Press-O

48、-Film Replica Tape 68 PHOTOGRAPH 6 Elcometer 142 Dust Tape Test Kit . 68 PHOTOGRAPH 7 Elcometer 116 Whirling and Sling Psychrometer 69 PHOTOGRAPH 8 Elcometer 319 Dewpoint Meter 69 PHOTOGRAPH 9 ISO 8502-9 Compliance Bresle Test Kits 70 PHOTOGRAPH 10 Steel Plate after Blasting on the Shop Primer Line

49、72 PHOTOGRAPH 11 Shop Primer Application. 73 PHOTOGRAPH 12 Steel Plate Coated with Shop Primer . 73 PHOTOGRAPH 13 Edge Preparation . 76 PHOTOGRAPH 14 Edge Preparation . 76 PHOTOGRAPH 15 Bristle Blasting . 77 PHOTOGRAPH 16 Vacuum Blasting 78 PHOTOGRAPH 17 SpongeJet 78 PHOTOGRAPH 18 Stripe Coating Application 80 PHOTOGRAPH 19 Spray Coating Application 80 SECTION 9 Coating Requirements for Cargo Spaces of Bulk Carriers . 85 FIGURE 1 Extent of Internal Cargo Space Areas in a Single Side Skin Bulk Carrier . 86 FIGURE 2 Extent of Internal Cargo Space Areas and Hatch Cover 86 SECTION 10 C