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NAVAL SEA SYSTEMS COMMAND NAVAL SEA SYSTEMS COMMAND Performance Update - High Solids Tank Coatings Performance Update - High Solids Tank Coatings

Mega Rust – 2015Norfolk, VA

June 2015

Mr. Mark Ingle, P.E.

SEA 05P2

(202) 781-3665

mark.w.ingle@navy.mil

Distribution A – Approved for Public Release

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Objectives

• Summarize evolving Naval Sea Systems Command (NAVSEA) organization and coating requirements:

•• Headquarters NAVSEA Organization & Objectives.

• Summarize history and background for extending tank coating service life through the use of high-solids, and rapid-cure, single-coat, tank coatings:

•• Business case or motivation for effort.•• SEA 05 policy & requirements.

• Discuss results to date on high-solids tank coatings.•• Ballast tanks.•• Other tanks.

Naval Systems Engineering Directorate (SEA 05)

Technical Domain Manager (TDM)Chief Systems Engineer (CSE)

Office of the CHENG

SEA 05B Deputy / COS(SEA 05B1)

Aircraft Carrier Design & Systems Engineering (SEA 05V)

Chief Finance Office(SEA 05B3)

Surface Ship Design & Systems Engineering (SEA 05D)

Integrated Warfare Systems Engineering (SEA 05H)

Cost Engineering & Industrial Analysis (SEA 05C)

Ship Integrity & Performance Engineering (SEA 05P)

Chief Workforce Office(SEA 05B2)

Special Projects(SEA 00U/05X)

Executive Director / CHENG Deputy / Chief Technology Officer (SEA 05B)

Littoral and Mine Warfare Design & Systems Engineering

(SEA 05L)

Submarine/Submersible Design & Systems Engineering

(SEA 05U)

Undersea Warfare Systems Engineering (SEA 05N)

(NUWCNPT TD)

Surface Warfare Systems Engineering (SEA 05W)

(NSWCDD TD)

Marine Engineering (SEA 05Z)

L&MW Warfare Systems Engineering (SEA 05M)

(NSWCPC TD)

Explosive Ordnance Engineering(SEA 05E) (NSWC IH TD)

Deputy Commander/CHENG (SEA 05)

Chief HR & Admin Office(SEA 05B6)

Draft: June 2015

SEA 05P2

Code Product Related SpecsAll All Technical Products, Managerial AllAF Antifouling Coating Systems MIL-PRF-24647TNK Tank Coatings, Epoxy Primers MIL-PRF-23236

MIL-DTL-24441PRM Primers, Single Component TT-P-645TOP Topside, Alkyds & Polysiloxanes MIL-PRF-24635INT Interior Coatings (SEA 08) MIL-DTL-24607

MIL-PRF-24596MIL-DTL-15090MIL-DTL-1115

HT High Temp Coatings, Metallic TT-P-28PWD Powder, Interior, Cosmetic MIL-PRF-24712NSK Nonskid MIL-PRF-24667DCK Deck Coverings MIL-D-3134

MIL-PRF-3135MIL-PRF-24613MIL-PRF-32171

SUR Abrasive blasting, surface prep MIL-A-22262SEL Sealants & Preservatives MIL-PRF-16173

NAVSEAINST 9360.1DOC Policy Documents NSTM 631, NSTM 634

Standard Item 009-32Standard Item 009-26

COR Corrosion/PCOE Policy/Design DODI 5000.67RSH Research & Development To be determinedUNDS Regulations, Underwater hull TBD

NAVAIR Aircraft Engines

TWH: Habitability

SEA 08R

TWH: Underwater Hull Husbandry

SDMs: Surface, Submarine,

Carrier

Technical Authority Pyramid - Coatings & Corrosion Control - ShipsDraft: June 2015

Navy Employee Navy Developmental Employee Contractor

Ingleall

Castle(EM)

All, COR

LemieuxLemieux(EA)

All, RSH

Vacant(EM)

NSK, All

Wegand(EM)

RSH, NSK

Lattner(EM)COR

Haslbeck(EM)

All, AF

J. Martin(EM)

TOP, TNK

Melhuish(EM)

All, NSK

Brinckerhoff(EM)All

Tagert(EM)

TNK, NSK

Kenney(EM)

VA-Class

Jones(EM)

NSK, DCK

Iezzi(EM)

RSH TOP

Smith(EM)

UNDS

Wigle(EM)

CCAT

Slebodnick(EM)

RSH,TNK, NSK

Merlino(LE)

DOCs

Ehrich(LE)COR

Thomas(LE)COR

Clayton(LE)

DOCs

Lawrence(LE)AF

LangasterTNK

HolmAF

Eppard(LE)

NSK, RSH

ChasseCOR

MiekleCOR

CisconAll

ParkDOCs

FosterAll

StankeRSH, All

F. MartinHT

BerghTNK, SUR

Needham(LE)

COR, All

WebbRSH

InternAll

EllorCOR

AultTNK, RSH

Steinberg(LE)AF

Ranero(EM)

All, NSK

EAs

EMs

LEs

KoglerSUR

TWH

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Delegated signature authority

Duckworth/Duckworth/DeloachDeloach

(EA)All

McKelvey(EM)

COR, DOC

Tank Coating History

• There are ≈ 9,4009,400 tanks on Navy ships that contain:- Fuel (ships & aircraft) - Ballast water - Cooling Water- Potable water - Wastewater

1997, tank recoating was largest cost item (~25%) in availability work packages with annual cost estimate of ~$244M to re-preserve tanks/voids.

• Modern ballast tank coating era began on 27 Sept. 1971 with implementation of MIL-P-24441, “Mare Island” Formula 150 epoxy.

•• Polyamide epoxy formulation that contains <340 gm/l volatile organic compounds (VOC), (still in service in U.S. Navy).

•• Product was intended for “universal” service including potable water.•• System effectively supports 3 to 5 year docking cycles.

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Poor performance on welds, corners, and edges – Not edge-retentive.

Mare Island epoxy is a good coating with long history of service on Navy ships.55

What is Edge Retention?

Edge retention of high-solids,rapid-cure, single-coat paint

Edge Retention Evaluation of MIL-DTL-24441

Old solvent-based epoxy pulls away fromthe edge.

New solvent-free, edge retentive epoxy

MIL-PRF-23236 Appendix A requires measurement of coating thickness on aluminum extrusion with 1/32-inch or 0.8mm corner radius

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Edge-retentive coatings must have >70% of the coating thickness on the flat surfaces retained on the edge

1997 Business Plan for High-solids, Edge-retentive Coatings

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● 1997 plan to shift from a 3-5 year tank recoating periodicity for Mare Island to a 20 year service life (i.e., 80% of the population being in a EXCELLENT or GOOD condition at end of service period) by:

- Qualifying ultra-high solids, edge-retentive paints.

- Improving coating application process (e.g., surface cleanliness, profile, environment, and oversight).

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1997 Business Case Proving Accurate for Seawater Ballast Tanks

∙ Business case predicated on avoiding need to repaint tanks. - 60% to 80% Job cost associated with opening and preparing tank.

- Labor and QA required to spray paint, inspect paint, and touch-up regardless of type. - Higher priced high-solids paint cures more rapidly, saves time.

88Avoiding Tank Repaint Work Using High Solids is Lowering Total Ownership Costs

* 15 UHS tanks are blistered and are rated CCIMS 3 or 4

Ballast Tank Coating Performance on LHD 2

• LHD 2 seawater ballast tanks coated in 1998/1999 to support twelve year docking.

- Larger tanks, more challenging access.- One platform, one contractor, one system.

• Tank coating assessment by Naval Research Laboratory using camera and visual inspections in 2012/2013. Total of 35 ballast tanks assessed as follows:

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All Inspected Legacy Tanks in POOR Cond.

UHS coatings can support 12-year docking with minimal risk to material condition99

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Service Life of Fuel and Compensated Fuel Showing Blistering

∙ Compensated fuel, fuel, and JP-5 tanks include wide range of service and in-service history. - JP-5 sumps and drains (e.g., 36 month inspection).

- Fuel oil storage (e.g., 120 month inspection). - Corrosion, pitting, and “steel contamination” increase blistering risk.

1010Extended service life being achieved, but blistering is significant issue.

* 13 UHS tanks are blistered and are rated CCIMS 3 or 4

What To Do About Blistering?

∙ Paint Center of Excellence funded analysis to determine if blistering is a significant risk issue for tank service life. - Do blisters lead to tank corrosion, metal loss, and the repair “hockey stick”?

- Do blisters grow and lead to catastrophic coating failure (e.g., sheets)?

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Extended service life being achieved, but blistering may be avoided without appreciable corrosion risk.

What To Do About Blistering?

∙ Corrosion data indicate blisters are not a risk to structure. - Blistered panels show similar mass loss in abrasion testing (e.g., foot traffic).

- Tanks inspection could be completed even on blistered tanks.

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Blistering would not be a problem with tank inspection and tanks could be placed back in service.

Business Case for Potable Water Tanks Initiated After Ballast Tanks in 2002

1414Potable water system limited to two coat UHS, but shifting to single coat in 2016

Qualified a Class 9/18 in 2014. Adding Class 9/18 to nextStandard Item 009-32 Update

∙ Potable water UHS tank coatings are all qualified to MIL-PRF-23236D “COATING SYSTEMS FOR SHIP STRUCTURE” that includes all corrosion control performance tests and the following additional requirements:3.4.1 Class 9 coatings shall maintain NSF International to NSF Standard 61 for 500-gallon storage tanks.3.4.2 Color in water. Color units shall not be greater than 10. 3.4.3 Taste in water. Threshold taste values shall not be greater than 2. 3.4.4 Odor in water. Threshold odor values shall not be greater than 2. 3.4.5 Chlorine residual. Chlorine residual shall not decrease in excess of 50 percent of concentration.3.4.6 Phenol contamination. The cured coating shall not leach phenolic compounds in concentrations greater

than 1 part per million.

High Solids, Type VII

Class 5/18 and 7/18 Single CoatBallast & Fuel tanks, chain lockers, voidsClass 18 signifies single-coat Class 9

Potable Water

Class 19 and Class 19/18 Well Deck Overhead

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Business Case for Potable Water Tanks Initiated After Ballast Tanks in 2002

∙ Potable water tank performance history limited to thirteen years of data. - Qualification of coatings to MIL-PRF-23236, Type VII, Class 9 is complex.

- Coating manufacturers must commit to maintain NSF 61 listing.

1313Potable water system limited to two coat UHS, but shifting to single coat in 2016

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CHT / Sanitary Tanks are Providing Up to 15 Years of Service

∙ NAVSEA never predicted extended service life for CHT/waste tanks. - Fatty acids actually degrade epoxy coatings.

- Tanks small and difficult to coat. - Qualified coatings most frequently based on novolac chemistry.

1515Performance to date suggest qualified novolac epoxy coatings can support 12 year docking

Tank/Void Coatings in New Ship Acquisition

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Expanding applications on every hull

Added to ship specification

Rapid-cure, high-solids,

edge-retentive, single coat

tank coatings

Demonstration testing

Specification Development

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Conclusions

• UHS tank coating technology developed and fielded in late 1990’s is performing effectively as measured by 1997 NAVSEA Business Case:

- Ballast tanks on track to achieve 15-20 years of service.

- Tank coatings on USS ESSEX (LHD 2) supported 12-year docking.

- Fuel, CHT, and Potable water tanks exceeding expectations.

• Key issue is end of life tank performance.•• Blistering. •• Schedule driven recoating.•• Service life beyond 20 years?

• NAVSEA to continue efforts to support extended tank coating service life.

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