corrosion in ballast tanks marine coatings rina conference feb 2010 presented by: dr m raouf kattan...
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Corrosion in ballast tanks
Marine Coatings
RINA Conference Feb 2010
Presented by: DR M Raouf Kattan - managing director
www.Safinah.co.uk
Doc No. 270CXXXP-RINA Oct 2005
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ACME = Corrosion
Air (Oxygen)
Cathode
Metal
Electrolyte
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New build costs
Misc 2%
Ohds 28%
Labour 19%
Paint 2%
Pipes etc 7%
Equip 22%
Main Eng 16%
Steel 8%
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5%
19%1%
50%
7%
7% 4%
3%
2%
2%
Repairs Spares Man Fee Dry DockLub oil Stores Provisons Crew CostsPaint Fuel
The cost of coatings
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The cost of failure
Ballast tank refurbishment– $50 - $100 per sqm
Total area for a Panamax bulk carrier - 70,000dwt - 80-100,000 sqm
New build price - $36-48 million
Percentage on average of catastrophic failure - 16%of first cost
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Prevention of corrosion
Provide a break in ACME– No Air - inert the space, some ballast water
treatment systems propose to do this, (but anaerobic corrosion)
– No Cathode - same metal to metal problems or non-metals
– No Metal - no real alternatives at present– No Electrolyte - treat the water or alternatives, no
ballast ships or water alternatives.
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Current solution
Create a physical barrier in the form of a coating to break the contact between the ACME elements.
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The solution does workWith good Surface preparation and application the Current range of products can create a suitable barrier that can last in theory up to 15 years or more
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Causes of failure
Poor design
Material selection (paint selection/specification)
Production processes control
Surface preparation
Application
In service conditions/planned maintenance
Coating chemistry
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Have regulations helped
12 new regulations and guide lines over the last 15 years to do with ballast tanks.
Little evidence that they have improved the situation beyond what paint companies may have done to respond to client demand/environmental concerns.
Statistics hard to come by.
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Size of the problem
Safinah estimate some– 7117 bulk carriers and COT– Totalling 557.6 million dwt– 7 - 8 billion sqm of ballast tank afloat– Average vessel age range 11-14 years
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Expenditure
A US Study indicated $8.5 - $11 billion is spent each year– Cost of design measures– Cost of new building measures– Cost of through life
Safinah believe these estimates to be very conservative.
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The environment
A mix of– Air temp– Steel temp– Cargo temp– Sea temp– Ballast water treatment systems– Vessel design
Creates a distorted environment within the tank from outside shell to inside shell
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The solution envelope
Design review
Design guidelines (lessons learnt)
Functional specifications
New production technologies
Scheduling
Understanding the environment
Coating strategies
HS&E challenges
Planned maintenance
Education
Regulations across the chain of activities
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Get it right - it is cheaper