the motorship dec2011
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Motorship
THE
DECEMBER 2011 Informing Shipping Professionals since 1920
Vol. 92
Issue 1088
SET OUT TO SEA WITH
ENERGY-EFFICIENT PUMPS
FROM GRUNDFOS
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COATINGS & CORRISION
18 www.motorship.com December 2011
The right hull coating can, claim several paint
suppliers, make a real difference to a ship’s fuel
consumption and environmental performance,
through lowering hull resistance, and maintaining
smoothness throughout the life of the coating.
The problem with such claims is how to provetheir validity. It is not difficult to prove that, after
drydocking and recoating with a new product, fuel
consumption is lowered; that is almost inevitable. But
ship operators need to know that the superior
performance is being maintained.
Norwegian manufacturer Jotun announced earlier
this year (see The Motorship , May 2011) that it was
prepared to guarantee its HPS system by offering
to refund the extra cost if the savings were not
maintained within agreed limits throughout a 60-
month period. This, according to Jotun, can be proved
by analysis of vessel speed, wind, draught and
shaft power.
DEMONSTRABLE IMPROVEMENTS
Jotun has been joined on providing a method of
quantifying claimed improvements by International
Paints. International has joined forces with BMT Argoss
to, as the company puts it, “deliver demonstrable and
transparent improvements in performance, efficiency
and environmental emissions for the global
shipping fleet.”
The partnership is based in International’s fouling
control coatings in conjunction with the BMT
SmartServices system, to provide a measurable
reduction in energy use and CO2 emissions. The BMT
system is intended to independently monitor andreport the performance of vessels. It is based on
BMT’s SmartPower onboard, real-time performance
monitoring and reporting system which acquires and
records data automatically from ship sensors and
provides ship performance information to the crew
and shore based management.
The package combines the BMT system with
either International Intersmooth SPC, which is a
self-polishing copolymer biocidal antifouling, claimed
to be unique in its formulation and benefits, or
Intersleek, International’s latest fluoropolymer foul
release coating. These benefits include, for
Intersmooth SPC, a 4% saving based on observations
on some 5,000 drydockings of 50 ships, and for
Intersleek, fuel and emission savings of up to 9%,
based on an analysis by Energy & Environmental
Research Associates.
Han Wensink, managing director of BMT Argoss
says: “BMT SmartServices will clearly and trans-
parently demonstrate any in-service performance
changes when International Paint’s hull coatings have
been used. Equipped with a user friendly Web based
interface and drawing on BMT’s 24/7 access to high
quality metocean data, the new system can play a
major role in improving operational efficiency of the
global shipping fleet.”
Paul Robbins, worldwide marine marketing director
at International Paint adds: “We are confident that our
high performance biocidal antifoulings and foul
release coatings when used in conjunction with BMT
Smartservices will deliver quantifiable added value for
ship owner and operators. One of the reasons we
partnered with BMT is that the new system can
accurately determine total performance levels by
recording over 30,000 readings per day, providing
complete transparency and evidence to owners and
operators of the performance improvements ouradvanced hull coatings technology can deliver. The
BMT system can be installed at newbuilding or as a
retro-fit and by utilising International Paint’s and BMT’s
global networks, in-service support will be provided
at every stage throughout the life of the coating
and the monitoring system.”
LOW FRICTION FOR FUTURE SHIPS
Similar, or even greater, benefits are claimed by
Japanese company Chugoku Marine Paint for its
low-friction Seaflo Neo hull paint. The claims have
been confirmed by ship operator Mitsui OSK Lines
which has analysed the results of an onboard test of
the paint applied to a newbuilding vessel, and
confirmed that the new paint offers improvements in
fuel efficiency compared to other paints. MOL is
adopting Seaflo Neo for its environmentally-friendly
shipbuilding programme, known as the Sempaku Ishin
next-generation vessel concept. It is initially being
used on two car carrier newbuildings.
MOL says that the paint will contribute to the
reduction of CO2 emissions from its vessels. As friction
between the hull and the water accounts for the
majority of resistance, reducing friction drag can
be shown to be effective in reducing CO2 emissionsduring vessel operation. The two newbuildings
adopting the new paint are a pair of car carriers, both
of 6,400 standard passenger car unit capacity, built by
Quantifiable results
from hull coatingsSmooth, low-resistance hull coatings are being offered tothe market as ways of saving fuel costs and cutting harmfulemissions in addition to their traditional anti-fouling role;but, we ask, is it possible to prove the benefits of usinga premium coating?
MOL’s ‘Brilliant Ace’, which has demonstrated the benefits of Seaflo Neo
Deliver demonstrableand transparentimprovements inperformance, efficiencyand environmental
emissions for theglobal shipping fleet
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COATINGS & CORRISION
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shipowners have set their own environmental targets
in an effort to reduce CO2 emissions. But, finding
effective ways to meet these targets can be a
challenge, and that’s where Hempel’s complete
fouling control concept can help.”
At a previous drydocking, the five VLCCs were coated
with a standard fouling release silicone product.
During the current conversion, Hempasil Nexus X-Tend,
a tiecoat for repair and touch-up, will be an integrated
part of the new paint system. “Nexus X-Tend makes
using Hempasil X3 as simple as using a conventional
anti-fouling coating,” says Rasmussen. “In the past,
spot repair was time consuming and complex and
oftenled to substandard results, such as poor adhesion
between coats.”
TEN YEAR COATING WARRANTY
Another hull coating with a warranty comes from the
Belgian brand Ecospeed. In this case, it is durability
that is guaranteed, with a 10-year period covered,
though Ecospeed believes the paint should last the
lifetime of the ship.
The paint is often applied to rudders as well as hull
surfaces, and Ecospeed claims a reference list of over
70 full underwater hulls and 135 rudders. The paint is
described as an environmentally safe underwater hullcoating system which improves a ship’s performance
and provides it with long-term protection. The
company says it is easy to apply, provides superior
protection, offers a smooth surface for hydrodynamic
optimisation and minimizes long term maintenance
of the underwater surfaces. Ecospeed’s improved
hydrodynamic characteristics result in increased
fuel efficiency. This has been shown in several cruise
vessel applications, where the Ecospeed-coated ships
are able to run at normal speeds with reduced
propulsion power.
Among the successful case studies reported by the
company is the Antarctic research ship RRS Ernest
Shackleton , to which Ecospeed hull coating was
applied in October 2009. A 2011 drydocking showed
that, despite having operated in 2.5m ice on several
occasions, the coating was mostly intact with only
small areas of touch-up required. Some parts of the
underwater surfaces, including the rudder, had been
painted with traditional coatings rather than Ecospeed,
and the drydocking showed these areas to have
suffered severe corrosion and mechanical damage.
Hamburg-based operator Ernst Russ has a fleet of
five 1999-built ro-ro ships, on which the rudders had
a history of cavitation damage, said to result from
higher than average propeller speeds. Standard epoxy
coatings proved inadequate, and exhibited damagein the first intermediate docking, two or three years
after launch.
One of the ships, the Elisabeth Russ , received
Ecospeed coating on her rudder as an experiment
during a 2004 docking. Despite receiving only two
coats, and less preparation than recommended, the
trial is reported to have been entirely successful, with
the coating holding firm in 2007, and still intact when
the ship was docked again in 2011. All five ships now
have Ecospeed applied to the rudder blades, with
highly satisfactory results.
Grzegorz Girjat, superintendent at Ernst Russ,
reports: “I would say for me it is quite clear. Had we
German filter supplier Armaturen-Wolff says that
it has developed, with a partner company, a
superior method of protecting seawater filters
against corrosion.
Galvanic corrosion protection is commonly
applied to low-budget filter systems, where the
zinc coating from hot-dip galvanising serves as a
sacrificial anode. This has the disadvantage of a
limited life; the zinc will locally dissolve within a
few years. The use of corrosion-resistant alloys is
a highly satisfactory, though expensive, solution,
which because of the cost is normally used for the
filter element only.
Armaturen-Wolff says that it can offer another
solution, namely an FBE (fusion-bonded epoxy)
powder coating. The filter is sand-blasted andwashed before being sprayed with epoxy powder
at a controlled temperature, to a film thickness of
250-500m. The smooth sealed surface prevents
encrustation by salts and organic substance, and
remains effective as long as the layer remains
intact.
For an even longer lifetime, Armaturen-Wolff
offers a 4.0mm thick hard rubber lining, which is
directly vulcanised onto the filter. The company
claims that the lifetime can equal the economical
life of the vessel itself, and because of the long life
and low maintenance requirement the cost can
prove highly competitive.
The rubber lining is bonded to the filter after all
edges and weld seams have been rounded off,
with no cavities or large pores. After sandblasting
and application of a bonding agent, the lining
material is cut to size and fitted into the filter,before the entire filter is put into an autoclave
for curing.
Corrosion protection for seawater filters
One of Vale’s VLOCs being coated with Hempasil X3 over theoriginal coating and the yellow coloured tie-coat Nexus X-Tend
Belgian Navy vessel, after sailing for five years withEcospeed coating on the underwater hull surfaces
Minaminippori Shipbuilding. The Brilliant Ace was
completed in March 2011, and the Eternal Ace four
months later.
The main characteristic of Seaflo Neo is said to be
the high smoothness of their paint film surface, the
result of a newly developed low-viscosity hydrolysed
polymer. The ultra-smooth finish is intended to
minimise friction drag, improving fuel efficiency by
3% to 5% compared to an identical vessel with a
conventional hull coating. Seaflo Neo is claimed to be
very low in volatile organic compounds (VOCs), a
major source of air pollution.
ANTIFOULING FOR CONVERSIONS
Danish company Hempel is currently supplying
150,000 litres of its third generation fouling release
coating, Hempasil X3, as part of a five-vessel con-
version project for Brazilian mining giant Vale.
Five of Vale’s VLCCs are being converted to very
large ore carriers (VLOCs) at the Yulian and Huraung
Dan Dong shipyards in China. The first Ore Itaquia , was
completed in October at Yulian while the second wascompleted at the same yard in November.
“The shipping industry is facing increasing pressure
from governments and legislative authorities to reduce
greenhouse gas emissions,” says Torben Rasmussen,
group product manager at Hempel. “In response, many
Many shipownershave set their ownenvironmental targetsin an effort to reduceCO2 emissions
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COATINGS & CORROSION
December 2011 www.motorship.com 21
not applied Ecospeed on the rudders, we would
certainly have extensive work to do in drydock.”
Among other users of Ecospeed is the Belgian Navy,
which has found the paint to last well with only a few
touch-ups needed at drydocking. Among the Belgian
Navy vessels using Ecospeed are the mine hunterM915 Lobelia , which was coated in 2006, and three
tugs, two of which were also coated in 2006 and a
third, A950 Valcke , which has now been sailing with
Ecospeed for over five years. The company points out
that Naval ships can spend long idle periods between
operations, allowing fouling to build up. As Ecospeed's
properties prevent fouling from penetrating the
surface, and allow easy cleaning, the optimum
average hull roughness will be regained after each
cleaning because surface integrity is maintained.
TRADITIONAL ANTIFOULING
For owners looking for a traditional antifouling, PPG
Protective & Marine Coatings has launched its high-
activity Sigma Nexeon 750 antifouling product, which
is claimed to deliver optimum protection against
hard fouling and whitening, with good performance
characteristics and reduced environmental impact.
Nexeon 750 is said to provide a solution to the
challenge of keeping a ship’s underwater hull clean
from discoloration and/or fouling pick-ups while it
is stationary in seawater. With prolonged outfitting
periods for newbuildings such as LNG carriers, FPSOs,
offshore support ships and drill ships, there is an
increasing demand for vessels to look clean and not
incur extensive costs on cleaning the underwater
hull before delivery. Nexeon 750 is a copper-free,
high-activity antifouling based on self-polishing binder
technology. It is said to be particularly suitable for
static and low-activity vessels, both at new build and
providing consistent polishing even in stationary
service conditions.
Nexeon 750 is usually recommended in combination
with the existing Sigma Coatings antifouling product
range, as a final antifouling coat.
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The rudder of the 'Friedrich Russ' before Ecospeed wasapplied, showing cavitation damage
Grzegorz Girjat, superintendent at Ernst Russ, shows thestate of the rudder of the 'Elisabeth Russ' in drydock in
2011; the original cavitation pitting from before the originalEcospeed application is still visible but no further cavitation
damage has occurred in the intervening seven years