Jotun Solutions to Oil & Gas

Corrosion Challenges

Jotun Paint School

Effect of activities through a project on

the end result of a painted structure
The Coating Quality Chain
1.Philosophy

3.Coating selection

5.Pre-treatment

Initial
Expectation

End
Result
2.Specification

4.Pre-blasting

6.Application

The quality line

Theoretical Control
Jotun Paint School

Practical Control

Factors Influence On
Coating Selection

Current Country and / or Company legislations HSE

(Health, Safety, Environment)
The contractor facilities and skills for doing a good job
The required / expected lifetime of the system
The pre-treatment required
System suitability for protecting the structure
The maintenance frequency, methods and routines
Paint system compatible with the supplementary
cathodic protection system (if applicable)
Satisfactory performance records, test data and other
required documentation
The manufacturer capability of providing adequate
technical services

Jotun Paint School

Understanding The
Conditions
Structure type?
Substrate nature and complexity
Exposure? (protecting against what?)
New building or old? (present condition
and special requirements)
Surface preparation?
Life expected?
Paint budget $/sq. m?
Jotun Paint School

Coating Systems
Selection
Introduction to Coating Systems
Referring to
International Standard ISO 12944
Corrosion protection of steel structures
by protective paint systems

Jotun Paint School

Coating Systems Selection

1Definetheexposure
External
C3, C4, C5I or C5-M

Immersed
/Internal

Above Ground

Im1, Im2
Immersed
/Underground
Im3
Jotun Paint School

Under
Ground
2Definethedurability(Years)
low(2:5),medium(5:15),high(>15)
6

External exposure up to 120 C

Jotun Paint School

Immersed Exposure
Im1
Im2
Fresh Water Sea, Brackish
Water

Im3
Soil

EP

EP

EP

CTE

CTE

CTE

PE GF

PE GF

PE GF

Polyester Glass Flakes

Polyester Glass Flakes

Polyester Glass Flakes

Jotun Paint School

1- Internal Linings

Main types of linings (API 652):

Epoxy and Phenolic Epoxies thin film

multi-coat
100% V.S. High Build 1/2 coat
Vinyl ester Glass Reinforced Ultra High
Build
Glass Mat SF Epoxy Lining
Other systems are used on occasion i.e.
C.T. epoxy
Jotun Paint School

82:105C
71:82C

60:71C
71:82C
82:105C

82C

Jotun Paint School

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Tankguard HB
(Epoxy Thin Film Multi-coat)

Advantages:

Easy application

Good film application

Good Chemical resistance

Proven track record

control

Disadvantages:
V.O.C.
Time consuming application
of multi-coat
Over-coating times
life cycle (8-12 years)
Health & Safety
Air removal and circulation
Not preferred for pitted
floors

Main Use: New tanks or maintenance with minimum breakdown.

Typical system: Tankguard HB 3 x 100

Jotun Paint School

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Tankguard Storage
(Phenolic Epoxy Thin Film Multi-coat)

Advantages:

Easy application
Good film application control
Very Good Chemical resistance
Higher temp resistance than
pure epoxy
Extended over-coat time up to
30 days
Variable film build (125 - 200)
2 Coat System
Normally higher volume solid
than Pure epoxy thin film

Disadvantages:

life cycle (8-12

years)
Health & Safety
Air removal and
circulation
Not preferred for
pitted floors

Typical system: Tankguard Storage 2 x 150

Jotun Paint School

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APPROVALS AND TEST DATA

Def Stan 80/97 certificate for jet A1 storage

Air bp

Wet and dry adhesion 3 cycles readings 3.9 to

5.1Mpa

Spanish equivalent of Mill spec 4556E for jetA1

storage
Exxon Mobil
Salt spray exposure 2 x 125 6 months no
blisters, rust or damage from scribe test

Jotun Paint School

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Vinyl ester Glass Flake

Advantages:

1/2 coat application

Standard airless application
High volume solid 96%
Greatly reduced down time
Fast cure
Wet on wet application
Short re-coat times
Extended life cycle
V.O.C./E.P.A. compliant
Extended life cycle 10-16 years
Repair to moderately pitted floor

Disadvantages:

less flexural strength

than GRP
Over-coating
limitations

Main use: New tanks and maintenance where a

fast turn round of tank is required

Typical system: Chemflake 2 x 750

Jotun Paint School

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Jotun Paint School

15

Chemflake

An advanced vinyl ester coating

Economical - high DFT in one coat
Easy application
Resistant to sulphuric acid solution
Prolonged life time - reduced maintenance
costs, solid glass-flake protection, max.
adhesion
Time Saving - rapid curing
Resistant to most commonly traded solvents
and chemicals and dry temp up to 150oC

Jotun Paint School

16

Chemflake Range
Chemflake Special
exceptional protection against abrasion -

suited for lining floating roofs and screen

tanks
effective against crude oil up to 95oC
naphtha, refined petroleum, slop, waste
water, distilled water up to 60oC
also variety of acids (sulphuric solution),
alkalis and chemicals
Temp resistant dry conditions up to 150oC
Temp resistance 85c in water

Jotun Paint School

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The Benefit of Coating with

Chemflake to the Client

Fast turn-round of tank

Less site disturbance
Extended tank life for 30% less

investment
Better utilisation of tankage availability
Less hot work on site
Better Health & Safety

Jotun Paint School

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Test data Chemflake

Saltspray
Sea water exposure
Cathodic Disbondment
Taber Abrasion

Adhesion
Impact resistance
Tensile strength

Water Vapour Transmission

Elongation
Hardness (barcol)
Norsok

Jotun Paint School

ISO 7253 4000HR

24 Months
ASTM G8 30 days
ASTM D4060
5000 cycles
ASTM 4624 7.1MPa
ASTM G14
Bend Test ISO 1219
40NM2
ASTM E-96
ISO 4624 0.4%WRC
ASTM D 2583
Cyclic Test 25 cycles

19

Estimated costs based on a like for like specification of 1000

microns. 1000 m area. 2 applicators.
2 coat application. Tank base, no access required.

Materials

Labour

Plant

Site services

paint,thinner,
consumables

applicators
stand-by man

DH, compressors,
fuel, transport etc

fire,safety,medical,
p.t.w. system

Cure days
10
9
8
7
6
5
4
3
2
1

Application
Materials

Epoxy
Jotun Paint School

Chemflake
20

Chemtech 340
G.R.E. Laminate

Advantages
Less susceptible to

mechanical damages

Bridge over small

perforations of supporting
steel bottom

Disadvantages:

Multi-coat application

Time consuming application

Requires quality trained staff

Non-carcinogenic catalyst
Crude Oil up to 75C
Capable of filling pitting
Good bond and flexural
strength

Ref. API 652

V.O.C./ E.P.A. complaint

Faster /Cheaper than steel
replacement

Extended Life Cycle & Long

track history

Jotun Paint School

21

Where to use?
New or Maintenance lining where tank

floor has light to heavy pitting corrosion.

Main use is as an insurance to extend
the life of the tank, even if the floor fails
the G.R.P. lining can for a short period
provide a sealed tank and prevent
leakage
Where other coatings may crack and
allow leakage to take place
Jotun Paint School

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CHEMTECH SYSTEM Example

Chemtech Primer
40 micron
Chemtech Epoxy filler
Chemtech 340
1500 micron
1 Layer of 450 gm/m glass mat OR
2500 micron
Chemtech 340
2 Layer of 300 or 450 gm/m glass mat
300 micron
Chemtech 340
Optional tissue layer 30 gm/ m
The system can be applied in one or two layer
systems depending on clients needs
Jotun Paint School

23

CHEMTECH 340
FEATURES
100 %Volume Solid Pure Epoxy
DFT Range 1000-3000Micron
Main use Crude and Light Chemical
Crude Oil up to 75C
Non Cancerous catalyst
Jotun Paint School

24

BENEFITS

20 Year track history

Shell approval
Excellent bond(adhesion) properties
Replacement for products containing Aromatic
Amines (catalyst)

Ability to maintain tank integrity for a short

period of time if floor plates become corroded

Extended O/Coating
Good sag resistance
Good wetting properties
Jotun Paint School

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2- External Coatings
Main types used for external coatings:
1. Zinc rich primers
2. High build epoxies
3. Glass flake epoxy
4. Polyurethane
5. Polyester glass flakes
6. Epoxy mastics
7. Silicones
8. Phenolics
Jotun Paint School

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Five year North Sea offshore field test of

Organic Coatings for Corrosion Protection

Ranking (creep at scribe, adhesion, chalking, cracking and flaking)

Source SINTEF, Norway
Jotun Paint School

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Correlation Coefficient, r

Outdoor exposure testing

r = 0.85

Water Immersion testing, 500 h

r = 0.45

Salt Fog testing, 1000 h

r = 0.50

Cyclic TNO test, 1000 h

r = 0.65

Cyclic Salt Fog/UVA, 2000 h

r = 0.70

NORSOK M-501, rev.4, 4200 h

r = 0.70

r = 1.0 means 100% correlation with actual coating

lifetime performance

Jotun Paint School

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NORSOK M-501, Rev. 4

Aim of the standard:

To obtain high durability coating systems which

ensures;

1. Optimal protection of the installation with

minimum need for maintenance

2. Maintenance friendly system

3. Application friendly system
4. HSE impacts are evaluated and documented
(This standard requires pre-qualified coatings &
personnel)
Jotun Paint School

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NORSOK M-501, Rev. 4

REQUIREMENTS

TEST PROCEDURE
Cyclic test:

Salt Spray (ISO 7253) - 72 hours

Dry in Air

- 16 hours

UV-A (ASTM G53)

- 80 hours

Duration one cycle

- 168 hours

1. Corrosion creep from scribe: < 3

mm

2. Blistering (ISO 4628-2): rating 0

3. Rusting (ISO 4628-3): rating Ri0
4. Chalking (ISO 4628-6): max.

Total Duration of 25 cycles - 4200

hours

Adhesion before exposure (ISO

4624)

Adhesion after exposure (ISO

4624)

rating 2

5. Cracking (ISO 4628-4): rating 0

6. Min. 5 MPa
7. Max. 50% reduction from original
value

8. Overcoatable without mechanical

treatment obtaining min. 5 MPa in
adhesion value.

Overcoatability (ISO 4624)

Jotun Paint School

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Submerged areas

Epoxy Mastic
2 x 200

Jotamastic 87

Jotun Paint School

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Splash Zone

Glass flakes reinforced polyester

Baltoflake 2x750 m

Jotun Paint School

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Exposed steel above splash

zone, piping and valves

Epoxy Mastics + Polyurethane

2 x 200 m Jotamastic 87 + 1 x 50 Hardtop AS m

Waterborn (Epoxy + Hard Acrylic)

2 x 100 WaterFine Primer m + 1x50 m
WaterFine Topcoat

Jotun Paint School

33

Heli-deck, walkways, floor

areas, escape roots and decks

Glass flakes reinforced polyester

2x750 m

Jotun Paint School

Baltoflake

34

Baltoflake
Glass flakes reinforced polyester
coatings

Ultimate corrosion protection

Jotun Paint School

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Whats special with the

Baltoflakes?
Excellent adhesion to steel
Very fast curing
Superior abrasion resistance
Excellent mechanical strength
Excellent water resistance
Very good chemical resistance
Excellent corrosion protection
The most long-lasting system
Solvent free
Jotun Paint School

36

Baltoflake test results

Salt spray-Jotun-4000h
750-1000
ASTM B117 SS-4000h, Ext 1200
ISO 2812 SW 1000h, Ext
1200
Cyclic Test, 1000h,
1000
ASTM G 26 Weathering 100h
ASTM B117 Salt spray 100h
ISO 2810 Weathering 2 Yrs.
1200
ISO 2812 SW Immers,2Yrs 750-1000
ISO 2812 Dest.W. 40C 2Mths. 750-1000
ASTM G8
1500
ASTM D 2583 Barcol Hardn.

Jotun Paint School

37

Rust:Ri0, Blisters:0
Rust:Ri0, Blisters:0
Rust:Ri0, Blisters:0
Rust:Ri0,Blisters:0
Checking:0
Cracking:0
All readings:0
All readings:0
All readings:0
All readings:0
40

Baltoflake test results

ASTM 4060 Taber Abr.

1000cycles/1000g/CS10W 40mg
1000cycles/1000g/CS17W 107mg

Ext.
Ext.

3000cycles/1000g/CS17W

116mg

5000cycles/1000g/CS17W 103mg

ISO/R527-55.Tensile Strength

48N/sq.mm

IO/R527-55. Elongation of break

0.9%

ISO/R 75-74

92 C

ISO/R178-75 Flexural strength

70N/sq.mm

ISO/R178-75 Modules of Elasticity

7500N/sq.mm

ASTM G 14-77 Impact Resist.

1000

4.0 J

ASTM G 14-77 Impact Resist.

1300

ASTM D 2794 Impact, Ext.

1000

lb/inch)
Jotun Paint School

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>50 inch/pound
1.8-2.0Nm(16-18

Baltoflake Test Results

ASTM G 62 Pore Detection.

ISO 4624 Adhesion:

Temp.Expans.coeff.(Linear) :
Zone 24-93 C : 27.4x106
Zone 23-24 C: 20.2x106

ISO7R-1958 Water Abs.

0.075%
Testing at elev.temp.
1000
Steel temp 70 and 100C
Seawater temp 8 and 14C;
6 months exp. No defects
NORSOK M-501 Syst.1 and 7 1500
Passed

Jotun Paint School

5KV/mm
6MPa-Elcom.
10MPa PAT

39

Baltoflake References SA

Royal Commission W/E

Riyadh DIP Sewage Plant

PEMREF Yanbu

Salt Filter

1993

PEMREF Yanbu

Diesel Storage Tank

1993

PEMREF Yanbu

Oil Slop Tanks Pipes

1993

PEMREF Yanbu

SAMAREC

Jotun Paint School

Brine recycling pumps

1992

Sewage Pumps Diffuser

1992

Vacuum Tank Intl.

Bridge

40

1993
1989

Baltoflake References

Phillips Norway
Phillips Norway
Phillips Norway
ESSO Malaysia
Sarawak Shell
Conoco UK
Statoil
Petronas Caligari
BP Norway
ELF Donges
Gaz de France

Jotun Paint School

Ekofisk Field since

1980
Ekofisk 2/4 J since
1997
Ekofisk 2/4 X since
1997
Various Platforms since
1987
Various platforms since
1990
Britannia Integrated Deck
1999
Heidrun TLP Steel in Columns 1994/5
Various Platforms since
1990
Gyda Platform - various decks 1989
Storage tanks for propylene
Jetty piles

41

Baltoflake References UAE

ADNOC

Total ABK

Platform Decks

ADMA - OPCO

Platform Bridge

ADMA - OPCO

Helideck Crane

ADMA OPCO

Khoff Gas D. Platform

Water Electr.Dept
Intake

Pump Stations / Seawater

Structural Steel

Ministry of Fisheries

Floating Jetty

Dubai Municipality

Pontoon

Bunduq

Jotun Paint School

Splash zone on 6 steel jackets

42

Baltoflakes versus HS
epoxies
Better adhesion
Better resistance

(abrasion, impact, water)

Double lifetime
lower LCC ~ 40-50%

Jotun Paint School

43

Baltoflakes versus HS
epoxies cont.

Jotun Paint School

44

The Baltoflake
family

Baltoflake

Baltoflake Ecolife (styrene free)

Baltoflake Holding Primer

Jotun Paint School

45

Surface Tolerance

Pure Epoxy

Epoxy Mastic

Penetration provides improved adhesion and extended life

Jotun Paint School

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Pure Epoxy Vs Epoxy Mastics

Water resistance & adhesion is better for epoxy

mastics:
Longer life out of same dft
Better adhesion gives longer life
Surface preparation will never be perfect
- NBs, weld seams to be repaired etc.
- Refurbishment, blastcleaning/waterblasting etc.
Connect with CTE for water tanks
Most owners preferred CTE
All the benefits with NONE of the drawbacks

Jotun Paint School

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Why are we the Master of

Mastics?

The widest selection of mastics:

in areas of use
in VOC compliant products
in dry to handle
in min. & max overcoating time
for submerged areas
for low temperature curing products
for min. & max. dry film thickness
in high solids & solvent free products
Jotun Paint School

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Water fine ..Why?

Environmentally friendly
(No Thinner emission)

Jotun Paint School

49

Environmentally friendly
Many risks are involved
when working with solvents
Safety
Explosion and Fire
Health
Manufacturing and Surface
treatment
Environment
Emission to air (VOC)
Emission to water (Maintenance)
Emission to soil (Waste handling)
Jotun Paint School

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Sources for VOC-emissions *

Petrol fumes/energy/production/waste
18%

Vegetation
22%

Use of solvents
25%
(38-47% from paint)

Traffic
35%
* Annual average.

Man-made emissions (EU): 10-12 mill tonns/year

Annual reduction in paint solvents > 1 mill tonn/year
Jotun Paint School

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VOC - What is volatile?

Environmental Protection Agency (EPA, USA)
What will evaporate from a paint film during 1

hour at 110 5C (ASTM D 3960 - 93).

European Union (EU) proposal:
Compounds with boiling point below 250C .
VS % in technical data sheets:
What will evaporate from a paint film during 7
days at 23C
Two methods for calculation of VOC
Actual - EU method (CEPE)
Water reduced method (USA)

Jotun Paint School

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Why waterborne and/or high solids

coatings?

VOC REGULATIONS
Country

USA

California

UK

EU

J apan

(Car Industry)

Year

1999

2002 (2006)

1998

1999 (2002)

Primer

350

200 (100)

250

540 (250)

Shopprimer

650

780

540

Topcoat

420

250 (50)

420 (560)

420

480

(400, Holland)
* Since legislation is still being discussed, please contact the technical support
departments for up to date details

Jotun Paint School

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What we are going to

do?

This legislations will not be enforced to the UAE?

NO ACTION IS REQUIRED

This legislations will come to the UAE, we have to

be prepared

TEST and evaluate the performance of different

Water Based & HS systems

Jotun Paint School

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What Is Waterborne Paint?

A coating where the liquid

carrier is substantially water.

Dependant on the choice of

binder, small amounts of special

solvent (co-solvent) are added
to melt the polymer particles
together during drying.

Jotun Paint School

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Jotuns Waterborne Coatings

Product range

Binder Type

WaterFine Acrylic Primer Acrylic

Approx. VOC
Values
Actual
Water
reduced
66 g/l
127 g/l

WaterFine Primer

Epoxy

60 g/l

115 g/l

WaterFine Barrier

Zinc-rich epoxy

92 g/l

170 g/l

WaterFine Zn Primer

Zinc Silicate

0 g/l

0 g/l

WaterFine Special

Epoxy

72 g/l

127 g/l

WaterFine Topcoat

Hard Acrylic

106 g/l

145 g/l

Jotacote 5

HB Zinc Silicate

0 g/l

0 g/l

Jotun Paint School

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Case histories
Marine & Protective

Jotun Paint School

57

 Painted more than 2 million

m2
with water-borne paints
Jotun Paint School

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Jotun Paint School

Project:
Egersund Statoil Tank
Owner:
Statoil Norge AS, Norway
Date applied:
1995
System :
Barrier
50 m
WaterFine Special
90
m
WaterFine Special
90
m
WaterFine Topcoat
40
m
Total DFT 270
m
59

Project:

Location:
System :

Total 16 of railway and road bridges

3- 35 years service in 1998

Melbourne, Australia
Jotacote 5 ave. 95 - 190 m

Ri 2 Rusted Grade
No blistering
No flaking
Jotun Paint School

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Gas pipeline in Algeria, >

6 years
Paint System:
1 x 40 m DFT SB Zinc Epoxy Primer
2 x 125 m DFT SB Epoxy
1 x 50 m DFT WaterFine Topcoat
Results:
No rust, blistering, flaking or
cracking.
More than 200.000m pipes
protected with excellent results.

Jotun Paint School

61

Approvals - WaterFine Products

Institute of International Container Lessors (IICL

test procedure for transport containers):

IMO FTPC Part 5/ IMO Res. A 653(16) low flamespread certificate:

WaterFine Barrier, 60 m + WaterFine Topcoat, 80 m

WaterFine Acrylic Primer, 100 m + WaterFine Topcoat, 80 m

NORSOK M-501 rev.4 approvals (ISO 20340):

WaterFine Barrier (2)

WaterFine Primer (9)
WaterFine Topcoat (9)

ZADCO have approved a single coat protection

Jotacote 5 (125 )

Jotun Paint School

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Approvals - WaterFine Products

Jotun Marine and Protective Coatings Coatings Laboratory (internal
testing):

ISO 12944-5 Chemical resistance, C5-I:

WaterFine Topcoat, resistant to NaOH(10%), H SO (10%) and

2

White Sprite

Russian Test institute approval Ghost certificate (under

translation):
WaterFine Barrier, 50 m + WaterFine Primer, 120 m + WaterFine
Topcoat 80 m
WaterFine Primer, 2 x 100 m + WaterFine Topcoat, 150 m

ENERCON - specification EQ-2 for Windmills:

ISO 12944-6 Corrosion resistance for C5-I & C5-M:

WaterFine Barrier, 50 m + WaterFine Primer, 120 m + WaterFine

Topcoat 80 m

Jotun Paint School

63

Summary of Benefits
High Level Corrosion Protection
Long Term High Gloss Level
Often Lower DFT (easy maintenance)
Low Odour (more comfortable maintenance)
Fewer Coats (easy maintenance)
Faster Drying Times (improved maintenance)
Low Flammability (other trades can work close to
painting)

Jotun Paint School

64

Summary

It is said by many in our industry that

environmental legislation will stop the use of high
VOC containing products within a short time

So as not to get surprised; Jotun advice you to

try our Water-borne range now and understand,
what may be necessary to do in the future.

Jotun Paint School

65

Typical factors when selecting

an external pipe costing
Type of environment
Accessibility of piping system
Operating temperature of piping system?
Geographical and physical location
Handling, storage and field joints
Pipeline installation methods
Pipe surface preparation requirements
Cost
Jotun Paint School

66

Current flowlines
environment
1.

Atmospheric flowlines (areas above ground)

Corrosivety grade C-4 to C5-I

2.

Flowlines laying above ground (in contact

with soil) Corrosivety grade C-4 to C5-I and
Im-3

3.

Buried flowlines (due to moving sand dunes)

Corrosivety grade Im-3

4.

Immersed flowlines Corrosivety grade

Im2/Im-3

The flowlines are exposed to corrosivety level as

aggressive as the offshore structures tidal zone!

Jotun Paint School

67

Coating functionalities Summary

The coating should resist all weather

and give excellent corrosion protection
as atmospheric, immersed and
underground coating systems.

Ease of repair and field joint application

Jotun Paint School

68

Reference Standards

ISO 12944 5 Protective Paint system

ASTM G8 Cathodic disbonding

ISO 12944 6 Laboratory Performance Test Methods

ASTM B117 Saltspray
ISO 2812 Immersion Natural seawater
ASTM D 4060 Taber Abrasion
ASTM G 14-77 Impact resistance
Cyclic test - 1000h Cycle:ASTM G 26 Weathering, 100h
ASTM B117 Saltspray 100h
NORSOK M-501 (system 7)

Jotun Paint School

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Jotun Paint School

70

ISO 12944 - 5
1 coat of 500:1000 m

ISO 12944 - 5
1 coat of 400 m

Jotun Paint School

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30 days
60 days

125 days

Jotun Paint School

72

Jotun Proposed Liquid

Coating
We have few options to meet the main
requirements: (one coat of 500:1000, all
weather/soil resistance)

1. Baltoflake (Polyester Reinforced Glass Flakes)

2. Chemflake (Vinyl ester Reinforced Glass Flakes)
3. Jotacote 113 (ARAMCO approved - Epoxy Pipe
Rehabilitation)

The decision depends on: operating temperature,

chemical resistance and budget
Jotun Paint School

73

Thank you for your

attention!

Jotun Paint School

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