Presentation on theme: "IMO Performance Standard for Protective Coatings"— Presentation transcript:
1 IMO Performance Standard for Protective Coatings 19th June 2006Joo-Sung Park/Statutory Service Team
2 Adoption: To be adopted by MSC 82(Dec. 2006) Amendment to SOLAS regulationAmendment of SOLAS Reg. II-1/3-2 to introduce mandatory protective coating requirements in SOLASAdoption: To be adopted by MSC 82(Dec. 2006)Enter into force: 1 July 2008ScopeMaintenance and Repair: Guidelines to be developed later2. SOLAS Reg. XII/6.3(for bulk carriers): deleted as of 1 July 2008Mandatory performance standard by the SOLAS II-1/3-2:“PERFORMANCE STANDARD FOR PROTECTIVE COATINGS FOR DEDICATED SEAWATER BALLAST TANKS IN ALL TYPE OF SHIPSAND DOUBLE-SIDE SKIN SPACES OF BULK CARRIERS”
3 APPLICATION DATEContract date base:Vessel(s) contracted on or after 1st July 2008 orDelivery date base:Vessel(s) delivered on or after 1st of July 2012APPLICATION SCOPEDedicated seawater ballast tanks in all vessels above GT 500 T and aboveDouble –side skin spaces in bulk carriers of 150m in length and abovePermanent Means of Access(PMA): shall be applied to structural strength members and recommend to apply for non-structural strength membersEARLY IMPLIMENTATION By MSC circular to be approved by MSC 82Bulk Carriers of 150 m and above:The SOLAS Contracting Government may apply the PSPC in advance for the ships in its flag constructed on or after 1 July 2006(I.e. ships under SOLAS Reg.XII/6.3)
4 The Contents of PSPC (MSC 81/WP.13, Annex 3) PURPOSEDEFINITIONSGENERAL PRINCIPLESCOATING STANDARDCOATING SYSTEM APPROVALCOATING INSPECTION REQUIREMENTSVERIFICATION REQUIREMENTSALTERNATIVE SYSTEMANNEX 1:TEST PROCEDURES FOR COATING QUALIFICATION FOR BALLAST TANK OF ALL TYPESSHIP AND DOUBLE-SIDE SKIN SPACES OF BULK CARRIERS COATING- APPENDIX 1: TEST ON SIMULATED BALLAST TANK CONDITION- APPENDIX 2: CONDENSATION CHAMBER TESTANNEX 2:EXAMPLE OF DAILY LOG AND NON-CONFORMITY REPORTANNEX 3:DRY FILM THICKNESS MEASUREMENTSANNEX 4:STANDARDS REFERENCE TO THE PERFORMANCE STANDARDS ON PROTECTIVE COATINGS
5 DEFINITIONSDFT, NDFTEdge GrindingHard coatingTarget useful life: 15 yearsTechnical Data SheetGOOD conditionGENERAL PRINCIPLES- The coating ability to reach target life 15 yrs : depend on type of coating system, steel preparation, application, coating inspection and maintenance- Inspection of surface preparation and coating process: shall be agreed between ship owner, shipyard and coating manufacturer- Coating Technical File(CTF): shall be reviewed by Admin. or RO and be provided on board: Type approval cert. Technical Data sheet, Records of coating application, inspection and repair procedure during construction, procedure for in-service maintenance and repair of the coating system
6 COATING STANDARDCoating system- Selection of coating system: Deck and tank boundaries to withstand repeated heating/cooling- Coating type:epoxy based system(other type shall comply with test in Annex 1)- Pre-qualification test:* Epoxy based system shall be tested in accordance with Annex 1 or equivalent test procedures (e.g. Class B1?)* Documented field exposure results(5 yrs) also acceptable* New coating system shall be tested according to Annex 1Job specificationRust, grease, dust, salt, oil, etc. shall be removed prior to coatingAbrasive inclusions embedded in the coating shall be removed
7 COATING STANDARDJob specification - Stripe coatingThere shall be a minimum of two stripe coats and two spray coats, except that the second stripe coat, by way of welded seams only, may be reduced in scope where it is proven that the NDFT can be met by the coats applied in order to avoid unnecessary over thickness. Any reduction in scope of the second stripe coat shall be fully detailed in the CTF.Stripe coats shall be applied by brush or roller. Roller to be used for scallops, ratholes, etc. only.The application scope of brush may have a different interpretation according to the personnel knowledge, background and experiences.A strong necessity for development of a stripe coating tool which is combined two characteristic of roller and brush to improve quality and efficiency of stripe coating
8 NDFT 320 Microns with 90/10 rule COATING STANDARDNDFTNDFT 320 Microns with 90/10 rule- max. TDFT -> according to manufacture’s spec.- Gauge type: SSPC-PA2About 7% of paint material cost increaseIncrease application M/H and material cost due to the relatively wider range of DFT than Current Standardiii. More potential risk for high DFT (may impact on progress)Current Standard NDFTNDFT 300 Microns with 80/20 ruleSampling test result:DFT measuring based on the Current Standard 2 coats 300 ㎛Mean㎛Max.1, ㎛No. of Readings100 (100%)STD Deviation㎛Min.㎛Reading above23 (3%)Coef. of Vari.46.52 ㎛High Limit㎛Reading below7 (7%)Low Limit㎛
9 COATING STANDARDPrimary surface preparation- Blasting and profile: Sa 2 ½ (profile: ㎛) (average?) – ISO* restriction: humidity 85% or above, surface temp. below 3℃ - ISO /3* surface cleanliness and roughness profile check before application- Salt limit(NaCl): ≤ 50 mg/㎡ (ISO Conductivity test)- Shop primer:* Inhibitor free zinc silicate based or equivalent* Compatibility with main coating system: shall be confirmed by coating manuf.
10 COATING STANDARDSecondary Surface Preparation(SSP): Steel condition - Edge GrindingThe steel surface should be prepared so that the coating selected can achieve an even distribution at the required NDFT and have an adequate adhesion by removing weld spatter and any other surface contamination in accordance with ISO grade P2.Edges to be treated to a rounded radius of minimum 2mm, or subjected to three pass grinding or at least equivalent process before painting.The amount grinding activities will tremendously be increased at block assembly stage.A strong necessity for development of a grinding tool or process to mitigate the huge burden for labor and progress management.
11 COATING STANDARDSSP – surface treatmentAt block assembly stageDamaged surface of shopprimer and welds: SIS Sa 2½ ( ISO )Compatible intact surface of shopprimer: Sweep blasting, high pressure water washing or equivalent method. (cf. compatible zinc silicate shop primer - cross over with other epoxy coatings: appdx. 1)Intact shop primer not compatible with the main coat: Sa 2 (70% removal)After erectionButts: SIS St 3 or better or Sa 2½ where practicable. (ISO )Small damages up to 2% of total area: St 3Contiguous damages over 25m2 or over 2% of the total area of the tank: Sa 2½ (definition of damage, calculation of damaged area?, 순차적인 덧칠로 해결?)Block division, erection procedure, working process should be take into account the limit of the amount of coating damages, erection butts to avoid the application of the blasting after erection.
12 Sampling of Current Standard for DUST grade COATING STANDARDi Dust grade “1” for dust size class “3” to “5” by means of adhesive tape test (ISO )Ii Dust size classes “1” and “2”: shall be removed if visible(naked eye)SSP - DUSTDust Size (ISO )0 : Particles not visible under x10 magnification1 : Particles visible under x10 magnification but not with normal or corrected vision(usually particles less than 50㎛ in diameter)2 : Particles just visual with normal or corrected vision (usually particles between 50㎛ and 100㎛ diameter)3 : Particles clearly visible with normal or corrected vision(particles up to 0.5mm in diameter)4 : Particles between 0.5mm and 2.5mm in diameter5 : Particles lager than 2.5mm in diameterSampling of Current Standard for DUST gradeCeilingWallFloor
13 ISO 8502-6: Extraction methodology (Bresel only ?) COATING STANDARDISO : Extraction methodology (Bresel only ?)ISO : Assessment of soluble salt by conduct metricSoluble salt limit≤ 50 mg/m2 of NaCl (Pre-washing is not explicitly required)A test result for the comparison of the content of Sodium Chloride in Total Dissolved Salt
14 QUALIFICATION OF COATING INSPECTOR i. NACE CIP(COATING INSPECTOR PROGRAM): LEVEL II, orii. FROSIO(NORWEGIAN STANDARD NS 476): LEVEL RED, orIii Equivalent as verified by Administration or RO- Inspection items: Table in para 6.2Recordings: results from theinspection shall be recorded by theinspector and shall be included in theCTF – daily log and NC report.Current Status for Certified Coating Inspector (May, 2006)No. of InspectorNo of CertifiedRemarks (FROSIO)Ship Builder24039 (16%)7 major ship yard in KoreaPaint Maker50778 (15%)6 major paint Maker in KoreaIncreased inspection activities for DFT measurement acc. to Annex 3Increased documentation for provision of CTF.Increased activity for the test such as dust, soluble salt, profiles, etc.Other activity for approval of the quality control systemShip Builder480At least, more than two times of the present coating inspectors are necessary to meet the PSPC comparing with the current shipbuilding standards.Paint Maker1,014
15 More clarification is needed VERIFICATION REQUIREMENTSType Approval, Quality Control and VerificationApprove quality control system?)Type Approval of Costing System – by a third party (Who can be a third party?)CoatingAdministrationManufactureror R.OTechnical DataCheckSheetType ApprovalPaintTestTest Lab.Type ApprovalIssueCert.checkPreparation of Coating Technical File ?Approve quality control system ? (How ?)Ship BuilderCoatingVerifyWho will employ the inspectors ?InspectorCoatingInspectionMonitoringShould IACS do direct coating inspection rather than monitoring?InspectionCheck (How ?)ReportApproval of Quality Control System of the ship yards?CoatingReviewTechnical FileShip OwnerMore clarification is neededSafetyConstructionIssueCertificate
16 ANNEX 3 DFT measurements The following verification check points of DFT are to be taken:.1 one gauge reading per 5 m2 of flat surface areas;.2 one gauge reading at 2 to 3 meter intervals and as close as possible to tank boundaries,but not further than 15 mm from edges of tank boundaries;.3 longitudinal and transverse stiffener members:One set of gauge readings as shown below, taken at 2 to 3 meters run and not less thantwo sets between primary support members;Note: Arrows of diagram indicate critical areas and should be understood to mean indication for both sides..4 Three(3) gauge readings for each set of primary support members and 2 gauge readings for each set of other membersas indicated by the arrows in the diagram;.5 for primary support members (girders and transverses) one set of gauge readings for 2 to 3 meters run as shown infigure 3 above but not less than three sets;.6 around openings one gauge reading from each side of the opening;.7 five gauge readings per square meter (m2) but not less than three gauge readings taken at complexareas (i.e. large brackets of primary support members); and.8 Additional spot checks to be taken to verify coating thickness for any area considered necessary by the coating inspector.
17 Expected additional man power Construction schedule delay (Day) Evaluation sheetItemsExpected increase of ship building cost based on evaluation of new performance standardsExpected additional man power(Area/persons)RemarksCost (USD)Man power(M/H)Construction schedule delay (Day)New facilities (USD)Total (USD)NDFT 320 ㎛ (90/10)Dust (ISO )Soluble Slat(ISO , 9)Stripe coatingEdge grinding(ISO , P2)Secondary surface preparationBlockHullQualified InspectorVerificationDFT measurement(ANNEX 3)Others (incl. provision of CTF)