High Heat Coatings Technology for Improved Productivity Vijay Datta, MS, Dr. Mike O’Donoghue October 11, 2018

Agenda Introduction and Challenges Novel Inert Multipolymeric Matrix (IMM) Technology – performance at ambient temperature and 400ºC to 650ºC Novel Alkylated Amine Epoxy – performance at ambient temperature to 230ºC Conclusion

Corrosion Under Insulation (CUI) Corrosion under wet thermal insulation is aggressive CUI is up to 20x faster than atmospheric corrosion (1.5 – 3.0 mm/year) Insulated high temperature steelwork requires protection against CUI

The Challenge Oil & Gas projects can involve thousands of pipe spools, valves, and vessels All require different coating schemes depending on: Carbon steel or stainless steel Insulated or un-insulated requirements Service temperature range V

The Challenge Narrow Environmental Tolerance Traditional coatings for high temperature are suitable for a narrow range of end uses Inorganic zinc silicates are widely used as a priming system to try and improve the ‘universality’ of a system, but this adds cost and complexity Technology Temperature Range Comment High Build Epoxy Ambient to 120°C (248°F) Poor high temperature resistance Epoxy Phenolic -196°C to 230°C (-321°F to 446°F) Poor resistance to UV Inorganic Zinc Silicate Ambient to 540°C (1004°F) Not suitable under insulation Aluminium Silicone IMM -196°C to 650°C (-321°F to 1202°F) Requires primer or heat cure V

The Challenge Reduced Productivity Specification complexity adds cost for applicators: Increased risk of application errors Reduced productivity Increased paint waste costs

The Challenge Increased Rework Costs Specification complexity adds cost at the EPC level: During the fabrication process, equipment can be installed with an incorrect coating system for the final operating environment, which causes: Increased rework required to correct coating Increased painting cost Increased risk of schedule impact

CUI Coating Solutions – Balancing… Anti-corrosive Properties Thermal Resistance (Cartoon Figs courtesy of Hexion)

High Heat Coating Solutions Temperature Higher bond strengths of Inorganic Si-O bond (452 KJ mol-1) vs Organic C-C bond (350 KJ mol-1) confers thermal stability IMM Technology 650ºC Thin Film Silicones, TSA 600ºC 400ºC Inorganic Zinc Silicates 220ºC Organic – Phenolic/Novolac Epoxy Organic – Epoxy 125ºC vijay Technology Protective Coatings

What if there was a coating that could be used over a much wider range of operating conditions, without heat cure or a primer?

Enhanced Inorganic Copolymer Technology Novel IMM Technology Enhanced Inorganic Copolymer Technology Corrosion resistance from -196°C to 650°C (-321°F to 1202°F) without heat cure or a primer

Specification Standardization Novel IMM technology delivers best in class corrosion resistance from cryogenic to 650°C (1202°F) Complex specifications can be replaced with a single system, standardizing and simplifying the coating process IMM Silicone Aluminium Polyurethane Polyurethane Silicone Aluminium Epoxy Phenolic Epoxy IMM Epoxy Epoxy Phenolic Zinc Silicate Zinc Silicate Zinc Silicate Zinc Epoxy Steel Steel Steel Steel Steel Novel IMM Novel IMM Steel V

Productivity Novel IMM delivers enhanced productivity compared to competitor systems with short minimum overcoating intervals Inorganic Zinc is not required to give additional corrosion protection Novel IMM Inorganic Zinc 6 12 18 24 30 Time to overcoat (hours) Competitor Competitor System Δ = 18 hours Data at 15°C (59°F) V

Hardness Novel IMM Technology demonstrates enhanced hardness and block resistance at ambient temperatures, reducing touch up and repair. Hardness grade B: passes block resistance testing after 2 hours cure 10oC/80% RH V

Novel IMM Technology Specification standardization Excellent corrosion resistance without a primer Increased productivity

“Extraordinary claims require extraordinary proof” Carl Sagan “Extraordinary claims require extraordinary proof” Our Coatings Journey – Not all coatings are created equal

Asset Management: Coatings Predictability & Risk $ Performance Productivity

Coatings Tested (SP0198-2017 CS-6) Packs Coating type Max steel service temperature* System tested 1 2K Novel IMM ≥ 650ºC 2 x 5 mils (2 x 125µm) All coatings cured at ambient (20ºC) for a minimum of 7 days before testing 2 IMM 3 4 1K 5 6 7 IMM = Inert Multipolymeric Matrix; * Information from TDS V

Anti-corrosive performance at ambient Non-insulated performance Anti-corrosive performance at ambient Anti-corrosive performance at 400 – 650ºC Dry heat resistance

ISO 20340 Cyclic Aging V System 1 Novel IMM 2 3 4 5 6 7 Photos Rust creep < 3 mm < 8mm Cannot be measured* < 8 mm Defects None Ri4 Ri2 Ri1 Ri5 ISO 20340 Cyclic aging test (10 cycles) – third party test Performance testing for C5 environment – High durability (ISO 12944:2018) * Could not separate rust creep from sub-film corrosion V

ASTM D5894 System 1 Novel IMM 2 3 4 5 6 7 Photos Defects None Ri 1 Ri 2 Ri 3 ASTM D5894 Cyclic aging test (4 cycles so far / full length test is 12 cycles): 1 week Prohesion (ASTM G85) 1 week cyclic UVA/condensation (ASTM D4587 cycle 2) Typical performance testing for industrial environments

External exposure External exposure in coastal site in the UK (North Sea) Highly corrosive environment, combining industrial and marine conditions Exposed for only four weeks

External exposure System 1 Novel IMM 2 3 4 5 6 7 Photos Defects None Ri3 Ri1 After only four weeks exposure, a significant difference in anti-corrosive performance and barrier properties could be observed and measured

Corrosion Protection 400 – 650ºC System 1 Novel IMM 2 3 4 5 6 7 Photos (x 10, except #3) Defects (rusting, cracking) None Cracked and delaminated after first heating step (pinholes from application) Hairline cracks Cyclic test: 1 day at 400ºC 1 day at 650ºC 4 days at 400ºC 1 day at ambient ASTM D5894 exposure (2 weeks, cyclic salt fog and UV exposure) x2 V

Dry Heat Resistance 200 – 300ºC System 1 Novel IMM 2 3 4 5 6 7 Photos Defects None Very fine hairline cracks just about visible with x10 lens Cyclic test: 1 day at 200ºC 1 day at 300ºC 4 days at 200ºC 1 day at ambient Exposure to four cycles so far V

Dry Heat Resistance 400 – 650ºC System 1 Novel IMM 2 3 4 5 6 7 Photos (magnified x10) Defects None Cracked and delaminated Hairline cracks Micro-cracks Cyclic test: 1 day at 400ºC 1 day at 650ºC 4 days at 400ºC 1 day at ambient Results after exposure to two cycles

Performance Non-insulated Ambient anti-corrosive performance Most coatings fail through poor barrier protection and/or poor rust creep resistance Novel IMM coating has excellent anti-corrosive performance after ambient cure Corrosion protection with ambient cure is essential if installation runs at ambient temperatures (several months/years before installation commissioned) High temperature resistance Not all coatings are defect free after 400ºC exposure with peaks at 650ºC Coatings may claim resistance to 650ºC as a minimum but discrepancy in level of heat resistance with various IMM coatings Novel IMM coating offers excellent anti-corrosion performance at ambient temperature after ambient cure (without need to post-cure) while also offering protection at temperatures up to 650ºC

Performance under insulation Performance up to 500ºC (Houston pipe test) Performance at 400 – 650ºC (dry heat)

Houston Pipe Test 100ºC Diameter = 6 cm Length = 60 cm 1 litre 1% NaCl twice/day Temperature °C Time 500ºC 8 hours Naturally cooled 16 hours Heated to 500ºC Repeated x 30 500ºC V

CUI Pipe Test Pipe temperature (ºC) Systems Initial / dry Wet 1 Novel IMM 2 3 4 5 6 7 120 50-80 140 175 190 200 225 75-130 250 275 300 330 375 400 110-200 Intermediate

Corrosion Protection 400 – 650ºC System 1 Novel IMM 2 3 4 5 6 7 Photos (x 10, except 3) Defects (rusting, cracking) None Stains Cracked and delaminated after heating Onset of rusting (pinholes from application) Onset of rusting and hairline cracks Cyclic test: 2 weeks at 400ºC with weekly peaks at 650ºC (24 hours every week) 1 week immersion in 40ºC seawater 1 week exposure to cyclic salt spray test (ISO 16701; Alternating between 35ºC/50% RH, 35ºC/95% RH and salt spray) Exposure to one cycle.

Performance Under Insulation Not all coatings are equal to protect against CUI, especially at (400-650ºC) despite TDS claims Most 1K coatings tested suffered under insulation at <200ºC, indicating heat-cure at 200- 250ºC might be necessary for adequate anti-corrosive protection Novel IMM coating offers excellent protection against CUI from ambient up to 650ºC compared to some of the other products tested, without the need for post-curing V

Novel High Heat Epoxy Coating

Conventional Epoxy Phenolic Coating Solutions Typically two coats of epoxy phenolic @ 4mils (100µm) DFT/coat Add-on costs to fabricator – heat >15C Poor cure <10C Brittle & Crack if overbuilt: $$$ Damage Repair Inspections Shipment Delays = Delayed Project and $$$

Typical phenolic epoxy problem – Why?

Novel High Heat Epoxy Coating with Low Temp Cure Chemistry Alkylated Amine Epoxy Max temp resistance 401°F (205°C) with peaks to 448°F (231ºC) Volume solids 60% Typical scheme 2 x 4 mils (2 x 100µm) DFT VOC 390g/l Colors available Grey, Olive Grey, Pink Drying & overcoating times -5°C(23°F) 10°C(50°F) 20°C(68°F) 35°C(95°F) Touch Dry 7hrs 5hrs 4hrs 2hrs Hard Dry 10hrs 8hrs 6hrs Overcoating 14hrs V

Alkylated Amine Epoxy V

What are Alkylated Amine Epoxies? Typical Epoxy Phenolic Alkylated Amine Epoxy Rigid network restricts DFT tolerance Hardener flexibility increases film DFT tolerance, Low Temp Cure

Epoxy Phenolic: Film Build Sensitivity Test Method: Panels are cured at ambient for seven days and then subjected to five heat cycles. One cycle consists of eight hours at target temperature followed by 16 hours cooling to room temperature. Panels are then assessed visually for cracking, blistering and disbondment and graded No visible defects Cracking and defects observed around weld only Cracking and defects observed across the face of the panel

Epoxy Phenolic: Film Build Sensitivity SYSTEM/ TEMP 120C 150C 200C Typical Epoxy Phenolic 1 x 8 mils (1 x 200µm) 1 x 8 mils ( 1 x 200µm) 2 x 4 mils (2 x 100µm) 2 x 6 mils (2 x 150µm) 2 x 7 mils (2 x 175µm) 2 x 8 mils (2 x 200µm) 2 x 9 mils (2 x 225µm) 2 x 10 mils (2 x 250µm) Slightly wider application thickness for optimum performance V

Alkylated Amine Epoxy: Film Build Sensitivity SYSTEM/ TEMP 120°C 150°C 200°C Alkylated Amine Epoxy 1 x 8 mils (1 x 200µm) 2 x 4 mils (2 x 100µm) 2 x 5 mils (2 x 125µm) 2 x 6 mils (2 x 150µm) 2 x 7 mils (2 x 175µm) 2 x 8 mils (2 x 200µm) 2 x 12 mils (2 x 300µm) 2 x 14 mils (2 x 350µm) 2 x 16 mils (2 x 400µm) 2 x 18 mils (2 x 450µm) 2 x 20 mils (2 x 500µm) Summary: Excellent resistance to over-application V

Alkylated Amine Epoxy Low temperature cure Flexibility Tolerance to over-build application Performance at high temperatures Can be used over stainless steel and carbon steel Excellent anti-corrosive properties Saves time, money, lowers risk and conflict V

Conclusions – IMM coatings Most but not all IMM technologies perform well at temperatures > 200ºC Most IMM technologies (particularly 1K coatings) require a post-curing to provide adequate anti corrosion protection Most IMM coatings may require zinc primer for adequate anti-corrosion protection if used between ambient -150C Novel IMM affords broad anti-corrosion performance from cryogenic to 650°C, including ambient conditions, without need for post-cure or zinc primer

Conclusions – Alkylated Amine Epoxy Alkylated amine epoxy provides low temperature cure for high heat coatings Alkylated amine epoxy provides excellent resistance to DFT overbuild and improved productivity Alkylated amine epoxy can be used over carbon steel and stainless steel

Not all coatings are “Created Equal” Within a generic class of coatings, performance variations can be as great as the difference between oil and water …………….

Thank You