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

2. 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

3. 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

4. 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

5. 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

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

7. 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

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

9. 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

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

11. 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

12. 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

13. 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

14. 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

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

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

17. Asset Management: Coatings
Predictability & Risk $
Performance
Productivity

18. 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

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

20. 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 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

21. 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

22. 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

23. 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

24. 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

25. 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

26. 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

27. 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

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

29. 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

30. 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
Intermediate

31. 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.

32. Performance Under Insulation
Not all coatings are equal to protect against CUI, especially at ( ºC) despite TDS claims
Most 1K coatings tested suffered under insulation at <200ºC, indicating heat-cure at ºC 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

33. Novel High Heat Epoxy Coating

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

36. Typical phenolic epoxy problem – Why?

37. 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

38. Alkylated Amine Epoxy V

39. 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

40. 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

41. 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

42. 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

43. 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

44. 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

45. 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

46. 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 …………….

47. Thank You