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Corrosion Prevention Strategies in Ballast Tanks: Insights from RINA Conference

Learn about the impact of corrosion in ballast tanks, cost implications, prevention methods, causes of failure, regulations, and the overall size of the issue with practical solutions and industry insights shared at the RINA Conference.

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Corrosion Prevention Strategies in Ballast Tanks: Insights from RINA Conference

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  1. Corrosion in ballast tanks Marine Coatings RINA Conference Feb 2010 Presented by: DR M Raouf Kattan - managing director www.Safinah.co.uk

  2. ACME = Corrosion Air (Oxygen) Cathode Metal Electrolyte Doc No. 270CXXXP-RINA Oct 2005

  3. New build costs Ohds 28% Paint 2% Equip 22% Steel 8% Main Eng 16% Misc 2% Labour 19% Pipes etc 7% Doc No. 270CXXXP-RINA Oct 2005

  4. The cost of coatings Doc No. 270CXXXP-RINA Oct 2005

  5. The cost of failure • Ballast tank refurbishment • $50 - $100 per sqm • Total area for a Panamax bulk carrier - 70,000dwt - 80-100,000 sqm • New build price - $36-48 million • Percentage on average of catastrophic failure - 16%of first cost Doc No. 270CXXXP-RINA Oct 2005

  6. Prevention of corrosion • Provide a break in ACME • No Air - inert the space, some ballast water treatment systems propose to do this, (but anaerobic corrosion) • No Cathode - same metal to metal problems or non-metals • No Metal - no real alternatives at present • No Electrolyte - treat the water or alternatives, no ballast ships or water alternatives. Doc No. 270CXXXP-RINA Oct 2005

  7. Current solution • Create a physical barrier in the form of a coating to break the contact between the ACME elements. Doc No. 270CXXXP-RINA Oct 2005

  8. The solution does work With good Surface preparation and application the Current range of products can create a suitable barrier that can last in theory up to 15 years or more Doc No. 270CXXXP-RINA Oct 2005

  9. Causes of failure • Poor design • Material selection (paint selection/specification) • Production processes control • Surface preparation • Application • In service conditions/planned maintenance • Coating chemistry Doc No. 270CXXXP-RINA Oct 2005

  10. Have regulations helped • 12 new regulations and guide lines over the last 15 years to do with ballast tanks. • Little evidence that they have improved the situation beyond what paint companies may have done to respond to client demand/environmental concerns. • Statistics hard to come by. Doc No. 270CXXXP-RINA Oct 2005

  11. Size of the problem • Safinah estimate some • 7117 bulk carriers and COT • Totalling 557.6 million dwt • 7 - 8 billion sqm of ballast tank afloat • Average vessel age range 11-14 years Doc No. 270CXXXP-RINA Oct 2005

  12. Expenditure • A US Study indicated $8.5 - $11 billion is spent each year • Cost of design measures • Cost of new building measures • Cost of through life • Safinah believe these estimates to be very conservative. Doc No. 270CXXXP-RINA Oct 2005

  13. The environment • A mix of • Air temp • Steel temp • Cargo temp • Sea temp • Ballast water treatment systems • Vessel design • Creates a distorted environment within the tank from outside shell to inside shell Doc No. 270CXXXP-RINA Oct 2005

  14. Design review Design guidelines (lessons learnt) Functional specifications New production technologies Scheduling Understanding the environment Coating strategies HS&E challenges Planned maintenance Education Regulations across the chain of activities The solution envelope Doc No. 270CXXXP-RINA Oct 2005

  15. Get it right - it is cheaper Doc No. 270CXXXP-RINA Oct 2005

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