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Corrosion in ballast tanks

Corrosion in ballast tanks. Marine Coatings RINA Conference Feb 2010 Presented by: DR M Raouf Kattan - managing director www.Safinah.co.uk. ACME = Corrosion. A ir (Oxygen) C athode M etal E lectrolyte. New build costs. Ohds 28%. Paint 2%. Equip 22%. Steel 8%. Main Eng 16%. Misc 2%.

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Corrosion in ballast tanks

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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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