Transcript Corrosion in ballast tanks - is rust a must?

Corrosion in ballast tanks
Marine Coatings
RINA Conference Feb 2010
Presented by: DR M Raouf Kattan - managing director
www.Safinah.co.uk
ACME = Corrosion
Air (Oxygen)
Cathode
Metal
Electrolyte
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New build costs
Ohds 28%
Misc 2%
Paint 2%
Equip 22%
Steel 8%
Main Eng 16%
Labour 19%
Pipes etc 7%
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The cost of coatings
4%
7%
5%
7%
2%
50%
1%
Repairs
Lub oil
Paint
3%
Spares
Stores
Fuel
Man Fee
Provisons
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19%
2%
Dry Dock
Crew Costs
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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
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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.
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Current solution
Create a physical barrier in the form of a
coating to break the contact between
the ACME elements.
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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
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Causes of failure
Poor design
Material selection (paint
selection/specification)
Production processes control
Surface preparation
Application
In service conditions/planned maintenance
Coating chemistry
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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.
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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
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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.
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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
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The solution envelope
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
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Get it right - it is cheaper
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