U.S. Navy Tank and Void Maintenance and Lifecycle Cost Reduction - - PowerPoint PPT Presentation
Materials Engineering Office, O5P23 U.S. Navy Tank and Void Maintenance and Lifecycle Cost Reduction Initiatives Arthur A. Webb Head, Marine Coatings Section Naval Research Laboratory Paul Slebodnick Corrosion Engineering Section Naval
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Arthur A. Webb
Head, Marine Coatings Section Naval Research Laboratory
Paul Slebodnick
Corrosion Engineering Section Naval Research Laboratory
Beau Brinckerhoff
Corrosion Control Division Naval Sea Systems Command
Materials Engineering Office, O5P23
Presented to The International Symposium on Shipbuilding Technology (ISST 2007) September 6-7 2007 Osaka University, Japan
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Traditional Solvent Based System High Solids Systems 1996 Solvent Free Rapid Cure System 2001 Present
Reduction in VOC and HAPS
1994: Initial implementation of improved QA 2001: Improved application equipment 2002: Development of specialized resin materials 2004: First rapid cure product placed on Navy QPL 1995: Use of edge retentive coatings 1996: Initial implementation of plural
component for handling solvent-free coatings
1997: Institutionalization of enhanced QA!
1991 1997
Materials Engineering Office, O5P23
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Low Employ rapid cure coating with plural component High Employ post application heating Rapid Turn-around Required Low Employ plural component High Work Rapidly High Environmental Temperature Low Employ heated plural component High Employ localized heating Low Material Temperature Low Employ cold cure with plural component High Employ localized and or space heating Low Environmental Temperature Risk Long Term Solution Risk Short Term Solution Problem
Relative Humidity <50% Surface Profile 75-125um Condition SSPC SP-10 (Sa 2 1/2) Chloride <3ug/cm^2 Surface Preparation Requirements (Navy SI 009-32)
Materials Engineering Office, O5P23
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1,125-1,350 375-450 375-450 375-450 Solvent Free 1000-1,250 200-250 200-250 200-250 200-250 200-250 High Solids 625-875 125-175 125-175 125-175 125-175 125-175 Solvent based Total Topcoat Stripe Coat Mid Coat Stripe Coat Primer System
Current U.S. Navy Shipboard Tank Coatings Systems at a Glance
(All thicknesses in microns)
Moving toward solvent free, direct-to-metal, fast-cure in all applicable areas
Maintain Present Quality Assurance Requirements
Materials Engineering Office, O5P23
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– 7 year program aimed at employing latest state of the art in solvent free coatings for reduction in maintenance costs and for life cycle extension – Program management and technology identification and insertion through demonstrations – Materials identification and performance/process development by the Naval Research Laboratory code 6138.
– Acceptance documents and placement on Qualified Products List (QPL) – Revisions to standard maintenance procedures and fleet directives
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Office of Naval Research Code 332 Materials and Process Development Naval Research Laboratory Code 6130 Design and Acquisition Managers Naval Sea Systems Command 05P23 Product Demonstration Naval Research Laboratory Naval Surface Warfare Center Fleet Implementation Regional Maintenance Centers Performance Review
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Traditional Solvent Based System Solvent Free Rapid Cure Systems
5-7 Years Service Life 15-20 Years Service Life
High Solids/Solvent Free System
5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 Three-coat Rapid Cure Single-coat (Multipass) Rapid Cure Three-coat Traditional Cure Five-coat Traditional Cure
Theoretical Required Time for Application/Cure-out and QA (Hours) Required Time for Application/Cure-out and QA (Hours) Required Time for Application/Cure-out and QA (Hours)
10 20 30 40 10 20 30 40
15-20 Years Service Life
10 20 30 40
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Cure Class Standard Cure Traditional solvent free epoxy Rapid Cure Solvent free epoxy using enhanced curing agents Single Coat Polyurethane and Polyurea with low catalyst levels Coating Chemistry
< 5 sec 5-10 sec 30-45 sec 1-3 min 2-3 min 3-5 min Polyurea <1 min 5-10 min 10-20 min 20-30 min 40-60 min* 60-90 min* Rapid Cure Polyurethane 1-2 hrs 2-3 hrs 3-4 hrs 5-7 hrs 8 hrs No curing Rapid Cure Epoxy <4 hrs 4-6 hrs 6-8 hrs 8-12 hrs 12-18 hrs 18-24 hrs Cold Cure Epoxy 4-6 hrs 6-8 hrs 8-12 hrs 12-24 hrs No curing No curing Standard Cure Epoxy 43C 32C 24C 15C 4C 0C Time to Cure Coating Type
* High catalyst levels required
Materials Engineering Office, O5P23
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Time to Cure at 25C (77F) 2 4 6 8 10 12 14 Standard Epoxy Cold Cure Epoxy Rapid Cure Epoxy Rapid Cure Polyurethane Product Type Cure Time (hrs)
20 minutes
Materials Engineering Office, O5P23
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Type Cure to Handle Recoat (hrs) Full Service Equipment Reqt's Epoxy (8) 3 hours 4 to 8 max 7 days PC/single feed gun Polyurethane (2) 20 minutes 4 max 7 days PC/impingment gun
Current list of products under evaluation for corrosion control
Use Area Standard Cure Epoxy Rapid Cure Epoxy Rapid Cure Polyurethane Dedicated Seawater Freshwater Gray/black water Fuel/compensated fuel Voids Air Plenums Bilges Acceptable Marginal Not Recommended Solvent Free System Line-up System Application Acceptability
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Blast Cleaned 1st Coat (primer)
Wait 3-4 Hours
Stripe Coat Topcoat
Wait 3-4 Hours
Inspect and Close
1st Evolution 2nd Evolution 3rd Evolution
Wait 3-4 Hours
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Completed
First Pass Second Pass 3rd Pass (Completed)
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Topcoat applied by First Crew
Primer Coat Application Mid Coat begins as Primer team finishes Final Coat begins as Mid Coat Team finishes
Wet Cure to Handle
Primer Mid Coat Topcoat Prepared Structure
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1,125-1,350 1,125-1,350 Multipass Single Coat 1,125-1,350 375-450 375-450 375-450 Solvent Free 1000-1,250 200-250 200-250 200-250 200-250 200-250 High Solids 625-875 125-175 125-175 125-175 125-175 125-175 Solvent based Total Topcoat Stripe Coat Mid Coat Stripe Coat Primer System
(All thicknesses in microns)
All Inclusive in Application
Materials Engineering Office, O5P23
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(note that applicator is standing directly on completed and cured deck)
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Process Legacy System Solvent Free System Rapid Cure Epoxy Rapid Cure Polyurethane Surface preparation Sa 2.5 Sa 2.5 Sa 2.5 Sa 2.5 Required profile 75-125um 75-125um 75-125um 75-125um Time required (hrs) 40 40 40 40 Application Equipment Singe feed Singe feed Plural Feed Plural Feed Training QP-1 QP-1 QP-2 + Vendor Training QP-2 + Vendor Training Cure Temperature, C Minimum 15 15 10 Maximum 35 35 35 35 Paint Cure Schedule (hrs) Prime 8 8 3 1 Stripe 8 8 3 1 Mid 8 Stripe 8 Top 8 8 3 1 QA/QC Prime 4 4 4 4 Stripe 4 4 4 4 Mid 4 Stripe 4 Top 4 4 4 4 Overcoat Minimum 12 hrs 12 hrs 12hrs 1 hr Maximum 30 days 30 days 14 days 4 hrs Environmental Control <50 RH <50 RH <50 RH <50 RH Total Time to Completion (hrs) 100 76 61 55
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Space Initial Application Subsequent Application Initial Application Subsequent Application Seawater Ballast
49 2 31 Freshwater
22 Fuel tanks 27 31 Polyurethane Epoxy System Savings Legacy Coating Rapid Cure Epoxy 51 Rapid Cure Polyurethane 30 Production Application Savings
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Application Cost Comparison Relative to Legacy System
20 40 60 80 100 120 Legacy System, Tradational Application Rapid Cure Polyurethane, Initial Application Rapid Cure Polyurethane, Subsequent Application Rapid Cure Epoxy, Initial Application Rapid Cure Epoxy, Subsequent Application
Systems Employed Costs (%)
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Task Hours Hours Savings Staging and containment 23 23 Surface preparation 32 32 Painting 53 29 24 Containment removal 20 20 Total: 128 104 24 Costs for Corrosion Control Process Traditional Coating Rapid Cure Coating
Savings realized from: No required repairs due to premature damage (typically 20-30% add’l cost) Reduced time required for environmental controls Full system applied during one evolution (planned application work shift) Epoxy with 3-hour cure to handle time at 25C
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Cost Comparison for First 35 Tanks Employed in Demonstration (Program Milestone Demonstrations)
Ship Tank Count Total Area (sq-ft) Average Cost (per sq-ft) Cost Avoidance (per sq-ft) Percent Savings (versus legacy system) Program Milestone Achievements GUNSTON HALL (LSD 44) 1 tank 2758 $28.44 ($2.44) (9) First-ever application of Polyurethane in a Navy-Shipboard tank WHIDBEY ISLAND (LSD 41) 1 Tank 3500 $18.63 $7.37 28 First Tank Cost primarly equipment setup, 1 Tank 4000 $12.23 $13.77 53 Second Tank Cost, application of Polyurathane WASP (LHD 1) 1 Tank 19495 $6.86 $19.14 74 First application of Rapid Cure product. Cost low because of high tank square footage G WASHINGTON (CVN 73) 1 Void 2200 $18.97 $7.03 27 First application of Polyurethane aboard Carrier TORTUGA (LSD 46) 3 Tanks 10849 $23.84 $2.16 8 First application during dry Dock Avail, First application both Single Coat & Rapid Cure ASHLAND (LSD 48) 4 Tanks, 2 PW Tanks 13551 $29.52 ($3.52) (14) First-ever application of Polyurethane in Shipboard Potable Water tanks T ROOSEVELT (CVN-71) 4 Voids 10177 $32.37 ($6.37) (25) First application during Dry Dock Avail, First application of Polyurethane aboard Carrier High visibility Demonstration GUNSTON HALL (LSD 44) 2 Tanks 5295 $13.01 $12.99 50 First Down River (pierside work) outside
GUNSTON HALL (LSD 44) 9 Tanks 23737 $16.76 $9.24 36 First production application in multiple tanks using Rapid Cure coatings NASHVILLE (LPD-13) 6 Tanks 14562 $17.85 $8.15 31 First application in Center Line tank with Rapid Cure High Complexity and large size Application Cost Avoidance for First 35 Demonstration Tanks
Red denotes no initial cost savings due to “first time” learning curve. All subsequent applications in same tanks/ship were 30-40% below legacy cost
Application Costs
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Traditional Slow Cure Solvent Free Epoxy
Navy Standard Item 009-32 Three Coat Application
Rapid Cure Solvent Free Epoxy
Single Coat Application
Rapid Cure Solvent Free Epoxy
Two Coat Application
Rapid Cure Solvent Free Epoxy
Single Coat Application
*All Times include Touch-up
Application of Rapid Cure Coatings, 2 Full Coats & Stripe – 90 Hrs *
35 hours to Completion 35 hours to Completion 70 hours to Completion 216 hours to Completion
Materials Engineering Office, O5P23
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Single Coat Polyurethane After 2 Years in a 300m2 Fresh Water Tank
(tank does not employ sacrificial anodes)
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Single Coat Polyurethane After Application in 290m2 tank
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Single Coat Polyurethane After Application in High Complexity 450m2 Tank
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Rapid Cure Epoxy After Application in 1,900m2 Tank
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Rapid Cure Epoxy After Application in High Complexity Fuel Tank
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Maintenance Legacy System (a) Solvent Free System (a) Rapid Cure Epoxy (b) Rapid Cure Polyurethane (b) Service Life 5-7 years 7-10 years 12-15+ years 15+ years** Repair Frequency 2-3 years 3-5 years 7-10 years 10 years Replacement* 100% 50% 25% Unknown Removal Full Abrasive Blasting Full Abrasive Blasting Full Abrasive Blasting Induction Heating + Sweep Blasting Training Minimal Minimal- moderate Moderate Moderate-high
(a) Demonstrated service life when applied under proper QA and environmental controls (b) Projected service life when applied under proper QA and environmental controls * Percent of tanks re-preserved (i.e., 100% of tanks coated with legacy coating are re-preserved after 7 years ** Projected service life based on comparison to epoxies under current field trials and laboratory testing
Materials Engineering Office, O5P23
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A B
2:1 Ratio 1:1 Ratio
A B
3:1 Ratio
A B Material Supplies Material Outlets Air Motor Hydraulic Metering Pumps Inlet Air (provides power) Pistons A B A B
2:1 Ratio Illustrated Components and Configurations
Ratio configuration change through quick disconnect
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A B
Ratio Controller
A B A B
Inlets
Static Mix Line Gun Line (whip)
Not suitable for fast setting polyurethanes or polyureas!!!
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Equipment Type UHS Epoxy Fast Cure Epoxy Fast Cure Polyurethane Plural Component Fixed Ratio YES YES YES Slug Mix Variable Ratio YES YES NO Equipment and Coatings Usage Allowance
Fixed Ratio Slug Mix Variable Ratio A B A B A B
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Valve Trigger Mixed Material Inlet Spray Tip Valve Trigger Air Inlet for Operation Spray Tip Component A Supply Component B Supply
UHS Epoxy Fast Cure Epoxy Fast Cure Polyurethane
Single Feed Gun Single Feed Gun w/mix Block Impingement Mix Gun
Equipment and Coatings Usage Allowance
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1 Results of most recent field production rates during repair
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