PCN – Communicating News In Protective Coatings Globally in Real-Time
Leading Source of Industry News on Protective Coatings for Oil & Gas, Pipelines, Marine and Construction
NEWSMAKERS: * Akzo Nobel * Aramco * Carboline * CUI * ExcelPlas * Failure Analysis * Helmut Fischer * Hempel * Jotun * International Paints * Interbond 2340UPC * Intertherm 228 * LNG * MCU Coatings * NanoRustX * PCN * PPG * Protective Coatings * Qlayers * Sherwin Williams * Wattyl
New Digital News Platform for Reaching the Entire Global Protective Coatings Industry in Real Time (Breaking News)
MCU Coatings Take On Challenge of Corrosion in Oil & Gas with Unique Formulations (Breaking News)
Jotun Announces Price Increases Following Sharp Rise in Raw Material Costs (Breaking News)
Akzo Nobel and Qlayers Develop Coating Robot to Coat Steel Storage Tanks with Protective Coatings
Helmut Fischer Launches New DFT Coating Measuring Device for Heavy Protective Coating
Wattyl Australia & New Zealand Now Officially Part of Hempel Group
Norwegian Paint-giant Jotun Starts Operations in Bangladesh
Aramco Announce New Centre of Excellence for Non-metallics and Polymers in Building and Construction
Aramco Senior Vice President of Technical Services, Ahmad Al-Sa’adi said Aramco is the leader in the use of non-metallic materials in oil and gas facilities to reduce corrosion
PPG Opens Innovation Centre to Develop Paint Products in China
PPG Expands PITTHANE™ High Durability Urethane Coating Line with New Low-Sheen, Low-VOC Solution
NanoRustX LLC Reinvents Primers to Prevent Chemical Facility Corrosion
Aramco to Cut Spending as Profit Drops 44%
Akzo Nobel Updates Interbond™ 2340UPC Application Guidelines
Judgement: JKC Australia LNG Pty Ltd v AkzoNobel NV (FEDERAL COURT OF AUSTRALIA)
Sherwin Williams v PPG Industries Patent Dispute
Common Tests for Protective Coatings in Immersion Service – Carboline Podcast Ep. 176
Carboline Vice President of Research, Development & Innovation Jeff Anderson joins Paul Atzemis and Jack Walker to discuss common testing for coatings designed for immersion service.
Jotun’s Researchers Celine Abadie and Hannah Shenton Explain How to Apply a High DFT Coating in a Single Shift
Self-Reporting Coatings for Autonomous Detection of Coating Damage and Metal Corrosion: A Review
Focused Review on Smart Coatings Tailored for Corrosion Protection: Developments, Applications, and Challenges
Design of Smart Protective Coatings with Autonomous Self-Healing and Early Corrosion Reporting Properties
Metal Oxide Based Epoxy Coatings for Corrosion Protection of Steel
Automated Steel Bridge Coating Rust Defect Recognition Method Based on U-Net Fully Convolutional Networks
Thermal Conductivity and Anti-Corrosion of Epoxy Based Coatings Doped with Graphene and Graphene Oxide
Study on the Degradation of a Zinc-Rich Epoxy Primer/Acrylic Polyurethane Coating in Different Simulated Atmospheric Solutions
Scratch Adhesion Testing and Failure Classification for Hard Coatings Using Relative Area of Delamination and Scaled Indenters
Experimental Study on Crack and Debonding of Intumescent Coatings and their Effects on Temperature Development of Steel Elements
Failure Mechanism of Pure Epoxy Coating in Near-Neutral Solution Focusing on Coating/Metal Interfaces
In-Situ Evaluation of the Protectivity of Coatings Applied to Metal Using Non-Destructive Electrochemical Measurements
Chugoku Marine Paints (Singapore) Seeking Coatings Chemist for Paint Film Analysis
Aramco Seeking Corrosion Engineer for Fadhili Gas Plant with Experience in Coatings Failures
To review and approve recommend solutions for coating failures and cathodic protection.
Hempel Seeking Executive Business Assistant (Coatings)
Hempel Seeking Senior Sales Executive (Coatings)
Jotun Seeking Brand Development Specialist – Performance Coatings
COATING FAILURE ANALYSIS
Protective Coating Failure Investigations – Causes of Coating Failure – Analysis of Coating Blister Failures
Protecting Steel Structures in the Oil and Gas Industry from Corrosion
Minimizing The High Potential Costs of Offshore and Onshore Coating Failures and Repairs
ExcelPlas investigates coating failures and analyzes the conditions that led to the failure. Our expert team collects background information on the coating type and application procedure, the service history and environment, and physical evidence of the failed coating to determine the cause of failure. By analyzing this information and the samples of failed coating/s, we assist owners with plans to move forward and repair the failing coatings or remove and apply a more effective system
FAILURE PREVENTION OF PROTECTIVE COATINGS
15 of the Most Common Causes of Failure of Protective Coatings & the Type of Failure (from ExcelPlas 25 Years of Experience)
1. Inadequate blasting and insufficient removal of mill scale from the steel leading to poor adhesion
2. Use of blasting grit with soluble salt contamination leading to osmotic blistering and under film corrosion
3. Oil contaminated compressed air used for blasting leading to surface contamination leading to poor adhesion and delamination of the coating
4. Inadequate blast profile i.e. shallow valleys leading to poor adhesion
5. Excessive blast profile i.e. high peaks leading to poor steel coverage and risk of rust-rash corrosion, particularly for low DFT coatings.
6. Excessive delay between blasting and coating causing flash corrosion contamination leading to poor adhesion and corrosion cells
7. Addition of too much thinner that increases the potential for porosity and pinholes in the coating. There is also an increased propensity for the formation of Bernard Cells where there are boundaries of resin rich coating, resulting in “crows feet” cracking.
8. Poor mix ratio of the epoxy with the hardener leading to incomplete cure
9. Inadequate mixing/stirring of the coating before application leading to poor distribution of barrier pigments leading to coating cracks and premature corrosion
10. Inadequate coating specification: lack of suitable topcoat for UV sensitive epoxies leading to chalking and UV breakdown
11. Inadequate curing of coatings leading to less than optimal properties of the coating with increased moisture penetration and formation of corrosion cells
12. Incompatibility of coating if different paint systems are used multicoat application leading to delamination/peeling
13. Poor QA leading to inadequate control of coating thickness (e.g. excessive DFT) leading to cracking of the coating due to residual stresses
14. Poor QA leading to inadequate control of coating thickness: low coating thickness or missing coats can lead to poor barrier performance and premature corrosion
15. Exceeding the recoat window leading to delamination of topcoat from primer coat due to blast-dust contamination or lack of interfacial adhesion.
Critical Questions for Protective Coatings for Asset Protection in Oil & Gas, LNG:
• Why is the coating not stopping corrosion?
• Why is the coating delaminating or blistering?
• Has the coating been correctly specified / applied?
• Does the coating meet the manufacturing standard, including properties such as correct hardness/cure, adhesion and thickness?
• What surface preparation and atmospheric conditions must be achieved to successfully apply the coating?
• Does the coating have any defects in it? How will these affect performance?
• Why did the coating fail? Root cause assessment.
• How can the coating be successfully repaired/remediated so that it doesn’t fail again?
ExcelPlas Labs can answer these questions
MARKETING YOUR BRAND
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This newsletter is brought to you by ExcelPlas Coating Labs (http://www.excelplas.com/)
ExcelPlas Labs provides independent testing, analysis and investigation on protective coatings to prevent corrosion.
ExcelPlas has extensive analytical capabilities for testing of Protective Coatings and Insulation Consulting for major oil and gas companies.
We conduct corrosion surveys, coating sampling, coating analysis and testing to ensure coating specifications for a wide range of onshore and offshore clients in Australia and the Asia-Pacific Region.
ExcelPlas Labs offer a full range of coating testing and analytical services to Australia’s mining, oil, gas and infrastructure sectors.
Forensic analysis for undertaking various coating based failure investigations and problem solving.
ExcelPlas Undertakes Analysis & Testing of Polymer Coating Systems including:
• Epoxy Protective Coatings
• Epoxy-Phenolic Protective Coatings
• Fusion bonded epoxy (FBE)
• Dual-Layer Fusion bonded epoxy (DLFBE)
• Liquid applied epoxy (LAE)
• Abrasion resistant overcoat (ARO)
• Three-layer PE (3LPE)
• Multi-component liquid spray (MCL)
• Heat shrink sleeves (HSS)
Testing on Coatings that ExcelPlas can Undertake includes:
• Coating identification by Infra-red Analysis (FTIR)
• Degree of Cure by Thermal Analysis (DSC)
• Coating Filler Identification by X-ray Analysis (EDS/XRD)
• Coating Microstructure by Embedding, Polishing and Optical Microscopy (OM)
• Coating Thermal Stability and Composition by Thermogravimetric Analysis (TGA)
DSC – Phase transition/volatiles / Tg / degree of cure/characterisation
TGA – Volatile compounds, inorganic mass % mix ratio
Element mapping for chlorides on paint flakes
Microscopy -Count layers and thickness of layers
-Assess porosity and voids
-Check distribution and orientation of filler particles
Condition monitoring and analysis of corrosion prevention coatings (epoxies, epoxy-phenolics)
Testing of Epoxy Coatings (LAE, FJC, FBE), heat shrink sleeves and tapes, barrier tapes and meshes.
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