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ISSUETWENTYONE2012
The Elements Edition
Bringing the rise of tidal energy,
fire protection expertise and air travel,
together under one grand design
Editor’s Note
of Tidal
CONTENTS
The Rise of
Tidal Power
3
Wuxi Grand Theatre
6
8
Protecting the
Golden Eagle
Melbourne Water
Choose Polibrid
10
Mauritius Airport
12
14
How to Correctly
Specify Epoxy
Passive Fire
Protection
Managing Editor:
Stuart Byers
Publisher:
International Paint
Cover Photo:
Jussi Tiainen for PES-Architects
2
Welcome to the new issue of
Surfaces magazine, which
requires a special introduction.
Surfaces turned global almost a decade ago in 2003;
reporting on the ‘dos and don'ts of tank linings
installation’ and the benefits of International Paint’s
Intersleek® coatings. But it first came to fruition
almost 17 years ago when our Australian business
launched the very first Surfaces Magazine that
brought news of an extension to the Dalrymple
Bay Terminal; one of Australia’s largest coal
export complexes, as well as an article discussing
the benefits of inorganic zinc coatings in
comparison to galvanising for large structures.
Editor:
Amanda Rouse
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ise
R
the
Over the years Surfaces has covered a range of high
profile projects, from the Laminaria, which back in
1999 when the article was featured, was the world’s
biggest floating production storage offloading facility,
to more recent projects including the London Array
offshore wind farm, which is expected to become the
world’s largest offshore wind farm, upon completion.
Surfaces has come a long way from its humble
beginnings and in true Surfaces style, this issue is
packed with more content spread across the power
generation, oil and gas, water and wastewater and
high value infrastructure markets, with a strong theme
of fire protection running throughout, ending with an
article highlighting the importance of specifying the
right passive fire protection products on page 14.
This issue also sees a success in Australia with
the introduction of the Polibrid® lining system,
which is being sold under license across a number
of regions, by International Paint. Their first big
success story with the system shows how Polibrid;
a new elastomeric chemical resistant lining,
was chosen over a range of alternative flooring
systems and resulted in a more efficient and cost
effective solution. Read more on page 10.
We hope you enjoy this issue of Surfaces and if
you would like to subscribe to additional copies
of the magazine, please submit your requests
to [email protected]
Power
M
ore predictable than wind energy and solar power and more sustainable in the
long term than coal power; tidal power generation has been boosted over recent
years with an increasing number of facilities being developed around the world.
This is largely attributed to an increased understanding of how best to harness the energy created by
tidal forces, with innovative solutions being brought to the marketplace over recent years.
Things have come a long way since 1966, when the French Rance Tidal Power Plant, the world’s first
large-scale tidal barrage power plant, was built.
A rise in power generation using renewable energy
sources has been evident over recent years; but what
role does tidal power play?
The energy potential of tidal power facilities is huge, with the
Crown Estate, who manage the UK’s seabed out to a 12nm
(nautical mile) limit, reporting there is the potential for 95TW/h
per annum from 32GW of installed capacity. The potential exists
for 20% of the UK’s energy to be drawn from wave and tidal
power alone and the UK is beginning to emerge as a central hub
for this type of power generation in Europe with 35% of all of
Europe’s tidal energy potential being off the coast of the UK.1
Unique to tidal energy is the confidence placed upon the consistent
flow of energy, made possible by the regular flow of water, controlled
by the moon and gravitational pull, which can be relied upon to the
point that it is ‘as regular as clockwork’. This reliance enables
accurate forecasting of power generation, as opposed to wind
power and solar power, where it is somewhat more difficult.
Recently, International Paint has worked with two big players in
the tidal power generation industry on large and technologically
innovative projects. Both Andritz Hydro Hammerfest Strøm and
Voith Hydro Ocean Current Technologies have both utilised
protective coatings from International Paint.
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Tidal Power Generation
Rise
Tidal Power Generation
Another recent tidal device seeking the benefits of
International Paint’s Intersleek coatings is the Voith
HyTIDE Tidal Power device, from Voith Hydro Ocean
Current Technologies, also located just off the coast
of Scotland. “The Voith HyTIDE Power Plant required
an antifouling coating system that did not include
biocides and that also boasted an excellent track
record in severe offshore environments. This made
Intersleek the perfect foul release system for the job”
said Daniel Christ of Voith Hydro Ocean Current
Technologies.
Photos courtesy of Voith Hydro Ocean Current Technologies
their ultra smooth, low energy surface, which is designed to reduce
friction and maintain efficiency. The collection of marine life on tidal
blades is a common concern in tidal power generation, as a build up
of such marine life can cause additional drag on blades; resulting in
reduced efficiency. The build up of marine life is also known to cause
sticking or even failure of moving parts within submerged turbines.
This large tidal power device uses a simple
yet robust system to drive the production of
power. To reduce complexity, the technology
used within the turbine is innovative,
removing the need for lubrication of bearings;
sea water is used instead. This is a new
technological innovation, recently adopted
by Voith Hydro Ocean Current Technologies,
which is designed to be not only kinder
to the environment than typical oil bearing
lubrication, but also results in a reduced
need for maintenance. Other advantages
of the simple turbine solution include an
adjustable rotor; which ensures optimal energy
extraction. The turbine is also capable of being
mounted onto a range of different foundations.
The environment is one of many important key factors within coatings
selection in the renewable energy market; therefore Hammerfest’s
choice to use International Paint’s Intersleek coatings was no surprise,
“Intersleek includes zero biocides and boasts extremely tough
and hardwearing characteristics, which denotes a reduced
requirement for maintenance, which when carried out in deep
water, is extremely costly and difficult” explained Jiří Fiala, Technical
Service Representative for Central Europe at International Paint.
The expectation from those involved in the
project is that just one single turbine from the
Voith HyTIDE Tidal Power Plant, which has a
nameplate capacity of 1.8MW will be capable
of supplying upwards of 330MW/h energy
annually (with a 50% conversion efficiency).
Then consider the prospect of an array of
hundreds of these turbines going into service
The Hammerfest Strøm HS1000 tidal device from Andritz Hydro is currently located off the coast of Scotland
and could be considered to be one of the most pioneering and important projects currently in progress for the
production of renewable energy. With the first tidal turbine already at pilot production stage, the company
are on track for deployment of a 95MW turbine array, off the north coast of Scotland, around 2015.
For such an important project, a coatings partner with extensive
success in the power generation market was required. Andritz Hydro
Hammerfest Strøm turned to International Paint to supply their high
performance, protective coatings in what is perceived to be one of
the world’s most severe environments; the North Sea. A coatings
system has been specified for the Hammerfest Strøm project including
International Paint’s heavy duty, chemical and abrasion resistant
Interzone® 954 which is to be applied to the turbine. “We have heard
of the success of Interzone 954 in an offshore environment,
so we were very pleased to see it on the specification” said an
ANDRITZ Kft. representative; manufacturer of the turbine. Intershield® 300
has also been specified and with its 15 year proven long term corrosion
and abrasion resistance in harsh environments, it’s easy to see why.
Two of International Paint’s foul release coatings; Intersleek® 737 and
Intersleek 970 were also specified for their high levels of durability and
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in the not too distant future and you will
have an idea of the potential that is yet to be
unleashed.
“For such a large-scale project, corrosion
protection as well as a high performance
foul release was needed to protect
the tidal power plant from the severe
surrounding environment” stated Andreas
Hoyer, Sales Manager for Germany at
International Paint. Alongside Intersleek 970
and Intersleek 737, a system consisting
of International Paint’s Interzinc® 52,
Interline® 975 and Intershield® 300 was
used. This system was favoured by those
involved due to it being approved by the
German Institute of Water Steelwork, for its
excellent abrasion resistance and its proven
track record for use in similar severe, offshore
environments. Following completion of
coating application and quality approval,
the turbine is to be installed and will be in
active service over the next two years.
record of International Paint’s protective
coatings systems that impressed those at Voith
Hydro Ocean Current Technologies, they were
also impressed by the testing of its foul release
system that International Paint carried out
alongside an acclaimed German university.
The potential of pursuing wave and tidal power
as a long term source of renewable energy is
huge, with the capability of providing 16% of
the world’s energy needs.2 The industry also
promises to continue to grow and develop
new and exciting methods of harnessing tidal
energy over coming years. It’s proving to be an
exciting time for tidal power generation.
1
2
UK Government Department of Energy & Climate Change
Source: IEA-OES Annual Report, 2009
It wasn’t just the outstanding proven track
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Wuxi
The
C
overing an area of over 70,000 m² (753,474 ft²), the
Wuxi Grand Theatre stands proudly on the south
bank of the Lihu Lake in Wuxi, China within its larger
100,000 m² (1,076,391 ft²) location. To put the sheer
enormity of the Wuxi Grand Theatre into perspective,
it is the equivalent in size to 10 standard football or
soccer pitches or four Sydney Opera Houses.
The Wuxi Grand Theatre, which is often compared to the Sydney Opera House in
terms of appearance, has been designed to resemble a butterfly landing close to
the Lihu Lake, with a roof constructed using eight large wing-shape sections.
Costing over RMB 1bn to build, the striking structure was completed in May 2011.
The development consists of a performance hall with a seating capacity of 1,700
and a second multi-functional hall with a further seating capacity of 700.
Home to the region’s newest performing arts centre, the Wuxi Grand Theatre will
play host to the Chinese Opera, Ballet and Symphony Orchestra. The design of the
theatre really does compliment the function of the building, with the artistic flair carried
throughout; from its butterfly-like exterior, through to its artistic and minimalist,
yet cutting edge interior.
Grand
Theatre
To compliment such a cutting edge project, a trusted and proven
coatings partner was needed. Following extensive dialogue, a
relationship was developed between PES-Architects, the architect
involved, and International Paint. This resulted in International Paint
being appointed as sole specifier for the project by the project owner.
“We really did require a coatings partner who we knew we could trust
to deliver high quality and aesthetically pleasing results” said Pekka
Salminen of PES-Architects.
International Paint secured specification of its Interthane® 990
Metallic coating for the exterior facets of the theatre. “A striking and
differential top coat effect was required by the customer, therefore our
Interthane 990 Metallic finish became the obvious coatings choice”
said William Ge, International Paint’s High Value Infrastructure Marketing
Manager for China. “The product, Interthane 990 Metallic, was also
chosen for its long term recoatibility characteristics” continued Ge.
The level of technical support that International Paint brings to a project
is highly regarded and known throughout the industry, which is one
of the reasons why the fabricators involved in the Wuxi Grand Theatre
were so keen to work with International Paint.
In keeping with the complex and groundbreaking design of the Wuxi
Grand Theatre, it was important that all elements of the complex
contract chain were happy with the decision to appoint International
Paint as sole specifier on the project. “All points of contact within
the contract chain were more than satisfied with International Paint’s
products in respect of quality, aesthetics and technical support”
concluded Ge, who was involved in the Wuxi Grand
Theatre project, from conception
to delivery.
Whilst aesthetics played a key role in the coatings
selection process, the level of technical
expertise and support
also featured high
on Pekka
Salminen's
wish list.
All Photos courtesy of PES-Architects - Photographer Jussi Tiainen
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7
W
ith first oil production scheduled
for late 2014, the Golden Eagle
project is expected to produce, at
an initial peak rate of 70,000 boe/d
(barrels of oil equivalent per day),
around 140 million barrels of oil
over an 18 year period.1
THE
Nexen Petroleum UK Limited, holds
a 36.54% stake in the project and
forms a consortium with three
other big players in the oil and gas
field. Maersk Oil North Sea UK
Ltd holds a 31.56% stake in the
project, Suncor Energy UK Ltd, has
a 26.69% stake and Edinburgh Oil
and Gas Ltd holds a 5.21% stake.
For such a large and high profile
project located in the UK North Sea,
where protection from potential
fires is of the utmost importance, a reliable and proven fire protection
coatings partner was needed.
International Paint was the successful bidder for this role and will supply
over 350 tonnes of Chartek® 7; a high performance epoxy Intumescent
fire protection coating, with an exceptional track record in protecting
many of the world’s offshore structures. With the potential for up to 400
workers to be on board the platform at any one time, it was imperative
that a high quality fire protection system was in place.
Not only is 350 tonnes of fire protection to be supplied to the Golden
Eagle project, but there was also a further agreement for 100 tonnes of
International Paint’s Intertherm® 7050 to be supplied. Both Chartek 7
and Intertherm 7050 were specified to protect a 4,000 tonne wellhead
deck, which is due for delivery during the second quarter of 2013 and
a three tier, 10,000 tonne production, utilities and quarters deck, which
is due to be delivered one year later. Both International Paint products
will be applied by Applied Corrosion Technology in the yard of Lamprell
Energy in Jebel Ali, Dubai.
“Nexen had exacting standards relating to the
coatings required for the Golden Eagle project,
of which we were able to meet through the
specification of the most appropriate coatings
available” said Mike Raynor, Area Manager Western
Europe and Central Asia.
The Nexen Buzzard leaving for the North Sea.
Another recent project with Nexen, where
International Paint supplied protective coatings
and Chartek fire protection.
All photos courtesy of Nexen Inc
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1
“Golden Eagle” http://www.nexeninc.com/en/Operations/Conventional/UKNorthSea/GoldenEagle.aspx
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9
MELBOURNE WATER
CHOOSE
POLIBRID
Information from manufacturers and contractors was sought to
confirm that the proposed options were constructible, to allow for
additional design options and to source new and unknown materials.
Six options for floor refurbishment or replacement
were considered as follows:
• Glass fibre reinforced polymer (GRP) lining
– chopped glass (refurbishment)
• Glass fibre reinforced polymer (GRP) lining
– woven fabric (refurbishment)
• Polibrid lining (refurbishment)
• High density polyethylene (HDPE) lining (refurbishment)
The contractor worked closely with Tony Ridgers, Technical
Representative for International Paint and Joe Pavia, Water and
Wastewater Market Manager for Australia, also of International
Paint, to achieve a very successful outcome. Joe Pavia, in
collaboration with Stuart Smith from Melbourne Water and
David Walker from McElligotts, also organised an ‘Open Day’
where people from other water authorities were invited to view
the first tank and were told about the solution that was being
undertaken. This was very well received with 25 attendees who
were excited about the project and how it was being managed.
The following two examples demonstrate the benefits of this solution:
The St Albans tank is 52m in diameter and was rectified
by replacing the steel floor. The cost to replace the steel
floor was $4.7 million and took 9 months to complete.
3,500 litres of Interline 975 were applied.
• Steel plate floor (replacement)
• Pre-stressed concrete floor (replacement)
The two GRP lining proposals had previously been used as a tank floor
liner. They had similar characteristics to the Polibrid lining system, which
had not been used before. These options were generally preferred
as they met most criteria including cost, construction program,
compatibility with the existing ICCP system, safety and other risks,
and sustainability. However, Polibrid was considered superior to GRP
and was recommended because of its flexibility and tensile strength in
regards to spanning perforations in the floor, should corrosion persist.
The Sydenham tank is 74m in diameter and was
rectified using the Polibrid system. The repair cost
$1.5 million and took 6 weeks to complete.
Approximately 20,000 litres of Polibrid were applied.
This solution was good for the customer as it saved them both
time and money. It was good for the contractor as it provided
a much bigger opportunity. It was also good for the paint
supplier in terms of improved sales opportunity. It also enabled
International Paint to establish a fantastic relationship with the
owner, whilst maintaining good relations with the contractor.
S
ometimes we come across unique situations that enable us to think
outside the box. Such an opportunity arose when Melbourne Water were
looking for solutions to underfloor corrosion in their water storage tanks.
Melbourne Water operates 38 steel storage tanks around Melbourne. The average size of these tanks is 62 meters,
with sizes ranging between 23 and 95 meters diameter. These tanks have steel floor plates that are corroding from
the underside, primarily as a result of the chloride content in the crushed limestone base. In some of these tanks
the corrosion is progressing to the extent that leakage will occur in the near future, and investigations by Melbourne
Water have identified that the floors will need to be replaced in many of these tanks over the next 20 years.
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11
mauritius
AIRPORT
W
hen the decision was taken to expand the existing
Sir Seewoosagur Ramgoolam International Airport of
Mauritius, Mauritius’s only airport, the EXIM Bank of China
stepped in to provide 85% of the finance needed to secure
the expansion of the terminal building. Following completion,
the new main terminal building has a capacity of 57,000m².
The novel design of the terminal building is closely linked to the
‘Mauritius Sustainable Island’ concept, which strives to harness
renewable energy and utilise it to provide lighting within the terminal.
Although it wasn’t just the sustainability aspects of this building
that were important to the owner, Mauritius International Airport
Terminal Operations Ltd; protecting the new terminal building from
the potential effects of fire was also high on their list of priorities.
International Paint worked with the China State Construction Engineering
Corporation (CSCEC) to ensure that the structure was sufficiently
and expertly protected from the effects of fire, in compliance with
local fire protection standards, via the specification of Interchar® 963.
As well as fire protection, International Paint also supplied coatings
for the structural steel, covering an area of 50,000m². A system of
Interseal® 670HS, Intergard® 251 and Interthane® 870 was specified.
“We have worked with International Paint before,
so we knew that they were equipped with the
global supply capabilities needed to meet the
demanding logistical requirements of this project”
Ms. Haiyan Yu from Nanjing CSCEC Steel Structure Co. Ltd
“This project really did require a truly global approach to supply” said
Miki Pavlovic, International Paint’s Regional Marketing Manager Fire and
Insulation Products, “it involved people within our UK, France, China and
South African facilities to ensure that the supply of coatings from each
location met exacting national and international standards, that combined
with our ability to support the entire contract chain including architects’
and project managers’ requirements is something which we really do
pride ourselves on being able to achieve” Pavlovic went on to say.
Technical service was also of the utmost importance to those involved in
the expansion of the Sir Seewoosagur Ramgoolam International Airport
of Mauritius. International Paint’s Technical Service Representatives (TSRs)
were on hand throughout the project, but their presence was non-more
prevalent that at a steel fabricator based in Nanjing, China where a full
time International Paint TSR was based to assist with the application
of the primer, prior to the primed steel being shipped to Mauritius.
A TRULY GLOBAL PROJECT
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13
How to Correctly Specify
Epoxy Passive
Fire Protection
ISO22899-1
NORSOK M501 Rev 6
Until recently, epoxy PFP assessment for jet fires was
inconsistent, done on an ad hoc assessment basis using
various technical reports and test set-ups.
“Given that for most of its life epoxy PFP acts as an
anticorrosive system, it is important that it has excellent
durability and corrosion protection properties” stated
John Dunk, Worldwide Director for Fire and Insulation Coatings
at International Paint.
With the introduction of the first and only internationally
recognized jet fire standard ISO22899-1 and the soon to be
published ISO TR22899-2, the oil and gas industry now has
a formal procedure to accurately assess and reliably rate
epoxy PFP jet fire performance.
ISO22899-1 is also the only jet fire standard for which many
classification societies (currently giving type approvals for
passive fire protection) will give type approval certificates (TACs).
The type approval brings greater quality control using audit
testing and factory production control assessments which
were not required in previous technical reports.
The ISO22899-1 standard gives guidance on how to assess epoxy
PFP jet fire resistance at different temperatures and assessment of
the data may show lower critical core temperatures require more
protection for the same jet fire duration.
The type approval should state the critical core temperature for
which the TAC is valid so that it is clear under what conditions the
thicknesses have been determined. This is the only way to ensure
that specifications are correct for the required jet fire duration.
O
ver the years, from real life experience of passive
fire protection (PFP) on offshore and onshore
installations, it has been clearly demonstrated that
there can be significant differences in performance and
life expectancy of various epoxy materials. In worst
cases, degradation of materials has required costly and
time consuming rectification of failing products.
“Owners and engineers should take care when
specifying epoxy PFP for use in the oil and gas industry
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to ensure that products used have clear qualification
to all elements of the most demanding standards
applicable” said Dr Ian Fletcher, Senior Market Manager
for International Paint.
There are two key standards that epoxy PFP should
fully comply with: NORSOK M501 Rev 6 System 5A
and ISO22899-1.
Critically, it is also important that the epoxy PFP systems maintain
their fire performance after weathering. The industry accepts
that if after weathering the steel temperature is higher than the
original design critical core temperature (typically 400ºC) by a
value of 10% or less when exposed to a hydrocarbon fire then an
acceptable insulation is maintained for structural stability.
International Paint’s epoxy PFP Chartek® 7 is fully compliant with
both the NORSOK M501 Rev 6 System 5A and with type approval
certification based upon ISO22899 standards.
The most accepted accelerated corrosion test standard in the
oil and gas industry is ISO20340 “Performance requirements
for protective paint systems for offshore and related structures”
because it most closely reflects the cyclic wet/dry weather
environments faced by coatings in the oil and gas onshore and
offshore markets. Furthermore, the ISO20340 test method
also shows similar coating breakdown mechanisms to those
observed in the field for Chartek.
The ISO20340 standard is used by NORSOK M501 Rev 6
System 5A to pre-qualify passive fire protection systems.
The standard assesses epoxy PFP systems after exposure
to 25 weeks of QUV/condensation, continuous salt spray
and -20ºC freeze cycles.
The System 5A pre-qualification requirements recognize that in
the real world top coats may not always be present on epoxy
PFP and so cannot be relied on to ensure that the epoxy PFP
coating system remains mechanically robust and able to provide
both optimum corrosion protection and fire performance.
For this reason the standard expects the epoxy PFP coating
system to pass System 5A without a topcoat. This means that
the epoxy PFP coating system must demonstrate mechanical
integrity by having a pull off value greater than 3MPa and a
corrosion creep value less than 3mm when using a zinc primer.
Epoxy PFP materials with a high retained pull off value tend to
correlate well with products having a low water absorption and
high hardness retention whereas the reverse is the case if water
absorption is high.
Chartek 7 is extensively certified and has been used to protect
many onshore and offshore oil and gas facilities around the world
against both hydrocarbon pool and jet fires for the past 40 years.
In summary therefore it is only by ensuring that products meet all
elements of these test standards, particularly fire performance
after NORSOK cycle exposure, that selection of proven and
durable fire protection can be made.
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15
Chartek 7 Fireproofing
With an impressive 15 year track record, Chartek® 7
continues to protect oil and gas installations
in severe environments all over the world.
Combining long term fire protection and anti-corrosive
performance, Chartek 7 is the world’s most certified
epoxy intumescent passive fire protection coating
for the oil and gas industry.
• Corrosion and fire performance not reliant
on top-coat maintenance
• Fully meets the pre-qualification requirements
for NORSOK M501 Edition 6 System 5A
without a top-coat
• Compliant to ISO22899 - the only internationally
recognised jet fire test standard
• Type approval certified by Lloyds, BV, DNV and
ABS for jet fire durations up to three hours
Tried and tested fire protection? Better choose Chartek 7
www.chartek.com
,
|
[email protected]
and all product names mentioned are trademarks of AkzoNobel. © AKZONOBEL 2012.