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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
Contents The Rise of Tidal Power
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Wuxi Grand Theatre
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Protecting the Golden Eagle Melbourne Water Choose Polibrid
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Mauritius Airport
12 14
How to Correctly Specify Epoxy Passive Fire Protection
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 Managing Editor: Stuart Byers Publisher: International Paint Cover Photo: Jussi Tiainen for PES-Architects
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Welcome to the new issue of Surfaces magazine, which requires a special introduction.
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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 pc.communication@akzonobel.com
ise R the
of Tidal
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
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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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. 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.
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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
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 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
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.
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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.
All Photos courtesy of PES-Architects - Photographer Jussi Tiainen
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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.
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Protecting Golden Eagle THE
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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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
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
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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.
“Golden Eagle” http://www.nexeninc.com/en/Operations/Conventional/UKNorthSea/GoldenEagle.aspx
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Melbourne Water Choose
Polibrid 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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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.
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mauritius Airport A TRULY GLOBAL PROJECT
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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.
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How to Correctly Specify
Epoxy Passive Fire Protection
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.
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.
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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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 ,
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