Protecting the splash zone areas of offshore facilities

By Simon Daly, Oil and Gas Segment Manager Hempel A/S

Abstract

In the past, glass flake filled epoxy resins, with a solids content of 75-90 per cent had been widely used within
the oil and gas industry for the protection of the vulnerable splash zone areas (the area which is repeatedly
immersed then exposed to the atmosphere) which often suffer from extensive corrosion. With the focus for
offshore development now increasingly shared between oil and gas and wind power with its very different
construction needs, we look at how ultra-high solids glass flake filled epoxy resins offer benefits for fixed and
floating construction projects offshore.
 Introduction

Offshore oil and gas facilities are exposed to some of the

harshest operational and environmental conditions and
are permanently subjected to the corrosive elements of
oxygen and water. Due to their location, there are high
costs and difficulties associated with maintaining and
re-coating these structures. This is particularly so in the
jacket areas where coating maintenance can be a very
hazardous activity. That’s why the right choice of anti-
corrosive coating at the new construction stage can
make all the difference.

Coating longevity, increasingly aggressive production

schedules, cost reductions and minimising
environmental footprint are just a few of the challenges
faced by asset owners and their subcontractors and this
has led to an increasing interest in coating systems with
a long lifetime, that reduce long-term operating costs and
extend maintenance intervals.

In splash zones two forces combine and corrosion can

be severe as this area suffers from the dual impact of
atmospheric and immersion conditions; as well as
physical damage such as abrasion and impact. It is at the splash zone where a robust, long lasting protective
coating is most required. Additionally, it is in this area where the effects of poor coating performance can be
particularly challenging to rectify.

Ultra-high solids glass flake epoxies for maximum protection

Providing long-term corrosion resistance for splash zone areas can be demanding. As well as the combined
corrosive effects of water and oxygen, often mechanical damage and abrasive forces must also be considered
- not only when the structure is in service but also during its transit and installation. The past few years has seen
an increasing move towards the use of ultra-high solids glass flake epoxies for use on different types of offshore
structures. This can deliver prolonged service life and reduced maintenance.

Hempadur Multistrength 35840 and 35842 are 98 per cent solids epoxy glass flake coatings specifically
designed for splash zone protection. Unlike conventional coatings, these two products are almost solvent-free
and contain reactive diluents that contribute to cross-linking (a chemical reaction which assists with hardening
the coating), and it is this that significantly enhances the resistance to corrosion.

In addition, the coatings are reinforced with overlapping glass flakes to further enhance their water resistance
and strengthen them against physical impact. Their high solids ratio (98 per cent) and low VOC (volatile organic
compound) content make them significantly kinder to the environment; it also helps protect those who have to
apply the product.

The presence of diluents which are reactive compared to conventional unreactive solvent / thinners also reduce
the risk of solvent entrapment which may ultimately impact the performance of the final coating.
Flexible areas of use
Hempadur Multistrength 35840 is suitable for application to splash zone and submerged areas of new
construction offshore facilities. It is NORSOK M501 (Edition 6) System 7A/B pre-qualified and can be applied
across a wide dry film thickness (DFT) range. For higher DFT applications up to 1000 microns it can be
substituted with Hempadur Multistrength 35842. Both products are designed for application without additional
solvent being required.

The science behind it

There have been many products that have been developed to protect the splash zone, but this coating follows
a different technological approach to deliver enhanced protection with a minimal environmental impact.
Hempadur Multistrength 35840 and 35842 replace most of the conventional solvent found in similar products
with reactive diluents. These low viscosity molecules allow the application characteristics of the product to be
maintained. And as these materials fully react with the polymer backbone of the coating, there is a much-
reduced possibility of solvent being retained within the finished coating film.

Increasingly as higher DFT’s are being used, often in short construction cycles with little time allowed between
coats, it makes sense to use a product with less risk of solvent being retained within the coating film if it is
over-coated too early to meet fabrication schedules. This problem is further exacerbated in colder weather when
additional solvents may be required in order to continue applying the paint satisfactorily in these conditions.

Physical property development (i.e. hardening) occurs much quicker when compared with lower solids epoxy
systems. This allows for quicker handling of coated items. As importantly, the higher volume solids contained
within the product means that less paint is needed to coat the same surface area, and this delivers benefits
in application time, wastage, paint transport and storage costs.

Key advantages of Hempadur Multistrength 35840/35842

• Improved performance due to low water permeability
• Can be specified across a wide range of thicknesses
• Impact and hardness develop quickly during curing allowing quicker handling
• Reduced physical damage, better abrasion and impact resistance
• Low environmental impact: high volume solids and low VOC for reduced emissions
• Low solvent content: excellent application, reduced risk of solvent entrapment and improved performance
• Pre-qualified to NORSOK M-501 (edition 6) standard for System 7A and 7B
• Certified to ISO 12944-9:2018 for CX, IM4 and CX/IM4 categories

Conclusion

Providing long term corrosion resistance for splash zone areas can be demanding. The challenging offshore
conditions are encouraging oil and gas offshore facility operators to search for more effective solutions from
their coating providers. Hempadur Multistrength 35840/35842 are unique low solvent and high solids coatings
offering offshore facilities tough and consistent corrosion resistance.

As always Hempel is committed to assisting its global customer base to prolong their assets by maximising
the effectiveness and durability of every protective coating. This is why Hempel has placed its expert technical
services team at the heart of the coating process. Hempel services deliver an increase in an owner’s overall
return on investment as well as ensuring maximum performance. Coatings advisors are now supporting and
managing the coating selection, application and maintenance in the most cost-efficient way. Through this
unique service costs are reduced, maintenance intervals are extended, and maximum uptime is delivered to
every asset.