PaintSquare.com
Follow us on Twitter Follow us on LinkedIn Like us on Facebook Follow us on Instagram Visit the TPC Store
Search the site

 

Problem Solving Forum

| More

November 14 - November 20, 2011

When is it cost-effective to use thermal spray in petrochemical facilities?

More items for Coating Materials


Selected Answers

From James Weber of Sulzer Chemtech Tower Field Service on November 17, 2011:
Typically, thermal spray coatings are cost-effective in the petrochemical industry when you consider the cost of inspection, especially under insulation.


Even the best, most expensive paints must be inspected in 3-7 year cycles when used in CUI (Corrosion Under Insulation) conditions. Inspections most often mean scaffolding, removing all cladding and insulation, intensive inspection, including a lot if UT testing of pits, blasting, painting, re-insulating, re-cladding, removing scaffolding, etc. If thermal spray aluminum (TSA) is used instead of paint, these inspection cycles are pushed out to 25 years (ExxonMobil) to 40 years (Shell).

In this case, blasting and recoating is not required, just inspection, as it is known that a properly installed anodic TSA coating system will not corrode or “sacrifice” itself unless it is installed in such a way that the TSA has to provide anodic protection for a large cathode (unfavorable anode to cathode ratio) when an electrolyte (water or wet insulation) connects the TSA to a non-TSA coated area. We don’t do this in the petrochemical field, as we coat an entire vessel, column, or pipe (flange to flange) instead of just a tiny area and expect it to protect the entire structure.

Regarding the cost of thermal spray in a refinery, one must consider the entire erected costs (scaffolding, cladding, insulation, grit blasting and disposal, etc.) of a coating job and not just “the coating.”

Around 6 years ago, ExxonMobil reported that when the entire erected costs are considered, TSA coatings cost them 0.5%-1.5% more than liquid coatings; however, some of the paints used in CUI service have doubled and tripled in price since then. Many times, thermal spray can be applied at lower costs than wet paint when you consider factors like weather conditions, no VOC regulations, ease of or less need for touch-up, robust coatings that can be applied offsite and then installed, etc. As a pipeline applicator who did both wet paint and thermal spray coating, we charged less for thermal spray than a three-coat paint system.

Please sign in to submit your answer this question    

Tagged categories: Petrochemical Plants; Thermal spray


Current PSF Question | Submit a PSF Question | Full PSF Archive

Advertisements
 
Sherwin-Williams
 
Sherwin-Williams Oil & Gas App
 
Our coatings and linings expertise available 24/7, allowing you to explore the best Sherwin-Williams solutions for oil refineries, shale drilling sites, and offshore. Android users
click here. Download today!
 

 
Mitsubishi Gas Chemical America
 
Performance Amine 1,3-BAC
 
A highly reactive cycloaliphatic diamine offering superior performance. Reasonable cost and curing efficacy makes it suitable for all types of epoxy resin applications.
 

 
Carboline Company
 
Fireproofing Solutions
 
Pyroclad® X1 Thermo-Lag® Pyrocrete® – protecting against hydrocarbon and jet fires, explosions, and cryogenic spills.
 

 
Detail Masters
 
Overspray Removal
 
We offer professional, turnkey service and unparalleled quality!
Our process can save hundreds— even thousands of dollars. It's fast, environmentally safe and 100% guaranteed.
 

 
BASF
 
New resins from BASF will have metals loving water!
 
Excellent corrosion resistance, low VOC, high gloss, thin films www.basf.us/industrialcoatings dpsolutions@basf.com 800-231-7868
 

 
PPG Protective and Marine Coatings Group
 
We Protect and Beautify the World
 
PPG is widely recognized as a world leader in protective and marine coatings, developing innovative, cutting-edge products and services.
 

 
Jotun Paints Inc.
 
Jotachar JF750 - The Time Saving Solution
 
The only mesh free solution for jet fire scenarios. Jotachar saves installation time and material costs - the next generation of epoxy passive fire protection.
 

 
HoldTight Solutions Inc.
 
NO FLASH RUST - NO CONTAMINANTS
 
Our HoldTight®102 salt remover & flash rust
preventer prevents flash
rust by removing surface contaminants. Contact us
for your nearest distributor.
(800) 319.8802 sales@holdtight.com
 

 
Monti Tools, Inc.
 
BRISTLE BLASTER® – THE ORIGINAL ONE
 
  • Abrasive blast with a power tool
  • Remove corrosion, mill scale and coatings
  • Cleans & roughens
  • Meets SSPC-SP 10 / NACE No. 2
  • Profile up to 4.7 mils
  • ATEX Zone 1
  •  

     
    Sidewinder/Persyst Enterprises, Inc.
     
    The Sidewinder Model M2 Solvent Recycler
     
    Combat the rising cost of gunwash, thinners, acetone & more while drastically reducing waste disposal coat.
     

     
     
     

    Technology Publishing Co., 2100 Wharton Street, Suite 310, Pittsburgh PA 15203-1951

    TEL 1-412-431-8300  • FAX  1-412-431-5428  •  EMAIL webmaster@paintsquare.com


    The Technology Publishing Network

    Durability + Design PaintSquare the Journal of Protective Coatings & Linings Paint BidTracker

     
    EXPLORE:      JPCL   |   PaintSquare News   |   Interact   |   Buying Guides   |   Webinars   |   Resources   |   Classifieds
    REGISTER AND SUBSCRIBE:      Free PaintSquare Registration   |   Subscribe to JPCL   |   Subscribe to PaintSquare News
    MORE:      About PaintSquare.com   |   Privacy policy   |   Terms & conditions   |   Site Map   |   Search   |   Contact Us