resimac ltd · for fbe tested and applied ... • pipe coating mill looking to use ha100/ ha80 as...

Resimac Ltd Engineered Polymer Solutions

Resimac overview

WHAT WE DO………. REPAIR Metallic surfaces subject to abrasion, wear and corrosion

PROTECT Metallic components, equipment and structures subject to erosion, corrosion and chemical attack

UPGRADE The performance of metallic components and equipment

FULL RANGE OF PRODUCTS COVER……… - Metal Repair - Ceramic enhanced coatings for abrasion and wear environment - High temperature protective coatings - Thermal Insulation coatings - Chemical protective coatings - Anti corrosion coatings - Waterproofing and roof coatings

Resimac customers worldwide

Resichem 530 HA100 – Fluid epoxy

Stand alone corrosion coating

Being tested as a replacement for FBE

Tested and applied as part of a flame sprayed system Being tested as part of a 3 Layer system

Pipe coating systems on the market


Product characteristics…. • Single pack heat activated epoxy novalac • Activated at temperatures in excess of 100°C • Applied by spray to hot surfaces - Pipework, process vessels, reactors etc • Dry temperature resistance of 240°C Chemical composition of the product…. • Low functionality epoxy novalac, 2.15 • Polyamine curatives blended with the novalac • Hazard Class 8 Application details • Apply to mechanically abraded, hydroblasted or abrasive blast surfaces • 2 x 250microns (10mil) is the system recommendation • Applied by airless spray, product heated to 70°C • Typical equipment GRACO EXTREME, 3000psi pressure +


Test Data…. (In house) Corrosion Resistance Tested to ASTM B117 Minimum 1000 hours salt spray resistance.

Hardness Shore D to ASTM D2240 20°C 90 100°C 86 150°C 80 200°C 72

Cure Times Cure times are dependent on the cure temperature as indicated in the table below. Temp Touch dry Light loading 100°C 50 mins 2 hours 110°C 35 mins 70 mins 120°C 25 mins 50 mins 130°C 15 mins 30 mins 140°C 7 mins 15 mins 150°C 3 mins 7 mins

Adhesion Tensile Shear to ASTM D1002 on abrasive blasted mild steel with 75 micron profile and cured at 120°C. 197 kg/cm² (2800 psi)

Mechanical Properties Adhesion Tensile Shear to ASTM D1002 on abrasive blasted mild steel with 75 micron profile and cured at 120°C. 197 kg/cm² (2800 psi)


Test Data…. (Doosan Babcock/ Chevron • Chevron Texaco looking at HA100 for subsea pipeline, high temp riser protection • Product applied on site at DOOSAN BABCOCK in prep for bend tests • 2 x 350 microns applied, cured at 150°C

PREPARED SURFACE SA2.5 HEATED TO 100°C APPLIED 1st COAT 300MIC

APPLIED 2nd COAT 300MIC HEATED TO 100°C JACKED TO GET 150°C


Test Data…. (Doosan Babcock) • Product tested on test rig, PASSED bend test set at 20%


Test Data…. (Doosan Babcock) • Follow on testing approved by Chevron • Samples at ELEMENT – product passed all tests • Cathodic disbondment testing 28 days - 20°C, ISO 21809 • Peel test ISO 21809, Water Immersion Test


Test Data…. Plascoat Systems – Corrib Pipeline - Shell • On site trial performed by COATSOL • System used is HA100 with flame sprayed PP from PLASCOAT • HA100 used as the primer layer • PP Flock sprayed onto wet film • Heated to 150°C to cure HA100 and to fuse the PP • Cathodic Disbondment test performed at PLASCOAT Labs

Test Results Test Sample Required Performance Test Result Sample 1 ≤7 mm <1 mm Sample 2 ≤7 mm <1 mm Sample 3 ≤7 mm <1 mm Conclusion When tested in accordance with ISO21809 Part 1, Resimac HA100 has been found to have an average radius of Cathodic Disbondment of <1mm. This result exceeds the requirements for the standard.


Test Data…. Plascoat Systems – Corrib Pipeline - Shell • Photos of CD testing for Corrib Pipeline


Test Data…. Plascoat Systems – Corrib Pipeline - Shell Cathodic Disbondment 28 days @ 90°C CAN/CSA-Z245.20 <5mm radial Adhesion after hot water soak 28 days @ 80°C CAN/CSA-Z245.20 Class 1 Peel Strength @ 23°C (over Novalac) ISO 2180-39: Annex D >12 N/mm Peel Strength @ 90°C (over Novalac) ISO 21809-3: Annex D >5 N/mm Hardness @ 25°C ASTM D-2240 Shore D >60 Flexibility @ 0°C CAN/CSA-Z245.20 No cracks @ 3°C PDD Impact resistance @ 23°C DIN 30670 >20 Joules Tensile Elongation (at break) of topcoat @ 25°C (after flame spraying) ASTM D-638 10% Taber Abrasion topcoat ASTM D-4060/84, H18 500Gm load 1000 cycles

55 mg weight loss


Field Qualification…. Plascoat Systems – Coatsol – South America • On site trial performed by COATSOL • System used is HA100 with flame sprayed PP from PLASCOAT • HA100 used as the primer layer • PP Flock sprayed onto wet film • Heated to 150°C to cure HA100 and to fuse the PP • Cathodic Disbondment test being performed at PLASCOAT Labs


Test Data…. BSR Ramco – External Pipecoating • Pipe coating mill looking to use HA100/ HA80 as external pipe coating • Use as part of a 3 layer system PP • Use as a primer for insulation Seawater Immersion Test in accordance with ISO 20340 using the method described in ISO 2812‐ 2 (to include full test report). Two versions of the product to be tested. Details to be discussed: • HA70 • HA100 Please note that if a document/test is not referenced in this offer then it is not applicable to Tata Steel’s scope of work and will not be a contractual requirement of any Order placed.


Advantages over existing coating systems • Single pack heat activated epoxy novalac • High temperature resistance up to 240°C • Compatible with a range of existing 2/3 layer systems • Excellent CD resistance • Simple to apply for pipe mills of in field coating • High build coating, 200-300 microns per coat • Fast curing at elevated temperatures • Based on existing epoxy coating technology • Cured coating has good flexibility on blast cleaned surfaces • Will fuse with 3 layer systems for increased inter layer adhesion

HSE GUIDANCE – FACTS AND FIGURES

BURNS AND SCALDS • At 44°C it takes up to 6 hours to get a 1st degree burn • At 60°C it takes less than 6 seconds • At 100°C it takes less than a second

HSE GUIDELINES • METAL Surfaces above 60°C must be protected • Approximately 1.5% of all reported incidents concerned thermal burns • Median days off was 4 • By law employers are required to protect employees and ensure there safety

AREA ALSO COVERED BY ASTM C1055 -92

ADVANTAGES AND DISADVANTAGES OF EXISTING SYSTEMS

MINERAL WOOL INSULATION

ALTERNATIVE SYSTEMS AVAILABLE ON THE MARKET WATER BASED THIN FILM COATINGS • Acrylic technology • Water Based • Thin film coverage 100-200 microns per coat • Based on glass bead technology • Proven track record in industry • 55 shore hardness • Multi coat systems – approx 8-10 coats to achieve protection • Restricted by weather conditions on outside applications 10°C - 30°C

EPOXY HIGH BUILD COATINGS • Based on proven epoxy technology • Solvent free 100% solids • High build system 0.5mm – 1mm per coat • Based on innovative filler technology • New to industry – 18 months track record • Suitable up to 160°C • Good corrosion resistance • Can be applied to damp, cold surfaces (condensation) • Can be applied to hot surfaces up to 120°C

Resimac High Temperature Coatings – 561 Thermal Barrier

561 THERMAL BARRIER – application features • Applied by Standard airless spray • Applied in 5 coats up to 1mm per coat • Can be applied to surfaces up to 110C • Manual surface prep, hydroblast, abrasive blast clean • Slump resistant upto 3mm in a single coat

561 THERMAL BARRIER – product features • Two pack epoxy system • Standard Bis A/F resin • Lightweight • Solvent free • 100% solids • Reduces surface temperature of metallic surfaces • Reduces heat loss by up to 40%

THERMAL CONDUCTIVITY OF MATERIALS – k value • Carbon Steel 43 W/mK • Mineral wool 0.04 W/mK • Water based 0.15 W/mK • Epoxy based 0.10 W/mK

HOW DO INSULATION COATINGS WORK?

Definitions….. K-value thickness matters because the thicker something is, the slower heat will pass through it. The thermal conductivity is a measure of how easily heat passes through the material and is called the k-value . k-value is measured in W/mK. Thermal conductivity is an inherent property of a material, like stiffness or density

U-value is measured in W/m2K – that is, Watts per square metre per degree Kelvin (1 degree Kelvin is the same as 1 degree Centigrade, but with a different zero). So if a wall has a U-value of 1.0, then 1 m2 of wall will let 1 Watt pass through it when there is a temperature

difference of 1 degree between the inside and outside.

HEAT LOSS OF MATERIALS – u value • Carbon Steel 8600 W/m²K • Mineral wool 8.0 W/m²K • Water based 30.0 W/m²K • Epoxy based 20.0 W/m²K

BASED ON 50MM OF ROCKWOOL, 5MM THICKNESS OF CARBON STEEL, WATER BASED AND EPOXY BASED COATINGS.

WHAT THIS EQUATES TO IN SURFACE TEMPERATURE REDUCTION USING STANDARD DEFINITIONS AND TESTING EQUIPMENT

• Based on the graph, if you apply 5mm of epoxy high build the temperature will be reduced from 118°C to 60°C

* Blue line on the graph


561 THERMAL BARRIER – testing • Independently tested by Gearing Scientific • Conforms to ISO 8301 • Proven to reduce surface temperature • Proven to have insulating qualities • Reduces heat loss by 40% compared to bare steel pipe

Test

No

:

Pla

te N

o:

Mat

eri

al

thic

kne

ss

(mm

)

Lower

temperature

set (C°)

Actual

Temperature

Recorded (C°)

Lambda Value

@ C° Mean

Steel

Plate

Temperature

(C°)

8 6 3.93 35.0 38.3 0.10 @ 69 100

8 6 3.93 40.0 40.4 0.10 @ 80.2 120

10 5 4.03 40.0 40.5 0.10 @ 80.2 120

8r 6 3.93 45.0 45.8 0.10 @ 93 140

8r 6 3.93 50.0 51.6 0.11 @ 106 160

8r 6 3.93 55.0 57.5 0.11 @ 117 180

95°C Evaporator • All surfaces mechanically abraded •Filler allowed to cure for 15 minutes • Thin film of 561 thermal barrier applied to all surfaces • Approx DFT ranging from 150 -250 microns • Coating allowed to cure off for 2 hours


95°C Evaporator • 2nd coat of material applied at 500 microns on to all surfaces • Surface of the evaporator can be touched with out fear of burns


Surface after 1st coat at 150-250 microns

Surface after 2nd coat at 500 microns

95°C Evaporator • 3rd coat of material applied at 750 microns on to all surfaces • Surface heat so reduced thicker WFT of material can be applied 1st coat 150-250 microns 2nd coat 500 microns 3rd coat 750 microns 4th coat 750 microns


Surface after 3rd coat at 750 microns Surface after 4th coat at 750 microns

Photo highlighting the WFT on 3rd and 4th coats

Final finish on the surface of the evaporator

95°C Evaporator DOES IT WORK???????????? JOB COMPLETED – CUSTOMER HAPPY NEW ORDER FOR 7 X EVAPORATORS ON SITE WORK COMMENCES MAY 2014


Pipework at 160°C • Surface manually prepared using coarse sandpaper • Material brush applied in 5 coats • Surface touch temperature reduced to 59°C

HIGH BUILD EPOXY APPLICATIONS

US Chemical plant • Pipe T’s in areas where operators work coated in thermal barrier • Surfaces abrasive blast cleaned and coated in workshop in a controlled environment • Touch up finished in situ at 90°C • Coating used as standard on site

HIGH BUILD EPOXY APPLICATIONS

UK based manufacture

Research and Development

Export to 32 countries

worldwide

High level of technical expertise

On site technical

support and back up

resimac ltd · for fbe tested and applied ... • pipe coating mill looking to use ha100/ ha80 as...

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