JPCL Chempetro Ebook2 PDF

Selecting and Sourcing
Coatings for Chemical and

Petrochemical Plants
A JPCL eBook
Selecting and Sourcing

Coatings for Chemical and
A JPCL eBook
Copyright 2011 by
Technology Publishing Company
2100 Wharton Street, Suite 310
Pittsburgh, PA 15203
All Rights Reserved
This eBook may not be copied or redistributed

without the written permission of the publisher.
Contents
ii
Contents
iii
Introduction
1
10
From New Construction Through Plant Operation:

An Overview of Protecting Chemical Plants
by Luke Clark
10
Coating Systems Guide for Chemical and

26
Coatings Company Profiles
SPONSORED BY
Storage tank in optimum condition to be restored.

All photos courtesy of Carboline Company.
Storage tank after minor surface preparation and overcoating.
Introduction
iii
Introduction
This eBook consists of a recent JPCL article on selecting and using
coatings for protecting chemical and petrochemical plants, followed by
JPCL Buying Guide material on coating systems for chemical and
petrochemical plant environments.
The Buying Guide is organized, rst, by exposure type, such as
Exterior Plant Exposure - Moderate to Severe Chemical, Weathering,
& UV, then by substrate type, rst steel, then concrete. Then, coating
manufacturers are listed in alphabetical order and their preferred
system is named in both proprietary and generic terms. Finally, contact
details are given for all the companies.
This collection is designed to provide general guidance on selecting
and specifying coatings for chemical and petrochemical plants, and
then to give sources for acquiring the appropriate systems.
Protecting
Chemical
Plants
By Luke Clark,
Carboline Company
Editors note: This article appeared
in JPCL in August 2007.
From New Construction through

Plant Operation: An Overview of
Protecting Chemical Plants
hemical fumes and humidity create aggressive exposure conditions for metal structures, concrete structures, and pipelines in chemical plants, adversely affecting operating/maintenance costs, appearance, and safety. In most chemical plants, the
challenges are to understand the potential types of corrosion caused by processing
conditions and environmental conditions and to then select suitably resistant coating
systems. This article illustrates the main types of corrosion found in the exterior surfaces of chemical plants, and it discusses coating selection for carbon steel from the perspectives of
new construction as well as maintenance.
Types of Corrosion in Chemical Processing Plants

In the chemical processing industry, corrosion takes many forms. The most common is uniform
corrosion, which normally affects the appearance of a structure first, and eventually weakens its
metal surface as the structure loses thickness and later fails. This type of failure usually occurs on
unprotected structures.
Galvanic corrosion is often ultimately a result of the design of a chemical plant. It occurs where
two dissimilar metals are in contact and share a common environment. For example, if a process
system is made of stainless steel components, and the process requires a secondary phase that is
made of painted carbon steel, two dissimilar metals will be in contact. The metals create two of
three conditions needed for corrosion: the cathode (the stainless steel) and the anode (the carbon
steel). When an electrolyte, such as moisture is added, corrosion occurs, with the carbon steel corroding first. If the surfaces are coated, premature coating failure will also occur (Fig. 1). As will be
shown in the discussion of zinc-rich primers, galvanic corrosion can also help protect steel.
Crevice corrosion is also related to design (Fig. 2). Crevices are inaccessible areas that are difficult to protect. When chlorides, chemical salts, and other airborne contaminants collect in crevices
and combine with moisture, they create mild acids. These acidic solutions create a very reactive
electrolyte that will increase the efficiency of the corrosion cell and concentrate corrosion at the
crevice. Normally, crevices are located in critical areas where coatings are already vulnerable to
premature failure. Sealing the crevice opening with caulks or welding can help avoid crevice corrosion.
Pitting is one of the most destructive and insidious forms of corrosion (Fig. 3). Pinholes and holidays are isolated voids in a coating system. These voids enable the concentration of corrosion, and
the result is Pit Corrosion. Pitting causes steel loss and holes in metal. Structural failures caused
by pitting often occur suddenly and unexpectedly. In a chemical plant, pitting will cause equipment failure, environmental disasters, and safety hazards.
Chemical processing plants also create their own corrosion conditions. Erosion occurs with solid
chemicals in aqueous solutions. The production process will erode protective coatings from a surface,
resulting in deterioration of the metal surface. Coating selection and maintenance are important to
prevent this kind of failure. Although this failure is generally associated with internal surfaces, such
coating failures are also found in exterior exposures as well.
2
Also common is stress corrosion cracking (SCC), caused by the simultaneous presence of tensile
stress and a specific corrosive medium (Fig. 4). The caustic embrittlement of steel is an example of
SCC. Normally, differences in operating temperatures create the stress, and the chemical environment provides the corrosive medium.
Fig 1: Galvanic corrosion of stainless steel piping

and carbon steel storage tank
Fig. 2 (Below): Crevice corrosion on exterior wall
of a storage tank. The exterior wall is skip welded.
The environment includes H2S and constant
moisture from steam.
New Construction
The painting of a structure during new construction should be given the same consideration as a
vital component of the chemical process. The structure that supports the process equipment must
be protected from the service environment. The operating conditions and chemical environment
will determine the severity of the service environment. Once the service environment has been defined and the corrosion issues identified, the coating selection process may begin.
New construction painting (in the fabricating or paint shop) has its benefits. Importantly, in these
settings, the substrate has not been exposed to the service environment, eliminating the need to remove contaminants and corrosion products created in a chemical processing plant. In addition, the
steel can be prepared and coated under controlled and appropriate ambient conditions, rather
than being subject to the elements when coating exterior surfaces. The methods of surface preparation and application of the coating system also may be effectively monitored, measured, and controlled in a shop. And any surfaces that would become inaccessible after erection are available for
cleaning and coating, and thus can be properly coated in the pre-fabrication stage. Ideally, all coats
should be applied in a shop, with damage from construction repaired in the field. However, for economic reasons on many projects, the normal process is to clean and prime the surfaces in the shop,
and, after construction and erection in the field, to make repairs and apply the rest of the coating
systems.
Coating Systems for New Construction
When selecting coating systems for carbon steel in chemical plant exteriors, it is important to keep in
mind the functions of each coating in a system. Here is a quick review of coating functions.
Primers
The most common new construction primers for carbon steel are zinc-rich coatings. These primers
offer sacrificial or galvanic protection to the surface and have excellent adhesion properties. That
is, when a zinc-rich coating is in contact with steel, the zinc will protect the steel from corrosive elements by corroding before (or preferentially to) the steel. Sacrificial protection is caused by the
electrochemical reaction of the galvanic couple of steel cathode and the zinc anode. These coatings will also allow the fabricator/applicator to incorporate some flexibility into the work schedule, because most zinc-rich coatings have an indefinite recoat period. They can be top coated long
after the initial application.
Zinc-rich coatings are classified as either organic or inorganic. An organic zinc-rich coating includes zinc dust in an epoxy or a urethane coating. Organic zinc coatings, which are chemically
cured, provide barrier protection and sacrificial or galvanic protection.
Inorganic zinc-rich coatings are applied by mixing the zinc dust with a silicate vehicle. Inorganic
zincs, which are moisture cured (ethyl silicates), are known for their superior sacrificial protection
properties.
Epoxies and alkyds are also commonly used primers in new construction. These primers can
provide excellent adhesion and barrier protection to a steel substrate.
Intermediate Coats
Intermediate coatsnormally epoxiesimprove the protective properties of the coating system,
mainly by adding thickness, barrier protection, and enhanced chemical resistance. Appropriate
coating thickness in most cases will improve service life and reduce maintenance painting costs.
Many types of coatings are used to expand the chemical resistance and abrasion resistance of the
Fig. 3: Pitting of steel cooling water pipe
3
coating system. Epoxies with lamellar type pigments are often used to increase moisture resistance and dielectric strength. Intermediate coats also provide cohesion, or a bond, between the
primer and the finish coat. The role of intermediate coats is elaborated in the sidebar, How effective is the epoxy barrier in extending overall system life?
Despite the benefits of the intermediate coat, it has been replaced recently in some systems with
a high-solids, thick finish coat. The main reasons for switching to two-coat systems have been cost
and time.
Fig. 4: Corrosion failure of stack due to stress

corrosion cracking
COATING SELECTION/
SErvICE CONdITION:
Durability
Hardness
Flexibilty
Plyability
Scratch Resistance
Gouge Resistance
Weathering
UV Resistance
Moisture Resistance
Temperature Resistance
Chemical Resistance
Acid Resistance
Alkali Resistance
Solvent Resistance
Recoatability
Primary coating use
Topcoats
The function of a topcoat in a coating system is resistance to the service environment. The basic
environment generally includes air, moisture, sunlight UV rays, and wind, which carries airborne
contaminants. These factors will contribute to weathering, a natural mode of failure for a coating
system. Weathering will usually begin with the degradation (chalking) of the binder due to exposure to UV sunlight (Fig. 5). Chalking erodes coating thickness. The coating system then becomes
porous and loses its barrier protective properties, allowing the migration of moisture through the
intermediate coat to the primer. Primers are generally porous coatings, not barriers to moisture, so
they begin to swell and crack when moisture penetrates them. The moisture then reaches the steel
substrate, causing corrosion of the steel and underfilm corrosion.
The selection of the proper finish coat will control the migration of the moisture through the
coating system and perform as an effective barrier for protection.
The box to the left
lists parameters for selecting finish coats for
exterior surfaces in a
chemical processing
plant. Table 1 (pg. 7) lists
service environments,
generic types of coatings, and coating performance ratings. In the
table, the weather rating
is considered the evaluation for color and gloss
retention.
Fig. 5: Epoxy coating system chalking
Surface Preparation
and Application
The quality of the coating system application
depends on the environment, workmanship, and
inspection (QC/QA)
controls. As much of the
coating work as possible
should be completed in
the shop before installing
the structure, because of
the advantages of shop
painting noted earlier.
The surface preparation that is required for
How effective is the epoxy barrier

in extending overall system life?
Three-coat systems have a mid-coat epoxy barrier. Epoxies are tough, high-build,
often high-solids coatings designed as additional barrier protection in three coat
systems. The longer the zinc primer can be protected from the elements, the
longer the last line of defense, sacrificial galvanic protection, can be postponed.
Epoxies are not UV tolerant. They chalk rapidly in sunlight. Once the mid-coat
epoxy barrier has chalked, the epoxy will also begin to absorb the broth of water
and environmental contaminants. As the moisture evaporates off, and is replaced,
the contaminants increase in concentration (acids, salts, chlorides). Corrosion is
now accelerating. Finally, blisters will occur between the epoxy and the zinc
primer. When the blisters break, the systems primer will be completely exposed.
4
new construction should focus on removing mill scale from the steel surface and creating a profile, or surface roughness. Mill scale must be removed to prevent the galvanic action between the steel surface and the
mill scale. Mill scale is cathodic to steel, meaning that the steel will corrode
before the mill scale and as a result, the mill scale will detach from the corroded steel surface. If coatings are applied to the mill scale, they also will
detach and expose the steel surface. Underfilm corrosion and subsequent
coating failure will occur.
Compared to a smooth surface, surface profile or surface roughness provides more surface area, or anchor, to which a coating can adhere. Smooth,
mirror-like surfaces will not provide a sufficient anchor for the coating and
will lead to adhesion failure of a coating.
As discussed above, primers in new construction are normally zinc-rich
because they will provide sacrificial or galvanic protection to the steel, corroding before it. To provide galvanic protection, the zinc pigments must be in
Fig. 6: The standard coating system for this motor was not suitable
for the service environment.
direct contact with the steel surface. Mill scale or other contaminants will interfere with the contact between the zinc and the steel surface. Therefore,
when a zinc-rich primer is used, the surface must be abrasive blast cleaned to an SSPC-SP 10 NearWhite blast or SP 5 White Metal blast, the two most rigorous types of abrasive blast cleaning.
Many times in new construction, the structural steel and other process components are considered off-the-shelf items and are painted by the original component or equipment manufacturer
with standard coating systemswhich are not necessarily selected or suitable for the severity of
chemical plant environments (Fig. 6). If these items are installed in the field with the original manufacturers coating system, they may begin to fail very quickly, leading to premature corrosion of
parts that are critical to plant operation. Premature corrosion means costly downtime for repair
and loss of production time. Although recoating them in the new construction phase adds to the
total construction cost, the maintenance costs are ultimately reduced, as is the downtime that
would otherwise be needed to take the items out of service for recoating.
In summary, while the cost of careful design, shop application and rigorous quality control may
seem high, the investment pays off in considerably reduced long- term maintenance costs.
Maintenance Painting
Protective coating systems are as much a part of an initial investment as the cost of fabrication
and installation. For a facility to implement a successful maintenance painting program, the existing protective coating systems must be monitored, evaluated, and maintained with the same diligence as the pumps, motors, structural steel, storage tanks, and other components of a chemical
plant.
Maintenance painting programs, therefore, should be designed with the
intention of managing the coating process from the initial application at
new construction to its current and future condition. The program
should include inspection procedures, record keeping, and condition monitoring of the coating systems. The goal of maintenance painting programs
should be to prevent deterioration of the protective coating to a condition
that will require the replacement of the coating system. That is, maintenance programs should prevent coating failures by identifying the most
cost-effective condition for repainting. This practice will result in a lower
cost per square foot per year and will provide the protection required by
the metal surface in the specific service environment.
Fig. 7: Typical failure process of an alkyd coating system
5
Condition Assessment
Organic coatings will lose their gloss, begin to chalk, and fail over time (Fig. 7). When they will fail
depends upon the service environment and the quality of coating maintenance. The purpose of
monitoring and assessing an existing coating system is to establish evaluation parameters that will
help us grade and measure the basic properties of an in-service coating system to determine if it
still meets its performance requirements or if it needs to be restored (or replaced, although we try
to avoid this).
Fig. 8: Failed existing coating system removed

to an adhered condition
Evaluation Parameters
Appearance: Most protective coatings applied to steel and other metals change in appearance as
they age and fail. We can make a basic visual evaluation by identifying gloss, chalking, rust/mill
scale, and pitting and other forms of corrosion. Once we have qualified the condition of the coating
visually, we quantify the failure based on the percentage of the coated surface area that has failed.
An industry-recognized standard, ASTM D610/SSPC-Vis 2, uses pictures and diagrams of
painted steel surfaces to quantify the extent of coating failure. Once we evaluate the appearance of
a coating, we need to determine the following mechanical properties of the coating system.
Adhesion: The most important property of any coating system is adhesion. The adhesion of the
existing coating system will affect the success or failure of the coating system used for restoration.
There are several standards that are readily accepted by the coatings industry to determine adhesion. ASTM D3359, Standard Test Methods for Measuring Adhesion by Tape Test, is the most
common.
The primary purpose of surface preparation is to promote the adhesion of the coating system to
the substrate. Since our objective is to minimize surface preparation costs, the better the adhesion
properties of the existing coating system, the less surface preparation is required for
repainting/restoration. Because some surface preparation will always be required, we should determine if manual surface preparation will be sufficient to repair and restore the existing coating
system. A technique used by many contractors is to simply use a scraper or a knife to remove the
failed coating (Fig. 8), at which point the remaining, tightly adhered coating can be feathered to an
acceptable repair condition.
Thickness: As coating systems age and lose their elasticity, they develop stress points. Coating
thickness will affect the ability of a coating system to tolerate the stresses and maintain its cohesive
properties. Measuring the thickness of the existing coating system is necessary to select the best
coating system for restoration. If the existing coating system is too thick, the application of more
coating may be self-defeating. In many cases, the coating thickness is a result of multiple layers of
alkyds and other thin-film coatings. The application of an epoxy and urethane coating system may
create stresses within the aged coating system that will result in cracking and other forms of stress
failures. In these situations, the coating system will have to be removed, because the stress condition will continue to manifest into premature failure.
Thickness measurements are taken with Type I (pull-off) or Type II (electronic)
dry film thickness gauges, in accordance with the procedure described in
SSPC-PA 2, Measurement of Dry Coating Thickness with Magnetic Gages.
The number of measurements taken will depend on the configuration and
condition of the random sample area selected.
Finding the Sweet Spot
in Failure Analysis
Failure analysis of coatings has become efficient enough that we can now
create real environmental conditions by implementing exposure cycling.
We have also documented enough information about actual field applications to understand the performance of different coating types in specific
environments. Therefore, we are able to predict the rate at which a coating
will fail in a specific service environment. If we can identify the optimal con-
Fig. 9: Gloss retention of urethanes
6
dition for repair in the service life of a coating system, we will be able to restore
the existing coating system rather than replace it, and thus reduce our maintenance costs (per square foot). Generally, the condition best for coating maintenance is when the primer is well adhered to the substrate and the coating film is
porous enough for topcoating with limited surface preparation and primer repair.
It is worth noting that chalking is the first indicator that a coating system
is about to begin an accelerating decline. As shown in Fig. 9, cyclic salt fog/UV
testing confirms the relationship between chalking and coating failure. The curve
associated with UV exposure and gloss loss is relatively steady as the gloss holds,
but when the coating begins to chalk, the coating swiftly deteriorates and total
system failure occurs. The fulcrum point in Fig. 9 indicates the exact time the system begins to chalk.
The reason for the sharp decline in coating performance as it loses gloss is
that the permeability and porosity of the coating increase to the point at which it
absorbs and holds moisture. The water and contaminants begin to accelerate corFig. 10: Surface contamination from caustic processing area
rosion by penetrating through the porous (chalked) coating film, as shown by the
sharp drop in readings in Fig. 9. Once topcoat chalking has begun, system failure can be predicted
within 35 years, depending on the coating system and the exposure.
Project-Specific Procedures
Unlike new construction painting, maintenance painting often is scheduled during plant operation.
The unique working conditions in maintenance painting create challenges that must be identified and
overcome. Hence, a successful maintenance painting project begins with a procedure for surface
preparation, application, and inspection that is tailored to the specific structure and operating conditions of the particular project at hand. The procedure should be focused on restoring the existing coating system to achieve the longest possible service life.
The procedure must address how the surface will be decontaminated and prepared, how the coating system will be applied, and how the crew will proceed in the working conditions inherent to the
process area where the painting will be performed. The scope of work will have to define working
hours; protection of the paint crew, the plant workers, and plant equipment; operating conditions;
control of hazards created by the surface preparation and coating application, such as airborne contaminants; and other conditions that will affect the successful application of the coating system.
Along with the natural environment, chemical processing plants are exposed to mineral acids, organic acids, alkalis, corrosive salts, solvents, and gases. This environment creates a surface contamination problem that can lead to premature coating failure.
During new construction, testing for contaminants is done,
depending on how much of the coating system is applied in
the field. When the chemical plant is operating, the testing
requirement is extensive because of the environmental
and processing conditions. The surface should be tested for
contaminants prior to any surface preparation. In fact, in
maintenance painting, the primary surface preparation
concern is removing the surface contaminants that have
accumulated on the surface. (See sidebar, Surface Preparation for Maintenance Painting in Chemical Plants.) These
contaminants are a direct result of the chemical process
and natural environmental conditions
(Fig. 10).
Maintenance painting projects will often include several coating systems, depending upon the condition of
the existing coating system and the part of the facility to
Fig. 11: Handrails, piping, and pumps in different stages of maintenance and repair
7
Table 1: Generic Coating Types and Their Performance in Chemical Environments
Coating Type
Cure Mechanism
Acid Oxidizing Alkali Salt Solvent Weather Max

Acid
Temp
Dry
Epoxy Polyamide
Chemical Reaction
Polyurethane
Chemical Reaction VG
VG
250 F
VG
VG
250F
Silicone Aluminum Heat
1000F
Inorganic Zinc
Hydrolysis
E*
E*
E*
750F**
Organic Zinc
Chemical Reaction VG*
VG*
VG*
VG
VG
VG
300F**
Rating Scale:
(E) Excellent- No effect, best selection where performance and appearance retention desired.
(VG) Very Good- No effect on performance, very little appearance degradation.
(G) Good- Little effect on performance, some appearance degradation.
(F) Fair- Performance and appearance affected by exposure.
(P) Poor- not suitable, coating attacked
* Results indicate zinc rich coating performance when topcoated. Use of these coatings untopcoated
in chemical environments is not recommended.
** Limited by topcoat in the system.
Surface Preparation for Maintenance

Painting in Chemical Plants
Pressure washing with detergents and chemicals is commonly used to neutralize the
surface and remove visible and non-visible contaminants. If chemicals and detergents are
used in combination with water or steam, the surface should first be rinsed with potable
water to remove residue.
When the surface has been decontaminated, we should then address the failed areas of
the coating system. Generally, the steel surface is exposed, and corrosion products are on
the surface.
Maintenance Painting ObjectiveAvoid pitting of the surface.
If the surface is pitted, the area
should be cleaned by abrasive
blast cleaning, which is the
most effective method to clean
a steel surface for coating
application, as per the specified
written standard and the visual
standard for abrasive blast
cleaning SSPC-VIS 1. However,
The existing coating system, feathered in preparation
because of process equipment
for primer application
or the extent of the failure,
abrasive blasting may not be practical. In such cases, manual cleaning methods, such as
hand tool cleaning and different degrees of power tool cleaning, may be employed, as per
the specified written standard and the visual standard SSPC-VIS 3. In both of these
situations, the cost of repainting will increase due to the amount of surface preparation that
will be required to achieve the maximum service life.
Regardless of the cleaning methods used, the failed existing coating system should be
removed to an adhered condition and feathered. Proper feathering techniques create a
gradual transition from the tightly adhered coating to the exposed steel surface (photo above).
The surface adjacent to the feathered steel surface should be abraded to a texture similar to
fine/medium grade sand paper to provide a surface suitable for the primer to adhere to it.
be painted (Fig. 11). For example, structural steel

might require a different coating system than is
needed for the operating equipment in the same
area, and the specification for a pump may be different than the specification for the attached piping. Careful testing for process contaminants is
also needed to determine maintenance systems
that can withstand the processing conditions;
thorough inspection of prepared surfaces is also
needed to assure that they are decontaminated.
Selecting Coating Systems
for Maintenance
When selecting an appropriate primer, the main
considerations are compatibility with the existing
coating system and the method of surface preparation. Because of their inability to adhere to an
existing coating, inorganic zincs are not commonly
used for maintenance painting. Organic zincs are
more common, but require constant agitation during application, which is difficult for most maintenance painting projects at chemical plants because
brushes and rollers are generally used for application. Other organic coatings such as alkyds, epoxies, and urethanes are used more commonly than
zinc-rich coatings.
When the existing coating system is not
known, the application of a field sample is recommended. Field samples are easy to apply and will
answer many questions regarding adhesion and
compatibility. Surface-tolerant coatings are commonly used for surfaces that have been cleaned
manually. Designed to adhere to marginally prepared surfaces, these coatings are usually highsolids products with effective barrier properties.
The intermediate coat in maintenance painting has several functions, depending on the scope
of work. It may be used as a primer over the existing coating system to improve the adhesion of the
new finish coat, to hide the color of the existing
finish coat, and to add depth to the color of the
new finish coat. In the restoration of an existing
coating system, a sealer may be applied, usually at
a DFT of 1.5- 2.0 mils, before the topcoat.
The selection of the topcoat is the same for
both maintenance painting and new construction.
However, the advantage we have for maintenance
painting is that we already know how the finish
coat has performed in the service environment. If
the coating system was properly applied at new
construction, the finish coat should chalk and
erode from the surface, exposing the intermediate
or primer (undercoats).
8
In some cases, the finish coat will delaminate or blister, exposing the undercoats. Blistering or
delamination may occur for several reasons, such as service environment exposure, contamination
between coats, incompatibility between coats, or the application of the top coat exceeded the recoat window of the undercoat. In these cases, the procedure for restoring the coating system is to
repair any areas of the exposed steel surfaces and the finish coat.
When coating failure is limited to the finish coat, the entire coating system does not necessarily
need replacement. For example, suppose a urethane finish coat on the roof of an external floating
storage tank has blistered and lost adhesion, exposing the epoxy intermediate coat. The roof surface is subject to ponding water conditions, and the urethane failed because of the immersion conditions created by the ponding water. In this case, the practical solution is to replace the finish coat
with an epoxy coating, because epoxy coatings perform better in water immersion. However, the
epoxy will chalk in UV exposure. So we will have to adjust our service life expectations and our
repaint cycle for the coating system. The new construction finish coat selection was correct for the
walls, windgirder, and platforms of the storage tank. But even though the roof has a drain system,
experience has shown that we will have to make adjustments to the coating system to accommodate the service conditions.
Summary
Contemporary economics has encouraged the outsourcing of many new construction and maintenance tasks, so the design and engineering of chemical processing plants is normally the task of a
hired firm that is assigned the goals and objectives of building a
THE MILESTONES FOR A SUCCESSFUL PROTECTIVE COATINGS PROGRAM
structure that will have the processing capability to produce a
Select the best possible coating system for the specific service environment
target amount of product. Once the design has been approved, the
Application and inspection procedures for new construction
task is to build the plant at the lowest cost. When the construction
New construction paint applicationDo it in the shop
task is complete and the owner accepts the plant, the duties and
New constructionHire a paint inspector for shop application and field repairs
responsibilities of maintaining the operating plant are assigned to
Design a Maintenance Painting Program that is specific for your site
another firm or group.
Yet the cost to maintain the plant will depend on the original
Monitor the performance of your existing coating systems, and update periodically
design
and construction. Usually, the impact of any cost concessions
Identify the condition of your existing coating systems. Restoration is preferred
made during construction will be realized after the plant is operatover replacement
ing, and the ultimate costs will be borne during maintenance. Main Site specific application and inspection procedures for maintenance
tenance painting of the plant must therefore take into account new
Inspection of maintenance painting
construction coating work as well as coating requirements during
Update maintenance painting program and service life expectations
plant operation.
Sources
Process Industry Corrosion / An Official NACE Publication. Published by National Association
of Corrosion Engineers, Library of Congress Catalog Number 75-28636 Copyright 1975.
Steel Structures Painting Manual Volume 1 Good Painting Practice Second Edition Copyright
1982, by Steel Structures Painting Council Second printing 1983.
Corrosion Protection by Protective Coatings Charles G. Munger / Louis D. Vincent, Ph.D. Revision Author 1984, 1999 National Association of Corrosion Engineers Second Edition 1999 ISBN
1-57590-088-2 Library of Congress Catalog Card No. 99-75864.
Material Performance December 2005 Volume 44, Number 12 p. 30 Using Organic Coatings to
Protect Mild Steel in a Viscose Industrial Atmosphere M, Natesan, M. Selvaraj, and K. Maruthan;
P. Rajendran.
Luke Clark is the director of technical service for Carboline Company. He has more than 25 years of experience
in industrial and marine coatings, working previously for such companies as Du Pont and Sigma Coatings USA.
He is a NACE Certified Coatings Inspector and Instructor and a SSPC Certified Protective Coatings Specialist.
JPCL
Click our Reader e-Card at paintsquare.com/ric
Coating
Systems
Guide
10
SPONSORED BY
Photos courtesy Hempel
Coating System Guide

for Chemical & Petrochemical Plants
Listings are alphabetized by company name.
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Battery Storage Floor

NovoRez 351
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Thiokol FNEC 2515
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Industrial Coatings Group

www.polyspec.com
2011
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Overspray Problems? We Have the Solution!

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Concentrate
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www.sprayclaims.com
26
Company Profiles
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Selecting and Sourcing

Coatings for Chemical and

Selecting and Sourcing

This eBook may not be copied or redistributed

From New Construction Through Plant Operation:

Coating Systems Guide for Chemical and

Coatings Company Profiles

Storage tank in optimum condition to be restored.

Storage tank after minor surface preparation and overcoating.

From New Construction through

Types of Corrosion in Chemical Processing Plants

Fig 1: Galvanic corrosion of stainless steel piping

Fig. 3: Pitting of steel cooling water pipe

Fig. 4: Corrosion failure of stack due to stress

How effective is the epoxy barrier

Fig. 8: Failed existing coating system removed

Fig. 9: Gloss retention of urethanes

Acid Oxidizing Alkali Salt Solvent Weather Max

Silicone Aluminum Heat

Chemical Reaction VG*

Surface Preparation for Maintenance

be painted (Fig. 11). For example, structural steel

Click our Reader e-Card at paintsquare.com/ric

Photos courtesy Hempel

Coating System Guide

Exterior Plant Exposure

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COATINGS LINING PRODUCTS

Chem & Petrochem Plants

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THIOKOL SEALANTS & COATINGS OFFER SUPERIOR

CR Expansion Joint System

Battery Storage Floor

Underground Fuel Tank Lining

Chemical Process Tank

Industrial Coatings Group

Chem & Petrochem Plants

Exterior Plant Exposure

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