Ballast Tank Protection

A focus of attention for the industry,

for governments, environmental
agencies and classification societies

Nguyen Cong Thuan/JPS DNV Vinashin Training/ 2007

 Ballast Tanks - The Challenge

• The Area where corrosion will have the strongest

effect on value reduction
• The Area where effective maintenance is most
difficult
• Our aim is to increase the lifetime of the vessel
• Better price if in good condition when sold
• The best time for lasting protection is at the new
building stage

Nguyen Cong Thuan/JPS DNV Vinashin Training/ 2007

 What are the rules?
Performance Standard For Protective Coatings for Dedicated Seawater
Ballast Tanks

Designed to control the quality of ballast tank coatings including:

– Surface preparation
– Coating application
– Inspection
– Coating quality

For application in Newbuildings and at least full refurbishment (not

concluded)

Improve quality means improved safety

Cost will increase – but all have to comply

Nguyen Cong Thuan/JPS DNV Vinashin Training/ 2007

 Timing

The New regulation shall apply to ships of not less than 500
gross tonnage:-

– For which the building contract is placed on or after 1 July 2008

– In the absence of a building contract, the keels of which are laid or

which are at a similar stage of construction on or after 1 January
2009

– The delivery of which is on or after 1 July 2012.

Nguyen Cong Thuan/JPS DNV Vinashin Training/ 2007

 The Demands on the Paint maker

• Coating manufacturers should give evidence of the quality

of the product
• Multi-coat systems are recommended
• Last layer preferably of a light colour
• The coating must be compatible with the cathodic
protection system
• The products should have documented satisfactory
performance records
• The manufacturer should also be capable of rendering
adequate technical service.

Nguyen Cong Thuan/JPS DNV Vinashin Training/ 2007

 Jotun Ballast Tank Products

• Balloxy HB Light
• Balloxy HB Lumi
• Jotacote Universal
• Jotamastic 87
• Primastic Universal

Nguyen Cong Thuan/JPS DNV Vinashin Training/ 2007

 The Demands - Testing

Marintek test
• Systems tested and rating
– WG Balloxy HB Light on St2 B1
– WG Balloxy HB Light on Mg-descaled B1
– Balloxy HB Light on zinc shopprimed B1
– Balloxy HB Light on St3 (moist surface) B1
– Balloxy HB Lumi B1
– Jotacote Universal B1

Nguyen Cong Thuan/JPS DNV Vinashin Training/ 2007

 Recommended system
Based on LCC, LCA, Rules and Regulations
System Description: Balloxy HB Light (New ship)
Year System Description
Application of 2 x 150 microns Balloxy HB Light
0
Installation of Anodes

5 Replacement of Anodes

High pressure cleaning on 2% of the area

10 Application of 2 x 200 microns Balloxy HB Light
Replacement of Anodes

High pressure cleaning on 5% of the area

15 Application of 2 x 200 microns Balloxy HB Light
Replacement of Anodes

20 Replacement of Anodes

25 End of life

Nguyen Cong Thuan/JPS DNV Vinashin Training/ 2007

 Coating Specifications
DnV’s “Corrosion Protection of Ships July 1996” Guidelines No. 8

Specification I Specification II Specification III

Coating System (5 ± 3 years) (10 ± 3 years) (15 ± 3 years)
Preparation I Preparation II Preparation III

- Epoxy-based, light coloured 2 x 200 µm

- Coal tar epoxy * 1 x 200 µm 2 x 150 µm or
- Other recognised system 3 x 130µm
Prep. I - Shop-primed or Sa 2 - 2½, Welds & burns to St3.
Prep. II - Zn rich shop-primed or Sa 2½ inc. welds/burns, Edges rounded & control of humidity/temp.
Prep. III - As prep. II but with additional cleaning and salts removal.
In all cases stripe coating is required

* Tar-containing coatings are dark and thus not recommended in water ballast tanks

Nguyen Cong Thuan/JPS DNV Vinashin Training/ 2007

 The Demands - Case History
VLCC with 90.000 sq.m. of ballast tanks

The original Balloxy HB system after full blasting

Nguyen Cong Thuan/JPS DNV Vinashin Training/ 2007

 Consequence of Rules & Regulations

Coal Tar Epoxy-On it’s way out

• Proven technology
• Tar is on the cancer list
• Requires good surface pre-treatment
• Dark colours
– SOLAS Regulations from 1998
– Poor working/inspection conditions

Nguyen Cong Thuan/JPS DNV Vinashin Training/ 2007

 Consequence of Rules & Regulations

Epoxy Mastics – Balloxy HB , Jotamastic

87, Primastic Universal
• Surface tolerant
• Outstanding performance
• Light colours
– Improved safety
– Good working/inspection conditions
– Recommended by IMO

Nguyen Cong Thuan/JPS DNV Vinashin Training/ 2007

 Key Factors at Newbuilding

• Life Cycle Cost (LCC)

– Total cost for protection over the life time of the vessel
• Secondary preparation
– Most coating failures are caused by inadequate
pretreatment, painting over contaminants, or the
entrapment of moisture or solvents
• Second hand value
• Delivery time
– A network of factories and stocks world wide

Nguyen Cong Thuan/JPS DNV Vinashin Training/ 2007

 Ballast Tanks - Newbuilding Stage

• Decisions at new building stage is the ideal

opportunity to increase the life of the coating
– Pre-blasting preparation
– Good surface preparation
– Correct choice of coating and film thickness
– The use of sacrificial anodes

Nguyen Cong Thuan/JPS DNV Vinashin Training/ 2007

 Equipments For Ballast Tanks
Inspection

• Bresle’s Salt Detector and conductivity Analysis

• Hygrometer, Dew Point Calculator, Steel Temperature
Gauge
• WFT, DFT Gauge
• Mirror for checking Scallops, Stiffeners etc.
• Holiday Detector, Knife , Scrapper, Lamp
• Check any possible condensation & Amine Sweating
between coats.
See also ISO 8501 - 2
Nguyen Cong Thuan/JPS DNV Vinashin Training/ 2007
 Key Factors in Application

• Wetting and adhesion properties

– The benefits of using surface tolerant epoxy mastics
• Solids and dry film thickness
• Stripe coatings
• 2 coats more than doubles security
– Single coats save time, but jeopardise the quality
• Regular planned inspections
– Quality control during surface preparation and painting
– Every stage must be monitored to assure that it conforms to
specification

Nguyen Cong Thuan/JPS DNV Vinashin Training/ 2007

 Key Factors in Application

Discussion on Painting Procedure

Nguyen Cong Thuan/JPS DNV Vinashin Training/ 2007

 Film Thickness Measurement

Have
Havewe
weChecked
Checkedthe
theBallast
BallastTanks
Tanksasasper
per80:
80:20
20rule
ruleof
of
total
totalfilm
filmthickness
thicknessspecified?
specified?

Remember
Remember:New
:NewIMO
IMOrule
ruleproposes
proposes to
tofollow
follow90:
90:10
10rule
rule
and
andNominal
NominalDFT
DFTof
of320
320microns.
microns.

Nguyen Cong Thuan/JPS DNV Vinashin Training/ 2007

 How to Measure
IMO
IMORecommendation:
Recommendation:
–– At
Atleast
leastone
onemeasurement
measurementper per5m²5m²ofofflat
flatsurface
surfacearea
area
–– At
Atleast
leastone
onemeasurement
measurementatat22––33meter meterintervals
intervalsand
andatat15
15mm
mmfrom
from
the
theedges
edgesof
oftank
tankboundaries
boundaries
–– Longitudinal
Longitudinaland andtransverse
transversestiffener
stiffenermembers
membersand andMain
MainSupporting
Supporting
Members
Members
•• Measurements
Measurementsaccording
accordingtotodrawings
drawings--ininthe
thestandard
standardatat22––33
meter
meterintervals
intervalsand
andnotnotless
lessthan
than33sets
setsbetween
betweenmainmainsupporting
supporting
members,
members, where one set at each end and one at the midpoint
where one set at each end and one at the mid point
–– Around
Aroundopenings
openingsoneonesetsetper
perside
side
–– 55measurements
measurementsper perm²m²but
butnot
notless
lessthan
thanthree
threeononcomplex
complexareas
areassuch
suchas
as
large brackets of main members
large brackets of main members
–– Additional
Additionalas asseen
seenfit
fitby
bycoating
coatingadvisor
advisor

Nguyen Cong Thuan/JPS DNV Vinashin Training/ 2007

 Maximum Film Thickness for a
completed Ballast Tank

Jotun
Jotunrecommends:
recommends:
Absolute
AbsoluteMaximum
MaximumDFT
DFT value900
value900microns
micronsfor
forstress
stressareas
areas
like
likeStiffeners,
Stiffeners,weld
weldseams
seams
Absolute
AbsoluteMaximum
Maximumvalue
valueofof1200
1200microns
micronsfor
forother
otherareas.
areas.

Note:
Note: Please
Pleasetake
takenote
notethat
thatexcess
excessthickness
thicknesscan
canresult
resultin
in
cracking
crackingof
ofpaint
paintfilm.
film.

Nguyen Cong Thuan/JPS DNV Vinashin Training/ 2007

 Ambience

Optimum
Optimum Lighting,
Lighting,ventilation
ventilationand
andstaging
stagingwill
willensure
ensure Quality
Qualitywork.
work.
Make
Makesure
sureyou
youcheck
checkand
andapprove
approvethis
thisbefore
beforestart
startof
ofwork.
work.
Or
Orelse?
else?
33degree
degreecentigrade
centigradeabove
abovedew
dewpoint,
point, RH
RHMaximum
Maximum85%. 85%.

Note
Note::Issue
Issue Non
Nonconformance
conformancebefore
beforeactual
actualwork
workstarts.
starts.

Nguyen Cong Thuan/JPS DNV Vinashin Training/ 2007

 Blasting Standard & Surface Profile

Blasting
Blastingto
toSa2.5
Sa2.5with
withSurface
SurfaceProfile
Profilebetween
between3030to
to75
75
microns?
microns?
Note:
Note:IMO
IMOrecommends
recommendsmedium
mediumblasting
blastingprofile
profileof
of 30
30to
to75
75
microns
microns..
..

Nguyen Cong Thuan/JPS DNV Vinashin Training/ 2007

 Hydro jetting

Are
Arewe
wewitnessing
witnessing Hydro
Hydrojetting
jettingin
inBallast
BallastTanks?
Tanks?
Please
Pleaserefer
referto
toNace
NaceVis7/
Vis7/SSPC
SSPCVIS
VIS44
Jotun
Jotuncan
canaccept
acceptflash
flashrust
rustgrades
gradesupuptotoand
andincluding
including
Medium
Medium
..

Nguyen Cong Thuan/JPS DNV Vinashin Training/ 2007

 Recoating

Recoating
Recoatingto tobe
becarried
carriedout
outwithin
withinrecommended
recommendedrecoating
recoating
interval
interval of
ofnormally
normally33toto77days
daysand
andbefore
beforethe
thenext
nextcoat
coat
cures
curesto
toensure
ensurebest
bestadhesion.
adhesion.

Nguyen Cong Thuan/JPS DNV Vinashin Training/ 2007

 Stripe Coating

Apply
ApplyStripe
Stripecoating
coatingto toensure
ensureOPTIMUM
OPTIMUMfilm filmthickness.
thickness.
Stripe
Stripecoat
coatisisrecommended
recommendedto to apply
applybefore
beforefinal
finalcoat
coat
application
applicationcompleted.
completed.

Nguyen Cong Thuan/JPS DNV Vinashin Training/ 2007

 Light Colours & Stripe Coatings

Nguyen Cong Thuan/JPS DNV Vinashin Training/ 2007

 Salt Level

Ensure
Ensurethat
thatsurface
surfaceisischecked
checkedfor
forSoluble
Solublesalt
saltbefore
beforeand
and
after
afterBlasting.
Blasting.Do
Dorandom
randomchecking
checkingof
ofgrit
grit and
andfresh
freshwater
water
used
usedfor
forwashing.
washing.
Note:
Note:IMO
IMOproposal
proposalisisfor
for50
50mg/m2
mg/m2forforchlorides
chloridesand and70
70
mg/m2
mg/m2for forsoluble
solublesalts.
salts.

Nguyen Cong Thuan/JPS DNV Vinashin Training/ 2007

 Dust Level

Please
Pleaseensure
ensurethat
thatDust
Dustisiswithin
withinprescribed
prescribedlimit
limitof
ofISO
ISO
8502-3
8502-3Level
Level2.2.
Using
Using aabright
brightwhite
whiteHand
Handgloves?
gloves?
Clean
CleanMasked
Maskedboot
bootfor
forall
allworking
workingin inBallast
BallastTank!
Tank!

Remember:
Remember:New
NewIMO
IMORegulation
Regulationproposes
proposes level
level1!!
1!!

Nguyen Cong Thuan/JPS DNV Vinashin Training/ 2007

 Coating Technical File
– Daily log
– Non-conformity log
– Shipyard's verified inspection
• completion date / inspection results / remarks /
signed
– Procedures for in-service maintenance
– Maintenance & Significant Repair during service life
• TDS
• Work records
• Procedure for inspection and repair

The Coating Technical File shall be kept on board for the remainder
of the life of the ship

Nguyen Cong Thuan/JPS DNV Vinashin Training/ 2007

 Curing of Ballast Tank

Based
Based onon ventilation,
ventilation, temperature
temperatureand and DFT
DFT ofof system
system
thickness
thickness ,, itit isis possible
possibletoto Ballast
Ballast between
between 33 toto 77
days
days after
after application
application of of Final
Final coat.
coat. (Half
(Half cured
cured time)
time)
Please
Please note:
note: ventilation
ventilation needs needsto to be
be continued
continued till
till the
the
process
process ofof curing
curing isis complete,
complete, otherwise
otherwise ititslows
slows
down
down and
and jeopardise
jeopardisethe the quality
qualityof of the
the coating
coating system
system

Nguyen Cong Thuan/JPS DNV Vinashin Training/ 2007

 Have
Haveyou
youenough
enoughexperience
experienceininBallast
BallastTanks?
Tanks?
Any
Anycertification?
certification?

Note:
Note:IMO
IMOrecommends
recommends Coating
CoatingAdvisors
Advisors to
tobe
be FROSIO
FROSIO
Red
Red//NACE
NACEIIIIcertified
certifiedfor
forBallast
BallastTank
Tankinspection.
inspection.

Nguyen Cong Thuan/JPS DNV Vinashin Training/ 2007

 Repairing BT

• Will you spot Blast a Ballast Tank ?

• Will you spot blast a tank with say 5% damage?

IMO Recommends:
– Butts and small damages up to 3% of total tank area, St3, or Sa2½
where practicable.
– More than 3%, then Sa2½

Nguyen Cong Thuan/JPS DNV Vinashin Training/ 2007

 Solids and Dry Film Thickness

The picture shows coating failure due to low film thickness. However,
note the band of stripe coating adjacent to the welded seams where
thickness is satisfactory and the coating is not breaking down.

Nguyen Cong Thuan/JPS DNV Vinashin Training/ 2007

 Key Factors at Maintenance

• The benefit of epoxy mastics

– Surface tolerant coatings for long, lasting protection
• Water Jetting
– Alternative when blast cleaning is not possible
• Time scale
– There are no shortcuts in ballast tank protection, but
there are time savings in selecting the right coating

• Frequent inspections and repair

Nguyen Cong Thuan/JPS DNV Vinashin Training/ 2007

 Remedial Treatment

• Small damages
– Not easy to detect, therefore regular inspections are vital
– The crew can carry out some maintenance
– Installation of anodes
• Moderate damages
– Wash down with freshwater followed by sweepblasting,
hydrojetting and two touch-up coats of a suitable coating
– Installation of anodes
• Larger damages
– Blastcleaning of the surface or electrolytic descaling
– Complete renewal of paint system and anodes

Nguyen Cong Thuan/JPS DNV Vinashin Training/ 2007

 Cracking-Discussion

This phenomenon widely seen by all the paint companies

in Ballast Tanks.
Many of these are not related to Product failure.
Even Shipyard’s are doing extensive study on this.

Nguyen Cong Thuan/JPS DNV Vinashin Training/ 2007

Nguyen Cong Thuan/JPS DNV Vinashin Training/ 2007
Nguyen Cong Thuan/JPS DNV Vinashin Training/ 2007