Corrosion protection converter platform repair instructions

Corrosion protection converter
TenneT Offshore GmbH platform HelWin beta plant 4 Page: Page 1 of 12

Eisenbahnlängsweg 2a BU- No.: 20-045-338
31725 Lehrte Date: 29.10.2020
Rev. No. 000
Repair instruction corrosion protection
jacket
Converter platform HelWin beta
Client: TenneT Offshore GmbH

Eisenbahnlängsweg 2a, 31725 Lehrte,
31725
Corrosion protection planning and quality assurance:
Helmut Müller GmbH

Gelsenkirchener Straße 2
26723 Emden, E-N
Phone: 04921 / 99 94 77 0
doc.title.: enclosure 4_KS_Rep.- Anweisung_Jacket_HelWin beta_TenneT


31725 Lehrte Date: 29.10.2020
Rev. No. 000
Item. content side

1.0 introduction 3
2.0 General information on carrying out 3
3.0 repair instructions 5
3.1 Jacket, damaged areas > 100 cm² Area 5
3.2 Jacket, damaged areas < 100 cm² 7
3.3 Corrosive ferritic particles Tests and 10
4.0 documentation 10
5.0 grounds 12

31725 Lehrte Date: 29.10.2020
Rev. No. 000
1.0 Introduction
This repair instruction is used to restore the corrosion protection system in the area of
the jacket of the helwin beta converter platform.
The corrosion protection system is damaged in various areas by processing errors in

the course of the initial coating, by transport and assembly damage as well as by
operational handling. In order to prevent further damage to the coating system by the
corrosion process in these areas, a professional repair of these damaged areas is
necessary.
2.0 General information on implementation
As already describedin the main document, corrosion protection work shall always
be carried outin accordance with the applicable standards, regulations and regulations and
the state of the art. Should services not be carried out or can only be carried out to a
limited extent in accordance with the specifications of the standards, the re- gelwerke
or the description of the specifications, the client must be informed immediately and
further instructions must be awaited. The same applies if there are discrepancies
between the information between the "technical descriptions" of the material
manufacturers and the specification or. the standards and regulations.
This repair instruction is to be checked by the AN professionally. Should technical

specifications and conditions be incorrect or insufficient, the CLIENT must inform
the CLIENT in writing.
The entire execution of the corrosion protection work is to be recorded completely. All
relevant parameters and operations as well as material information are to be checked
and documented (see point 4 "Testing and documentation").
The layer thicknesses indicated in the "coatingsystems" referred to below are minimum
layer thicknesseswhich maynot be undercut at any point in the system. The maximum
layer thickness of the coating system must not exceed 2.5 times the minimum layer
thickness. If stricter requirements are made by the material supplier, these must be
followed.
In the system selection, it was taken into account that for the factory-erfolgte corrosion
protection application coating materials of the company International Farben were used.


31725 Lehrte Date: 29.10.2020
Rev. No. 000
Irregularities in the steel substrate such as steel beads and sharp edges, etc. are in the
pre- field by means of suitable tools / machines to round or. to equalize. Here are the
requirements of EN ISO 8501-3 "P3" to implement.
In the surface preparation is to be ensured that the complete, defective coating is

completely removed. At the border areas , the intact coating must be worked over a
large area so that it is ensured that no loose and damaged areas remain untreated .
The transition to the old coating is, ofern due to the component structure so far
feasible, according to the following exemplary representation to realize:
For the repair measures, only original containers of the material manufacturer are to be
used. The addition of solvents can be foundin the respective data sheet. Unmit- telbar
after mixing, the material must be processed. Here, the maximum processing time
(pottime) must be observed. As soon as this time (see "Technical data sheet" of the
manufacturer) is exceeded , the material may no longer be processed and must be
disposed of immediately . The pot life is u. a. temperature-dependent, so that the current
ambient temperature must be taken into account. The application of the base coating has
to be doneby means of short-haired brush. A rolling of the base coating is prohibited.


31725 Lehrte Date: 29.10.2020
Rev. No. 000
As an alternative to the brush application, if the respective component geometry allows,

a spray application can also be carried out.
Before the start of the repair work, the climatic conditions must be determined for the first
time as well as later before each application in the immediate vicinity of the damaged
areas. No start of work at a surface temperature below 5 °C, a relative air- humidity
above 80 % or a dew point distance below 3 ° K. Setting the measuring instrument to
interval recording (every 15 min.) before the start of work until the complete curing of
the repair coating. If necessary, it is necessary for the measuring instrument to remain
overnight.
Note: The surface of Interzone 1000 may be sticky despite compliance with the
specified drying times, but this has no effect on the quality of corrosion protection,
unless it is a "sweating" of ines . The AG must be informed immediately about this.
For the exclusion of obesity, the following practical testis suitable: Rub over the coated
surface with wet fingers. If the fingers feel "shallow", it is Amin. In this case, the
surface should be wiped with suitable dilution.
3.0 Repair instructions
In the following, the area of the underdeck with the original coating structure, the
intended repair coating and a description of the implementation is presented.
3.1 Area jacket, damaged areas > 100cm²
Original coating structure (System 7A, Underside Deck)
Surface preparation Rays Sa 2.5 (ISO 8501-1), roughness 50- 100 μm (ISO 8503-5)
Basic coating Interzone 1000 Standard Yellow tinted 500 μm DFT
Topcoating Interzone 1000 Standard Yellow 500 μm DFT
1000 μm DFT Total
Repair coating structure
Surface preparation PSa 2.5 / PSt 3, (ISO 8501-2), roughness 75- 100 μm
Basic coating Interzone 1000 Grey 500 μm MDFT
Topcoating Interzone 1000 Standard Yellow 500 μm MDFT
1000 μm MDFT Total


31725 Lehrte Date: 29.10.2020
Rev. No. 000
Repair of damage images up to the substrate
1. Contamination by fats, oils, etc. are to be removed completely. Then intensi- ves
cleaning the damaged area and the surrounding area by means of high-pressure water-
wash with VE water (ifnecessary. with a suitable and approved cleaner).
2. Carrying out a Bresletest, according to EN ISO 8502-6 /9, in which a value of max.
50 mg / m² NaClequivalent must not be exceeded. In case of deviations must be
cleaned and checked again.
3. Preparation of the required surface purity at least PSa 21/2 (Surfacepro- fil of 50
microns - 75 microns) or PSt 3 by means of suitable tools (eg. Blasting devices, MBX
ruster system 7091, etc.). Soft transitions to the intact coating system are to be
produced.
4. Removal of the grinding dust by appropriate measures (brush, blow off, suck off).
6. Homogeneous mixing of the base coating Interzone 1000 by means of agitator. Then
repot into a clean and handy container. Note the product data sheet of the color
manor.
7. Uniform application of the base coating by means of brush. When applied with- tels
brushes are possibly. several operations required to achieve the required wet layer
thickness of DFT 550 μm.
8. The achieved dry film thickness of the base coating is to be determined and to docu-
mentieren. Minimum layer thickness of the base coating dry is 500 μm.
9. Before the coating is applied, in compliance with the interva llzeiten, the surface purity
(Bresletest, according to EN ISO 8502-6 /9) must be checked, if necessary. to restore-
put and document.
10. Homogeneous mixing of the top coating Interzone 1000 by means of agitator. Then
repot into a clean and handy container. Note the product data sheet of the color
manor.
11. Uniform application of the topcoating by means of brush or roller. In the application
by means of brush or roll are possibly. several operations required to achieve the for-
derte wet layer thickness of DFT 550 microns.
12. The achieved total dry layer thickness (min. 1000 microns) is to be determined after
complete Filmbil- dung and compliance with the prescribed drying times and to
dokumen- animals. Furthermore, meaningful photos are to be made.

31725 Lehrte Date: 29.10.2020
Rev. No. 000
Repair of damage patterns in the coating
3. Grinding the damaged area to the intact coating layer by means of suitable work-
testify. Make soft transitions to the intact coating.
4. Removal of the grinding dust by suitable measuring (brush, blow off, suck off ).
5. Determine the existing dry film thickness of the intact coating. The layer thickness of
the repair coating to be appli- adorned depends on the determined residual layer
thickness of the existing coating (see table repair coating structure).
6. Homogeneous mixing of the coating Interzone 1000 by means of agitator. Then repot
into a clean and handy container. Product data sheet of the color manufacturer be-
eighth.
7. Uniform application of the coating by means of brush or roller. When applied by

means of brush or roller are possibly. several operations required to achieve the
required wet layer thickness. The required wet layer thickness depends on the er-
mittlung under pts. 5.
3.2 Area jacket, damaged areas < 100cm²
Original coating structure (System 7A, Underside Deck)
Surface preparation Rays Sa 2.5 (ISO 8501-1), roughness 50- 100 μm (ISO 8503-5)
Basic coating Interzone 1000 Standard Yellow tinted 500 μm DFT
Topcoating Interzone 1000 Standard Yellow 500 μm DFT
1000 μm DFT Total

31725 Lehrte Date: 29.10.2020
Rev. No. 000
Repair coating structure
Surface preparation PSa 2.5 / PSt 3, (ISO 8501-2), roughness min. 30 μm

Basic coating Sika SW- 1000 RepaCor RAL 7035 500 μm MDFT
Topcoating Sika SW- 1000 RepaCor RAL 1023 500 μm MDFT
1000 μm MDFT Total
Repair of damage images up to the substrate
3. Preparation of the required surface purity (atleast PSa 2.5 /PSt 3) by means of ge-
suitable tools (eg. Blasting devices, MBX ruster system 7091, etc.). Make soft transitions
to the intact coating.
5. Preparation of the coating material SikaCor SW- 1000 RepaCor. The first 2 cm
coming out of the mixing unit must be disposed of and must not be processed.
6. With the cartridge press and suitable tools (brush, spatula, etc. ) a uniform
application of 500 microns on the damaged site.
7. The achieved dry film thickness of the base coating is to be determined and to docu-
mentieren.
8. Before applicating the topcoating, in compliance with the interval times, the surface
purity (Bresletest, according to EN ISO 8502-6 /9) must be checked, if necessary. to
restore- put and document.
10. With the cartridge press and suitable tools (brush, spatula, etc.) establish a uniform
application of 500 μm on the damaged site.

31725 Lehrte Date: 29.10.2020
Rev. No. 000
12. The achieved total dry layer thickness (min. 1000 microns) is to be determined
after complete film formation and compliance with the prescribed drying times and to
do- kumentieren. Furthermore, meaningful photos are to be made.
Repair of damage patterns in the coating
wash with VE water (ifnecessary. with a suitable and zugelassenen cleaner).
3. Grinding the damaged area to the intact coating layer by means of suitable work-
testify. Make soft transitions to the intact coating.
5. Determine the existing dry film thickness of the intact coating. The layer thickness of
the repair coating to be appli- adorned depends on the determined residual layer
thickness of the existing coating (see table repair coating structure).
7. With the cartridge press and suitable tools (pinsel, spatula, etc.) establish a uniform
application on the repair area. The required wet - layer thickness depends on the
determination under pts. 5.

31725 Lehrte Date: 29.10.2020
Rev. No. 000
3.3 Corrosive ferritic particles
It is necessary to check the extent to which the ferritic particles are present in the
coating or on the coating system. An investigation to evaluate the penetration- depth
of ferritic particles can becarried out with the use of a magnification (magnifying glass)
or by means of a grinding sample.
If it is found that the ferritic particles are within the coating system, the affected
areas shall be sandeduntil the ferritic particles are removed. The subsequent repair
of the coating system is carried out in this case in the respective area according to
the specifications repair of damage images in the coating.
If it is found that the ferritic particles are located on the coating system - gend, no
processing of these areas takes place.
4.0 Testing and documentation
Identification and identification of damaged areas
Before the start of the work, the damaged areas are determined in a joint inspection.
The found damaged areas are to be numbered and bzgl. to enter their position in a suitable drawing.
Several damaged areas directly next to each other should be combined into one.
Coating protocols
The execution of the coating work is to be documented continuously. The form used must be agreed in
advance with the client and must containat least the following information:
 Date and working time

 Number and name of employees employed
 Name of the area (according to common definition)
 Name of the work step (surfacepreparation, primer ...)
 Description of the materials used
 Batch numbers of the materials used
 Climate data during coating work (air temperature, surface temperature, rel. Humidity, dew
point distance). At least three measurements per working shift and area
 Information on tests carried out (self- and external control)
It is at least one coating protocol per layer and working area to be made. The coating protocols are to
be signed by the foreman /site manager and to be transmitted promptly to the ag.

31725 Lehrte Date: 29.10.2020
Rev. No. 000
Measurement protocols
The results of the required control measurements in accordance with this repair instruction shall be
recorded in a separate form as follows :
Bresletest:
 Information on the date, time and place (damagesite) of the measurement carried out
 Information on the measuring instrument used (clearly identifiable)
 Name of the examiner
 Indication of the reference value (null value)
 Indication of the measured value
 Calculation of the actual value (measuredvalue - null value)
 Information on the calculation of factors (measuringinstrument-specific)
 Evaluation of the result
 Photos of the measuring instrument display when the
measurement is carried out Layer thickness measurement:
 Information on date, time and place (damagesite ...) of the measurement carried out
 Information on the measuring instrument used (clearly identifiable)
 Name of the examiner
 Indication of the number of measurements
 Min.- and Max.-measured value
 Table of individual measured values
 Evaluation of the result
All measurement protocols must be signed by the examiner and transferred promptly to the client.
Photo documentation
About the execution of the repair work is to create a photo documentation. For this purpose,
the following photos are taken of each damaged area:
1. default
2. after surface preparation and cleaning
3. final state
The recordings shall be carried out in such a way that the corresponding sticker is clearly visible- and
legible . On all photos date and time are to be displayed.
All existing photos must be made available to the client or his representative at any time on request
for viewing. After completion of the work, the complete photo documentation in digital form (CD
o. a.) to the AG.

31725 Lehrte Date: 29.10.2020
Rev. No. 000
5.1 grounds
- Product data sheet International Interzone 1000
- Safety data sheet International Interzone 1000
- Product data sheet Sika RepaCor SW- 1000
- Safety data sheet Sika RepaCor SW- 1000

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Corrosion protection converter

TenneT Offshore GmbH platform HelWin beta plant 4 Page: Page 1 of 12

Repair instruction corrosion protection

Converter platform HelWin beta

Client: TenneT Offshore GmbH

Corrosion protection planning and quality assurance:

Helmut Müller GmbH

doc.title.: enclosure 4_KS_Rep.- Anweisung_Jacket_HelWin beta_TenneT

TenneT Offshore GmbH platform HelWin beta plant 4 Page: Page 2 of 12

Item. content side

2.0 General information on carrying out 3

3.0 repair instructions 5

3.1 Jacket, damaged areas > 100 cm² Area 5

3.2 Jacket, damaged areas < 100 cm² 7

3.3 Corrosive ferritic particles Tests and 10

TenneT Offshore GmbH platform HelWin beta plant 4 Page: Page 3 of 12

The corrosion protection system is damaged in various areas by processing errors in

2.0 General information on implementation

This repair instruction is to be checked by the AN professionally. Should technical

doc.title.: enclosure 4_KS_Rep.- Anweisung_Jacket_HelWin beta_TenneT

TenneT Offshore GmbH platform HelWin beta plant 4 Page: Page 4 of 12

In the surface preparation is to be ensured that the complete, defective coating is

doc.title.: enclosure 4_KS_Rep.- Anweisung_Jacket_HelWin beta_TenneT

TenneT Offshore GmbH platform HelWin beta plant 4 Page: Page 5 of 12

As an alternative to the brush application, if the respective component geometry allows,

3.0 Repair instructions

3.1 Area jacket, damaged areas > 100cm²

Original coating structure (System 7A, Underside Deck)

Repair coating structure

doc.title.: enclosure 4_KS_Rep.- Anweisung_Jacket_HelWin beta_TenneT

TenneT Offshore GmbH platform HelWin beta plant 4 Page: Page 6 of 12

Repair of damage images up to the substrate

TenneT Offshore GmbH platform HelWin beta plant 4 Page: Page 7 of 12

Repair of damage patterns in the coating

7. Uniform application of the coating by means of brush or roller. When applied by

3.2 Area jacket, damaged areas < 100cm²

Original coating structure (System 7A, Underside Deck)

TenneT Offshore GmbH platform HelWin beta plant 4 Page: Page 8 of 12

Repair coating structure

Surface preparation PSa 2.5 / PSt 3, (ISO 8501-2), roughness min. 30 μm

Repair of damage images up to the substrate

TenneT Offshore GmbH platform HelWin beta plant 4 Page: Page 9 of 12

Repair of damage patterns in the coating

TenneT Offshore GmbH platform HelWin beta plant 4 Page: Page 10 of 12

3.3 Corrosive ferritic particles

4.0 Testing and documentation

Identification and identification of damaged areas

 Date and working time

TenneT Offshore GmbH platform HelWin beta plant 4 Page: Page 11 of 12

measurement is carried out Layer thickness measurement:

the following photos are taken of each damaged area:

legible . On all photos date and time are to be displayed.

TenneT Offshore GmbH platform HelWin beta plant 4 Page: Page 12 of 12

- Product data sheet International Interzone 1000

- Safety data sheet International Interzone 1000

- Product data sheet Sika RepaCor SW- 1000

- Safety data sheet Sika RepaCor SW- 1000

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