Coating Technology Improves Project Predictability and Lowers Costs for FPSO Conversion Projects

Abstract

ABSTRACT The role protective coatings' play in the predicable and timely conversion of an FPSO conversion project is commonly overlooked. This is due in part to the low cost of the coating materials when compared to the overall project costs. In addition to improved predictability, new technology coatings can help lower the cost and speed projects completion. Failure to understand the importance of this role can impact both the project schedule and the durability of the protection, resulting in added costs and delays many times greater than the cost of the coating itself. This paper describes the main challenges being faced regarding coatings selection & application today, and presents a surface & humidity tolerant solvent-free epoxy technology incorporating a unique combination of features to address them: reduced solvent emission, surface tolerance, application without humidity restrictions, edge-retention and compatibility with water jetting as a replacement to abrasive blasting. The description is based on both laboratory and field data. This paper will help owners and shipyards identify traps posed by underestimating the impact of the blasting & painting activities in a FPSO conversion project. It also suggests an alternative concept, using water instead of abrasive for surface preparation and a novel tolerant coating system that copes with it, arguably with advantages for the project. Data from successful laboratory prequalification tests, relevant performance testing and actual field application is presented. Observations are shared encompassing the application of over four-million square meters of steel in FPSO conversion projects. Significant field data is presented evidencing the efficiency of the application (time & costs savings) and the protection effectiveness (survey reports after years of service). The conclusion claims that this concept can improve schedules & completion predictability, environmental compliance, cost effectiveness and corrosion protection efficiency in such projects. The concept presented changes, in a unique way, the traditional way of performing blasting & painting activities. This matter is being presented in the context of FPSO conversions for the first time and its significance arises also from the abundant data that is now possible to share as solid confirmation of the advantages claimed. INTRODUCTION The inability of owners and shipyards to accurately predict schedule and cost for FPSO conversions is the largest single factor affecting the conversion market today. The concepts presented in this paper have been documented to save 15% in coating system costs (surface preparation and application included) but, more importantly, allow for much improved scheduling for FPSO project completion time lines that can be greatly affected by coating application.