Corrosion background
Design basis
Atmospheric zone
Splash/Tide Zone
Full immersion zone
Soil area
The marine corrosion environment is a very complex corrosion environment, where steel corrodes 400-500 times more along the coast than in the desert. Steel samples 24 meters away from the coast corrode 12 times faster than homogeneous steel samples 240 meters away from the coast.
Corrosion is one of the important factors that must be considered in the design and construction of nearshore vessels. Understanding the characteristics of corrosion in the marine environment and adopting effective protective measures, as well as ensuring the effectiveness of the anti-corrosion system through daily inspection and maintenance, is crucial for the safety and reliability of nearshore vessels.
At present, offshore vessels are operating in increasingly deep waters, larger vessels, more complex structures, and higher investments. It is imperative to carry out corrosion control on platforms in order to economically develop oil and gas and provide guarantees for production safety.
Current national standards and regulations, mandatory standard provisions, etc;
Code for Construction and Acceptance of Building Anti corrosion Engineering (GB50212-2002)
GB8923-1988 "Standard for Corrosion and Derusting Grades of Steel Surfaces before Coating"
Safety Regulations and Safety Management Rules for Painting Operations (GB6514-1995)
Quality Requirements for Anti corrosion Coatings (GB6514-1991)
Safety Regulations for Paint Operations, Paint Process Safety, and Ventilation Purification (DJ/T6931-1999)
Code for Construction and Acceptance of Industrial Equipment and Pipeline Anti corrosion Engineering (HGJ229-91)
Safety Regulations for Painting Operations - Safety of Pre treatment Processes for Painting (GB7692-87)
Noise Limits for Construction Sites (GB12523-90)
ISO9001 Quality Management System Documents
ISO14001 Environmental Management System Document
GB/T28001 Occupational Health and Safety Management System Documents
Environmental conditions: The corrosion level of atmospheric environment on building steel structures under long-term action can be determined according to Table 1.
Classification of Atmospheric Corrosivity and Typical Environmental Cases | ||||||
---|---|---|---|---|---|---|
Corrosivity level | Loss of mass and thickness per unit area(After the first year of exposure) | Typical environmental cases under warm climate conditions(For reference only) | ||||
Bottom carbon steel | zinc | outer surface | interior surface | |||
Mass loss | Thickness loss | Mass loss | Thickness loss | |||
/g·m2 | /um | /g·m2 | /um | |||
C1Low content | ≤10 | ≤1.3 | ≤0.7 | ≤0.1 | / | Heated interior of buildings with clean air, such as offices, shops, schools, and hotels |
C2 Low content | >100-200 | >1.3-25 | >0.7-5 | >0.1-0.7 | Low pollution level atmosphere, mostly in rural areas | Unheated buildings where condensation may occur (such as warehouses, gyms, etc.) |
C3 Moderate content | >200-300 | >25-50 | >5-15 | >0.7-2.1 | Urban and industrial atmospheres, moderate sulfur dioxide pollution, and low salinity coastal areas | In production plants with high temperatures and some air pollution, such as food processing plants, laundry plants, distilleries, dairy factories, etc |
C4 High content | >400-650 | >50-80 | >15-30 | >2.1-4.2 | Chemical plants, swimming pools, coastal ships, shipyards, etc salinity | Chemical plants, swimming pools, coastal ships, shipyards, etc |
C5 High | >650-1500 | >80-200 | >30-60 | >4.2-8.4 | Industrial areas with high humidity and severe weather, and coastal areas with high salinity | Buildings and areas where condensation and high pollution continue to occur and exist |
CX Extreme | >1500-5500 | >200-700 | >60-180 | >8.4-25 | Marine areas with high salinity and tropical subtropical industrial areas with extremely high humidity and aggressive atmosphere | Industrial areas with extremely high humidity and corrosive atmosphere |
Note: The loss value used to define the corrosiveness level is the same as that given in ISO9223. |
The platform structure is entirely in the atmosphere. In atmospheric regions, corrosion is caused by moisture and oxygen in the air. The atmosphere has high humidity, long hours of sunshine, and contains salt particles and salt mist. These substances accumulate on the surface of the structure to form a good liquid film, which constitutes favorable conditions for electrochemical corrosion. The corrosion suffered is several times that of land. Especially the lower part of the deck, which has been in a humid area for a long time, is the most severely corroded area in this area.
Steel structures located in the atmospheric zone are generally coated for corrosion protection. The platform deck, wharf, pipeline support, and non insulated pipelines can all use anti-corrosion structures with primer, intermediate paint, and topcoat.
Design basis | ISO12944-5:2017 Corrosion Protection of Steel Structures by Paint and Varnish Protective Paint Systems |
Current environment | CX Extreme;outer surface:Marine areas with high salinity and tropical subtropical industrial areas with extremely high humidity and aggressive atmosphere |
Design Life | VH ultra long term |
Surface Treatment | ISO 8501-1 Sa2.5:Thoroughly spray or eject rust removal. There is no visible grease, dirt, oxide scale, rust, paint coating or other attachments on the surface of the steel, and any residual traces are only slight color spots in dots or strips. |
Thoroughly spray rust removal to Sa2.5 level (ISO) 8501-1:2007), when observed without magnification, the surface should be free of visible oil, grease, and dirt, and there should be no oxide scale, rust, coating, or foreign impurities. Any residual traces of pollutants should only appear as slight color spots in the form of dots or stripes. Painting area | Steel structural components in the atmospheric zone |
coating | Type of coating | Paint name | Color | Supporting diluent | A: B supporting facilities | Film thicknessμm |
---|---|---|---|---|---|---|
Step 1 | KnkaZinc | Graphene zinc foundation make-up KnkaZinc 60 Gns | Graphite grey | Graphene specific thinner KnkaThinner 17 Gns | 34.72:3.26 | 100 |
Step 2 | KnkaCover | Epoxy micaceous iron intermediate paint KnkaCover 150 | Light gray mica iron oxide | Epoxy diluent KnkaThinner 17 | 25.2:6.8 | 160 |
Step 3 | KnkaDur | Acrylic acid Hardtop AS KnkaDur 550 | Support Ra·l and GB color matching. | Polyurethane diluent KnkaThinner 10 | 21.4:3.6 | 60 |
Amount to | 320 |
Design basis | ISO12944-5:2017 Corrosion Protection of Steel Structures by Paint and Varnish Protective Paint Systems |
Current environment | CX Extreme;outer surface:Marine areas with high salinity and tropical subtropical industrial areas with extremely high humidity and aggressive atmosphere |
Design Life | VH ultra long term |
Surface Treatment | ISO 8501-1 St2:Thoroughly removing rust by hand and power tools, the steel surface should be free of visible grease and dirt, and there should be no loosely attached oxide scales, rust, paint layers, or other attachments. |
Thoroughly spray rust removal to Sa2.5 level (ISO) 8501-1:2007), when observed without magnification, the surface should be free of visible oil, grease, and dirt, and there should be no oxide scale, rust, coating, or foreign impurities. Any residual traces of pollutants should only appear as slight color spots in the form of dots or stripes. Painting area | Steel structural components in the atmospheric zone |
coating | Type of coating | Paint name | Color | Supporting diluent | A: B supporting facilities | Film thickness |
---|---|---|---|---|---|---|
Step 1 | KnkaCover | Hot dip zinc substrate embedded parts, guardrails, and utility polesl primer KnkaCover 221 | Light gray medium light | Epoxy diluent KnkaThinner 17 | 25:5 | 120 |
Step 2 | KnkaDur | Acrylic acid Hardtop AS KnkaDur 550 | Support color matching | Polyurethane diluent KnkaThinner 10 | 21.4:3.6 | 80 |
Amount to | 200 |
The interval between dry and wet alternation of the platform under the action of tides and waves. It is the most severely corroded part in the marine environment. Due to frequent wet surfaces and contact with air, there is sufficient oxygen supply on the surface. The alternating effects of long-term wetting and short-term drying of surfaces, as well as wave erosion, impact of floating objects, and erosion by marine microorganisms, result in physical and electrochemical corrosion damage, with the greatest damage.
Steel structures in the splash zone and tidal zone are coated for corrosion protection In addition, as this area is the most difficult to implement anti-corrosion protection, it is necessary to increase the corrosion allowance.
Design basis | ISO12944-5:2017 Corrosion Protection of Steel Structures by Paint and Varnish Protective Paint Systems |
Current environment | Im4;Seawater or brackish water: Immersion structures with cathodic protection (such as offshore structures) |
Design Life | VH ultra long term |
Surface Treatment | ISO 8501-1 Sa2.5:Thoroughly spray or eject rust removal. There is no visible grease, dirt, oxide scale, rust, paint coating or other attachments on the surface of the steel, and any residual traces are only slight color spots in dots or strips. |
Thoroughly spray rust removal to Sa2.5 level (ISO) 8501-1:2007), when observed without magnification, the surface should be free of visible oil, grease, and dirt, and there should be no oxide scale, rust, coating, or foreign impurities. Any residual traces of pollutants should only appear as slight color spots in the form of dots or stripes. Painting area | Steel structures in the splash zone and tidal zone |
coating | Type of coating | Paint name | Color | Supporting diluent | A: B supporting facilities | Film thicknessμm |
---|---|---|---|---|---|---|
Step 1 | KnkaZinc | Graphene zinc foundation make-up KnkaZinc 60 Gns | Graphite grey | Graphene specific thinner KnkaThinner 17 Gns | 34.72:3.26 | 120 |
Step 2 | KnkaCover | Epoxy micaceous iron intermediate paint KnkaCover 150 | Light gray mica iron oxide | Epoxy diluent KnkaThinner 17 | 25.2:6.8 | 250 |
Step 3 | KnkaDur | Acrylic acid Hardtop AS KnkaDur 550 | Support Ra·l and GB color matching. | Polyurethane diluent KnkaThinner 10 | 21.4:3.6 | 80 |
Amount to | 450 |
The platform is located in the soil below the splash zone and above. The corrosion of steel platforms in the fully immersed zone is mainly affected by dissolved oxygen, forming electrochemical corrosion. Corrosion in shallow waters may occur more rapidly than in the ocean atmosphere, and the oxygen content in deep sea areas is often much lower than in the surface. The water temperature is close to 0 ℃, and corrosion is relatively mild.
coating | Type of coating | Paint name | Color | Supporting diluent | A: B supporting facilities | Film thicknessμm |
---|---|---|---|---|---|---|
Step 1 | KnkaZinc | Graphene zinc foundation make-up KnkaZinc 60 Gns | Graphite grey | Graphene specific thinner KnkaThinner 17 Gns | 34.72:3.26 | 120 |
Step 2 | KnkaCover | Epoxy micaceous iron intermediate paint KnkaCover 150 | Light gray mica iron oxide | Epoxy diluent KnkaThinner 17 | 25.2:6.8 | 250 |
Step 3 | KnkaDur | Acrylic acid Hardtop AS KnkaDur 550 | Support Ra·l and GB color matching. | Polyurethane diluent KnkaThinner 10 | 21.4:3.6 | 80 |
Amount to | 450 |
coating | Type of coating | Paint name | Color | Supporting diluent | A: B supporting facilities | Film thicknessμm |
---|---|---|---|---|---|---|
Step 1 | KnkaCover | Graphene glass flake primer KnkaCover 152 Gns | Black, yellow | Graphene specific thinner KnkaThinner 17 Gns | 23.3:3.7 | 400 |
Step 2 | KnkaCover | Graphene glass flake primer KnkaCover 152 Gns | Black, yellow | Graphene specific thinner KnkaThinner 17 Gns | 23.3:3.7 | 400 |
Amount to | 800 |
The platform is completely inserted into the seabed soil, and there are bacteria such as sulfate and reducing bacteria present. The sources and characteristics of seabed sediments vary. The platform in this area is less affected by seawater, with low temperature and minimal corrosion, except for some corrosion at the junction of ocean currents.
Design basis | ISO12944-5:2017 Corrosion Protection of Steel Structures by Paint and Varnish Protective Paint Systems |
Current environment | Im3;Soil: Buried storage tanks, steel piles, and steel pipes |
Design Life | VH ultra long term |
Surface Treatment | ISO 8501-1 Sa2.5:Thoroughly spray or eject rust removal. There is no visible grease, dirt, oxide scale, rust, paint coating or other attachments on the surface of the steel, and any residual traces are only slight color spots in dots or strips. |
Thoroughly spray rust removal to Sa2.5 level (ISO) 8501-1:2007), when observed without magnification, the surface should be free of visible oil, grease, and dirt, and there should be no oxide scale, rust, coating, or foreign impurities. Any residual traces of pollutants should only appear as slight color spots in the form of dots or stripes. Painting area | Steel structures in the splash zone and tidal zone |
coating | Type of coating | Paint name | Color | Supporting diluent | A: B supporting facilities | Film thicknessμm |
---|---|---|---|---|---|---|
Step 1 | KnkaCover | Graphene glass flake primer KnkaCover 152 Gns | Black, yellow | Graphene specific thinner KnkaThinner 17 Gns | 23.3:3.7 | 300 |
Step 2 | KnkaCover | Graphene glass flake primer KnkaCover 152 Gns | Black, yellow | Graphene specific thinner KnkaThinner 17 Gns | 23.3:3.7 | 300 |
Amount to | 600 |