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Marine Coatings-Offshore Vessels

Offshore Vessels

The marine corrosive environment is a very complex corrosive environment, and the corrosion of steel on the coast is 400-500 times greater 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 offshore platforms. 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 offshore platform use.

  • Corrosion background

  • Design basis

  • Atmospheric zone

  • Splash/Tide Zone

  • Full immersion zone

  • Soil area

Anti corrosion measures for offshore vesselsAnti corrosion measures for offshore vessels

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.

Reference standards

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

Design basis

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.

Oceanic atmospheric zone

1. Corrosion environment in the marine atmospheric zone

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.

Table 1: Graphene coating technology is used for anti-corrosion of steel structures in atmospheric areas
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
Table 2: Hot dip galvanizing using graphene coating technology
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

Splash/Tide Zone

1. Corrosion environment in splash/tidal zone

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.

Table 1: Cathodic protection graphene coating technology is used for steel structures in splash and tidal zones
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

Full immersion zone

1. Corrosion environment in the fully immersed area

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.

Table 1: Graphene paint technology is used for anti-corrosion of steel structures in the fully immersed 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
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

Underwater mud area

1. Corrosion environment in the seabed soil area

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.

Table 1: Steel structures in the fully immersed and mud areas generally use cathodic protection graphene paint technology
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