Griekspoor VlamSpuitTechniek BV

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Bethanie Lindsey
5 years ago
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1 t.b.v. Technische- en economische aspecten Griekspoor VlamSpuitTechniek BV

3 Brief introduction of Griekspoor Vlamspuittechniek BV - Specialist in corrosion (incl. chemical)- and wear resistant coatings for (polluted) maritime environments - 43 year old/young family company - 24 years experience with flame sprayed coatings - 20 years experience with water projects Rijkswaterstaat - Over 10 years experience with Vlaamse Gemeenschap - Capacity: L=21meter, D=1.0meter, Weight 14,000KG

5 Plasma (High quality flamespraying)

6 HVOF (High Velocity Oxygen Fuel) (High quality flame spraying)

7 Flame spraying production sequence 1. Quality control (diameter, roughness, purity etc.) 2. Thoroughly cleaning 3. Heat up work piece (up to appr. 80 degrees centigrade) 4. Sand blast (purity Sa 3) 5. Flame spraying bond coating 6. Flame spraying topcoating 7. Grind to right diameter 8. Polish (finish) to right roughness (Ra appr. 0.3 um) 9. Quality control There s a quality check between every single production step

TOPCOAT TOPCOAT CERAMICS 1. Excellent corrosion resistance 2. Wear resistance better than chromium 3. Very good chemical resistance 4. Hard (appr.

8 TOPCOAT TOPCOAT CERAMICS 1. Excellent corrosion resistance 2. Wear resistance better than chromium 3. Very good chemical resistance 4. Hard (appr. 950HV) and a good ductility Is normally used: In maritime environments (salt water) Light/average aggressive chemical environments As an replacement for stainless steel

9 TOPCOAT ULTRA TOPCOAT ULTRA CERAMICS 1. Excellent corrosion resistance 2. Most wear resistant ceramic (better than chromium) 3. Excellent chemical resistance 4. Harder and less ductile than TOPCOAT Is normally used: Average and heavy aggressive chemical environments In maritime environments (salt water) As an replacement for stainless steel

10 TOPCOAT WCR / CCR ULTRA+ TOPCOAT ULTRA+ (Tungsten carbide) 1. Excellent corrosion resistance 2. Excellent wear resistance 50 to 100 times better than chromium 3. Fair/good chemical resistance 4. Harder than than TOPCOAT ULTRA 5. Good ductility Is normally used in: Environments where a combination off excellent corrosion resistance and wear resistance is required (dredging industry) As an replacement for stainless steel

11 Coating classification TOPCOAT Al2O3/TiO2 TOPCOAT ULTRA Cr2O3 TOPCOAT WCR Wolfraamcarbide TOPCOAT CCR Chroomcarbide Wear resistance

12 Cost Advantages Cost advantages can be divided in 3 main parts: 1. Material cost advantage a. the combination TOPCOAT /standard steel is often cheaper than lower quality coating/stainless steel. 2. Operational cost advantage (cost of ownership) a. less service- and maintance costs. b. the quality of the coating can be adjusted to the demands of the environment. 3. Delivery time cost advantage a. the delivery time of some special materials can be up to 12 months b. shorter project time.

13 Material Cost Advantage Cost optimum in relation to the rod diameter D rod >= (P coating higher Q P coating lower Q ) 2 x (P stainless P construction ) D rod = rod diameter [dm] (1 dm = 0,1m = 100mm. This for USA an UK) P coating higher Q = Price coating with higher quality [ /dm 2 ] P coating lower Q = Price coating with lower quality [ /dm 2 ] P stainless = Price material with hoge kwaliteit [ /kg] = Price material with lower quality P construction (Astimations made: 1. Specific weight steel = 8,0 kg/dm 3 2. coating length = total length of the rod. ATTENTION! Formula is when the coating length equals the total length of the rod. Almost always the coating length is shorter than the total length so the cost advantage of an coating is reached sooner than here calculated.

14 Service- and maintenance costs Direct costs of a service call Secundary costs of a service call 1. Total labour costs 1. Image damage supplier/customer 2. Replacement costs (spare parts) 2. Loss of confidence customers 3. Transport costs 3. Management costs 4. Costs because of production loss etc. 4. Stress etc. Difinition Cm-rate : mean number of service calls a year (Cm= Calls mean )

15 Service- and maintenance costs Total cost of ownership Calculated costs of Requirement: Corrosion resistance 1. Service call 400,- + replacement rod + seals ( 50,-) 2. Ni/Cr plating 5,- / dm 2 3. TOPCOAT plating 10,-/ dm 2 4. Stainless Steel 2,50 / kg 5. Standard Steel 0,75 / kg Service rates (Cm-rates) Cm Dimensions [mm] 1. SSt. + NiCr-plating 0,4 D 100 / L Standard St. + TOPCOAT 0,2 D 100 / L 1990 Initial costs Per cylinder Per set (4 cylinders) 1. SSt. + NiCr-plating 625, ,- 2. Standard St. + TOPCOAT 720, ,- 95,- 380,- Service costs (cost of ownership) 1 year Over 5 years 1. SSt. + NiCr-plating 1.720, ,- 2. Standard St. + TOPCOAT 935, , ,- Advantage TOPCOAT 5 years 3.545,-

16 Service- and maintenance costs Total cost of ownership Calculated costs of Requirement: High wear resistant 1. Service call 1.400,- + replacement rod + seals ( 250,-) 2. Ni/Cr plating 7, / dm 2 3. TOPCOAT plating 20, / dm 2 4. Stainless Steel 2,50 / kg 5. Standard Steel 0,75 / kg Service rates (Cm-rates) Cm Dimensions [mm] 1. SSt. + Ni Hard Cr-plating 2 D 240 / L Standard St. + Ultra plus+ 1 D 240 / L 4200 Initial costs Per cylinder Per set (2 cylinders) 1. SSt. + NiCr-plating Standard St. + TOPCOAT Service costs (cost of ownership) 1 year Over 5 years 1. SSt. + NiCr-plating , ,- 2. Standard St. + TOPCOAT , ,- TOPCOAT Advantage TOPCOAT 5 years ,-

17 LPM (Length Positioning Measurement system) Advantages LPM-system 1. LPM for measuring, monitoring and control 2. Long strokes possible (up to 20 meters) 3. Very reliable (and if necessary easy service and maintenance possible) 4. Dirt has scarcely any effect 5. Contact less 6. Compact 7. Accuracy 1 mm 8. Distance sensor rod appr. 0,6mm 9. Signal is ready for use 10. No sealing problems

18 SURFACE ROUGHNESS