HEAT-FLEX HI-TEMP 1200 Coating Under Insulation
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- Lucinda Davis
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1 INTRODUCTION Heat-Flex Hi-Temp 1200 is the industries next generation, single component inert multipolymetric matrix coating for use on high temperature steel up to 650ºC (1200ºF) Designed to protect insulated pipes and tanks in high temperature environments from corrosion under insulation.
2 CORROSION UNDER INSULATION
3 KEY MARKETS Refineries Oil Offshore & Gas Chemical Processing FPSO Marine FLNG Pipelines Heat stacks Recommended for high temperature applications and to protect from corrosion under insulation. Suitable for use under acidic & alkaline insulation systems. Acceptable for use on cryogenic equipment.
4 VALUE PROPOSITION FEATURE BENEFIT VALUE No adhesion loss No Blistering Increased Flexibility Greater Abrasion Resistance Harder Initial Film Faster Dry-to-Touch Faster Recoat Times Advanced Corrosion Resistance Better performance in cyclical temperature environments Enhanced Durability Less Damage During Transit Faster shop throughput Extended Life Cycle Prolongs Service Life Reduce costs & Downtime
5 PHYSICAL DATA Property Value Volume Solids % 57% VOC SED g/ltr <375 Dry film thickness range (µm) Min Max Carbon Steel or Stainless Steel : Atmospheric* Ambient or Hot Steel up to 260ºC Carbon Steel or Stainless Steel : Insulated Service Ambient or Hot Steel up to 260ºC Theoretical coverage (m 2 /l) 22.3 * Top coat may be required
6 APPLICATION Single Leg Airless Spray Brush* Roller* Surface Temp Application Conditions 10 C min. / 260 C max. *may require multiple coats to achieve maximum film thickness and uniformity of appearance Air & Material Temp RH 10 C min. / 49 C max. At least 2.8C above dew point 85% max Performance Tip: If applying an approved topcoat, apply a mist coat of the topcoat. Allow 10 minutes to flash off and follow with a full coat.
7 SURFACE PREPERATION Substrate Iron & Steel Stainless Steel Surface Prep SSPC-SP6 / Sa2 / Sa2½, 40-63µm profile, or SSPC-SP11 / St3, 40-63µm profile SSPC-SP1 / Solvent Clean Do not use chlorinated solvents for cleaning Performance Tip: Surface must be clean and dry, and in sound condition. Remove all oil, dust, dirt, grease, loose rust and other foreign material to ensure adequate adhesion.
8 DRYING SCHEDULE Drying 125m DFT 10ºC 25ºC 49ºC Touch 30 mins 20 mins 10 mins Handle 90 mins 60 mins 30 mins Recoat 3 hrs 2 hrs 1 hrs Ship 24 hrs 24 hrs 24 hrs Performance Tip: Higher film build affects cure time and will increase shipping time at lower temperatures.
9 PERFORMANCE DATA BOILING WATER TEST Scope: intended to test a coating designed for application to hot steel for resistance to heat, corrosion and thermal shock. Objective: to test a coatings ability to 1 - protect steel from corrosion under boiling water test conditions 2 - withstand severe temperature cycling for extended periods
10 PERFORMANCE DATA BOILING WATER TEST BOILING WATER TEST RESULT No Adhesion Loss No Blistering Increased Flexibility
11 PERFORMANCE DATA CUI TEST Developed by Sherwin-Williams R&D lab, based on NACE standards and rated according to ASTM D610 and ASTM D714 Scope: an accelerated test to gauge a coatings performance in a real life scenario Objective: to determine whether a coating will provide protection from corrosion under insulation (both acidic and alkaline) in cyclical temperature environment.
12 PERFORMANCE DATA CUI TEST HEAT-FLEX Hi-Temp 1200 passed with no loss of adhesion and the highest possible #10 rating for rust and blisters. CUI TEST RESULT No Adhesion Loss after 80 cycles Excellent Rating for Rust Excellent Rating for Blistering
13 CUI TEST METHOD Corrosion Under Insulation, Calcium Silicate, 6 cycles Corrosion Under Insulation, Mineral Wool, 6 cycles Competitor A Competitor B Heat-Flex Hi-Temp 1200 Control Panel Competitor A Competitor B Heat-Flex Hi-Temp 1200 Control Panel
14 PERFORMANCE DATA Substrate: Carbon Steel/Stainless Steel, 304, 316 Surface Prep: SSPC-SP10/NACE 2/Sa 2½ System Tested: µm Test Name Test Method Results Abrasion Resistance ASTM D968 Falling Sand 16.4 L/Mil* Adhesion ASTM D6677 Rating 10 Blocking Resistance ASTM D4946 Rating 10 Corrosion Under Insulation (Carbon Steel) Corrosion Under Insulation (Carbon Steel) Dry 177ºC / Wet 66ºC 12 weeks, 6 cycles (calcium silicate and mineral wood) Dry 177ºC / Wet 66ºC 12 weeks, 6 cycles (calcium silicate and mineral wood) Rating 10 per ASTM D714 for blistering; Rating 10 per ASTM D610 for rusting Rating 10 per ASTM D714 for blistering; Rating 10 per ASTM D610 for rusting
15 PERFORMANCE DATA Substrate: Carbon Steel/Stainless Steel, 304, 316 Surface Prep: SSPC-SP10/NACE 2/Sa 2½ System Tested: µm Test Name Test Method Results Direct Impact Resistance ASTM D in lb Dry Heat Resistance ASTM D ºC Exterior Durability (Carbon Steel) Flexibility 1 year at 45º South In-Process ASTM D522, 180º bend, 1/8 conical Passed Pencil Hardness ASTM D3363 2H Salt Spray (Carbon Steel) ASTM B117, 1,848 hours Rating 10 per ASTM D714 for blistering; Rating 8 per ASTM D610 for rusting
16 PRODUCT COMPARISON Feature Heat-Flex Hi-Temp 1200 Nova-Plate 325 Hi-Temp 1027 Heat Resistance 650 C 650 C Application Surface Temp 10 C C 10 C 316 C Recommended dft (µm) Theoretical 250µm dft (m 2 /l) Dry time (to 25ºC) hours 60mins 6 hrs 2 hrs To Ship* 24hrs 48 hrs (to service) 24 hrs Mix ratio n/a 2:1 n/a VS% 57% +/- 2% 100% 65% +/- 2% VOC <375 g/l 50 g/l 420 g/l Finish Low Sheen Gloss Flat Colours Gray / Dark Grey White Black, Lt/Dk Grey Flash point ( C) 31 C 94 C *Higher film build affects cure time and will increase shipping time at lower temperatures.
17 CUSTOMER TRIALS Overview Asset Criteria Process Pipeline Operating Temperature Circa 190ºC Surface Prep System Application NACE2 / SSPC-SP10 / Sa2½ 5 single pass mist coats to achieve 250µm dft Airless Spray, Graco X60 60:1 Ratio Pump
18 CUSTOMER TRIALS Conclusion The application trial of Heat-Flex Hi-Temp 1200 was successful. The customer made very favourable comments on the ease of stirring the coating, application characteristics, film forming properties and the visual appearance (dry spray and defect free).
19 SPECIFICATION GUIDE Oil & Gas System Guide Onshore & Offshore Coating Solutions
20 TYPICAL SPECIFICATION High Temperature Carbon Steel Insulated Product Heat-Flex Hi Temp 1200 Heat-Flex Hi Temp 1200 Total dft Insulated >120ºC-649ºC DFT (μm) 125μm 125μm 250μm
21 TYPICAL SPECIFICATION High Temperature Stainless Steel Insulated Product Heat-Flex Hi Temp 1200 Heat-Flex Hi Temp 1200 Total dft Insulated >120ºC-649ºC DFT (μm) 125μm 125μm 250μm
22 SALES COLLATERAL Corrosion Under Insulation The Hidden Problem By Tim Hanratty, Petrochem BDM CUI Exposures Hidden Threats Role of Protective Coatings Industry Standards
23 SALES COLLATERAL Heat-Flex Hi-Temp 1200 Product Sell Sheet Features Benefits Value Proposition
24 SALES POSITIONING Industry Next Generation CUI Extends service life Harder initial film - less damage during transport Higher flexibility - copes better with cyclical temperature environments for long term durabilty Provides corrosion protection in areas that also require heat resistance Focus on boiling water & CUI test results Ease of application / fast dry
25 SUMMARY No Adhesion Loss Increased Flexibility Harder Initial Film Faster Dry Times FEATURES BENEFITS Advanced Corrosion Resistance Enhanced Durability Faster Shop Throughput Reduced Costs Reduced Downtime Extended Lifecycle VALUE PROPOSITION
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