Resimac Ltd. Engineered Polymer Solutions

Transcription

1 Resimac Ltd Engineered Polymer Solutions

2 Resimac overview WHAT WE DO. REPAIR Metallic surfaces subject to abrasion, wear and corrosion PROTECT Metallic components, equipment and structures subject to erosion, corrosion and chemical attack UPGRADE The performance of metallic components and equipment FULL RANGE OF PRODUCTS COVER - Metal Repair - Ceramic enhanced coatings for abrasion and wear environment - High temperature protective coatings - Thermal Insulation coatings - Chemical protective coatings - Anti corrosion coatings - Waterproofing and roof coatings

3 Resimac customers worldwide

4 Resichem 530 HA100 Fluid epoxy Pipe coating systems on the market Stand alone corrosion coating Being tested as a replacement for FBE Tested and applied as part of a flame sprayed system Being tested as part of a 3 Layer system

5 Resichem 530 HA100 Fluid epoxy Product characteristics. Single pack heat activated epoxy novalac Activated at temperatures in excess of 100 C Applied by spray to hot surfaces - Pipework, process vessels, reactors etc Dry temperature resistance of 240 C Chemical composition of the product. Low functionality epoxy novalac, 2.15 Polyamine curatives blended with the novalac Hazard Class 8 Application details Apply to mechanically abraded, hydroblasted or abrasive blast surfaces 2 x 250microns (10mil) is the system recommendation Applied by airless spray, product heated to 70 C Typical equipment GRACO EXTREME, 3000psi pressure +

6 Resichem 530 HA100 Fluid epoxy Test Data. (In house) Corrosion Resistance Tested to ASTM B117 Minimum 1000 hours salt spray resistance. Cure Times Cure times are dependent on the cure temperature as indicated in the table below. Temp Touch dry Light loading 100 C 50 mins 2 hours 110 C 35 mins 70 mins 120 C 25 mins 50 mins 130 C 15 mins 30 mins 140 C 7 mins 15 mins 150 C 3 mins 7 mins Adhesion Tensile Shear to ASTM D1002 on abrasive blasted mild steel with 75 micron profile and cured at 120 C. 197 kg/cm² (2800 psi) Hardness Shore D to ASTM D C C C C 72 Mechanical Properties Adhesion Tensile Shear to ASTM D1002 on abrasive blasted mild steel with 75 micron profile and cured at 120 C. 197 kg/cm² (2800 psi)

7 Resichem 530 HA100 Fluid epoxy Test Data. (Doosan Babcock/ Chevron Chevron Texaco looking at HA100 for subsea pipeline, high temp riser protection Product applied on site at DOOSAN BABCOCK in prep for bend tests 2 x 350 microns applied, cured at 150 C PREPARED SURFACE SA2.5 HEATED TO 100 C APPLIED 1 st COAT 300MIC APPLIED 2 nd COAT 300MIC HEATED TO 100 C JACKED TO GET 150 C

8 Resichem 530 HA100 Fluid epoxy Test Data. (Doosan Babcock) Product tested on test rig, PASSED bend test set at 20%

9 Resichem 530 HA100 Fluid epoxy Test Data. (Doosan Babcock) Follow on testing approved by Chevron Samples at ELEMENT product passed all tests Cathodic disbondment testing 28 days - 20 C, ISO Peel test ISO 21809, Water Immersion Test

10 Resichem 530 HA100 Fluid epoxy Test Data. Plascoat Systems Corrib Pipeline - Shell On site trial performed by COATSOL System used is HA100 with flame sprayed PP from PLASCOAT HA100 used as the primer layer PP Flock sprayed onto wet film Heated to 150 C to cure HA100 and to fuse the PP Cathodic Disbondment test performed at PLASCOAT Labs Test Results Test Sample Required Performance Test Result Sample 1 7 mm <1 mm Sample 2 7 mm <1 mm Sample 3 7 mm <1 mm Conclusion When tested in accordance with ISO21809 Part 1, Resimac HA100 has been found to have an average radius of Cathodic Disbondment of <1mm. This result exceeds the requirements for the standard.

11 Resichem 530 HA100 Fluid epoxy Test Data. Plascoat Systems Corrib Pipeline - Shell Photos of CD testing for Corrib Pipeline

12 Resichem 530 HA100 Fluid epoxy Test Data. Plascoat Systems Corrib Pipeline - Shell Cathodic Disbondment C CAN/CSA-Z <5mm radial Adhesion after hot water soak C CAN/CSA-Z Class 1 Peel 23 C (over Novalac) ISO : Annex D >12 N/mm Peel 90 C (over Novalac) ISO : Annex D >5 N/mm 25 C ASTM D-2240 Shore D >60 0 C CAN/CSA-Z No 3 C PDD Impact 23 C DIN >20 Joules Tensile Elongation (at break) of 25 C (after flame spraying) ASTM D % Taber Abrasion topcoat ASTM D-4060/84, H18 500Gm load 1000 cycles 55 mg weight loss

13 Resichem 530 HA100 Fluid epoxy Field Qualification. Plascoat Systems Coatsol South America On site trial performed by COATSOL System used is HA100 with flame sprayed PP from PLASCOAT HA100 used as the primer layer PP Flock sprayed onto wet film Heated to 150 C to cure HA100 and to fuse the PP Cathodic Disbondment test being performed at PLASCOAT Labs

14 Resichem 530 HA100 Fluid epoxy Test Data. BSR Ramco External Pipecoating Pipe coating mill looking to use HA100/ HA80 as external pipe coating Use as part of a 3 layer system PP Use as a primer for insulation Seawater Immersion Test in accordance with ISO using the method described in ISO (to include full test report). Two versions of the product to be tested. Details to be discussed: HA70 HA100 Please note that if a document/test is not referenced in this offer then it is not applicable to Tata Steel s scope of work and will not be a contractual requirement of any Order placed.

15 Resichem 530 HA100 Fluid epoxy Advantages over existing coating systems Single pack heat activated epoxy novalac High temperature resistance up to 240 C Compatible with a range of existing 2/3 layer systems Excellent CD resistance Simple to apply for pipe mills of in field coating High build coating, microns per coat Fast curing at elevated temperatures Based on existing epoxy coating technology Cured coating has good flexibility on blast cleaned surfaces Will fuse with 3 layer systems for increased inter layer adhesion

16 HSE GUIDANCE FACTS AND FIGURES HSE GUIDELINES METAL Surfaces above 60 C must be protected Approximately 1.5% of all reported incidents concerned thermal burns Median days off was 4 By law employers are required to protect employees and ensure there safety BURNS AND SCALDS At 44 C it takes up to 6 hours to get a 1 st degree burn At 60 C it takes less than 6 seconds At 100 C it takes less than a second AREA ALSO COVERED BY ASTM C

17 ADVANTAGES AND DISADVANTAGES OF EXISTING SYSTEMS MINERAL WOOL INSULATION

18 ALTERNATIVE SYSTEMS AVAILABLE ON THE MARKET WATER BASED THIN FILM COATINGS Acrylic technology Water Based Thin film coverage microns per coat Based on glass bead technology Proven track record in industry 55 shore hardness Multi coat systems approx 8-10 coats to achieve protection Restricted by weather conditions on outside applications 10 C - 30 C EPOXY HIGH BUILD COATINGS Based on proven epoxy technology Solvent free 100% solids High build system 0.5mm 1mm per coat Based on innovative filler technology New to industry 18 months track record Suitable up to 160 C Good corrosion resistance Can be applied to damp, cold surfaces (condensation) Can be applied to hot surfaces up to 120 C

19 Resimac High Temperature Coatings 561 Thermal Barrier 561 THERMAL BARRIER product features Two pack epoxy system Standard Bis A/F resin Lightweight Solvent free 100% solids Reduces surface temperature of metallic surfaces Reduces heat loss by up to 40% 561 THERMAL BARRIER application features Applied by Standard airless spray Applied in 5 coats up to 1mm per coat Can be applied to surfaces up to 110C Manual surface prep, hydroblast, abrasive blast clean Slump resistant upto 3mm in a single coat

20 HOW DO INSULATION COATINGS WORK? THERMAL CONDUCTIVITY OF MATERIALS k value Carbon Steel Mineral wool Water based Epoxy based 43 W/mK 0.04 W/mK 0.15 W/mK 0.10 W/mK Definitions.. K-value thickness matters because the thicker something is, the slower heat will pass through it. The thermal conductivity is a measure of how easily heat passes through the material and is called the k- value. k-value is measured in W/mK. Thermal conductivity is an inherent property of a material, like stiffness or density HEAT LOSS OF MATERIALS u value Carbon Steel Mineral wool Water based Epoxy based 8600 W/m²K 8.0 W/m²K 30.0 W/m²K 20.0 W/m²K BASED ON 50MM OF ROCKWOOL, 5MM THICKNESS OF CARBON STEEL, WATER BASED AND EPOXY BASED COATINGS. U-value is measured in W/m2K that is, Watts per square metre per degree Kelvin (1 degree Kelvin is the same as 1 degree Centigrade, but with a different zero). So if a wall has a U-value of 1.0, then 1 m2 of wall will let 1 Watt pass through it when there is a temperature difference of 1 degree between the inside and outside.

21 WHAT THIS EQUATES TO IN SURFACE TEMPERATURE REDUCTION USING STANDARD DEFINITIONS AND TESTING EQUIPMENT Based on the graph, if you apply 5mm of epoxy high build the temperature will be reduced from 118 C to 60 C * Blue line on the graph

22 Test No: Plate No: Material thickness (mm) Resimac High Temperature Coatings 561 Thermal Barrier 561 THERMAL BARRIER testing Independently tested by Gearing Scientific Conforms to ISO 8301 Proven to reduce surface temperature Proven to have insulating qualities Reduces heat loss by 40% compared to bare steel pipe Lower temperature set (C ) Actual Temperature Recorded (C ) Lambda C Mean Steel Plate Temperature (C ) r r r

23 Resimac High Temperature Coatings 561 Thermal Barrier 95 C Evaporator All surfaces mechanically abraded Filler allowed to cure for 15 minutes Thin film of 561 thermal barrier applied to all surfaces Approx DFT ranging from microns Coating allowed to cure off for 2 hours

24 Resimac High Temperature Coatings 561 Thermal Barrier 95 C Evaporator 2 nd coat of material applied at 500 microns on to all surfaces Surface of the evaporator can be touched with out fear of burns Surface after 2 nd coat at 500 microns Surface after 1 st coat at microns

25 Resimac High Temperature Coatings 561 Thermal Barrier Surface after 3 rd coat at 750 microns Surface after 4 th coat at 750 microns Final finish on the surface of the evaporator 95 C Evaporator 3 rd coat of material applied at 750 microns on to all surfaces Surface heat so reduced thicker WFT of material can be applied 1 st coat microns 2 nd coat 500 microns 3 rd coat 750 microns 4 th coat 750 microns Photo highlighting the WFT on 3 rd and 4 th coats

26 Resimac High Temperature Coatings 561 Thermal Barrier 95 C Evaporator DOES IT WORK???????????? JOB COMPLETED CUSTOMER HAPPY NEW ORDER FOR 7 X EVAPORATORS ON SITE WORK COMMENCES MAY 2014

27 HIGH BUILD EPOXY APPLICATIONS Pipework at 160 C Surface manually prepared using coarse sandpaper Material brush applied in 5 coats Surface touch temperature reduced to 59 C

28 HIGH BUILD EPOXY APPLICATIONS US Chemical plant Pipe T s in areas where operators work coated in thermal barrier Surfaces abrasive blast cleaned and coated in workshop in a controlled environment Touch up finished in situ at 90 C Coating used as standard on site

29 UK based manufacture Research and Development Export to 32 countries worldwide High level of technical expertise On site technical support and back up