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1、Offshore WindpowerGordon Yeung(杨雱)2 Jun 2019 AREAS STANDARDS&TESTS PAINT SYSTEMS COST OF OFFSHORE PAINT FAILURES LIFETIME(JOB-REFERENCES)AGENDA2AREAS09.03.2019Comparing Onshore&Offshore Turbines 4Onshore turbines:Uniform exposureContact flanges metallized for abrasion protection and slip coefficient
2、 related reasonsLower parts of bottom section sometimes metallizedUniform systemsOffshore turbines:Complicated exposure:1.MIC(MP)2.Immersion(MP)3.Tidal zone(MP)4.Splash zone(TP)5.Atmospheric(Tower)Atmospheric area metallized-submerged and splash zone not soDissimilar systemsOffshore Turbine Areas5Su
3、bmerged/soil area:Fully submerged in waterBuried in soilISO 12944-2:Im 2-4Splash/tidal zone areaCyclic exposure to sea-water and atmosphereISO 12944-2:CX/Im 2*Must pass both test regimesAtmospheric area(Ext/Int):Marine atmosphereISO 12944-2:Exterior:CX(Zone 3)Interior:C4(Zone 4)Offshore Turbine Corr
4、osive Stress Categorization 6STANDARDS&TESTS09.03.2019STANDARDS-OVERVIEWTwo standards dominate offshore wind:NORSOK M-501 Edition 5&6The BAW standard:VGB-S-21-01-2016-03 These standards only serve as referenceOEMs and owners often diverge from standardsFROSIO/VGB specified test regimes are often req
5、uired thoughStandard shortcomings:NORSOK not made for windBAW only made for GermanyOther standards/guidelines exist!89Other different national guidelines,rulesDNVGL-RP-0416 Corrosion protection of offshore wind farmsoffshore wind turbines(Proposal no.2015-360)Low flame spread coating systems living
6、quarters(IMO)Anti skid coating systems deck and walk areas,escape routesMicrobial induced corrosion(ALWC-Accelerated low water corrosion)foundation structuresOffshore-Coating-Qualification-ColoursRAL 1023,Traffic yellowLight grey,mostlyRal 7035.Ral 3020Traffic red,optional,not a must Colour requirem
7、ents:IALA Recommendation E-108 on the surface colours used as visual signals on aids to navigation,05/2013Individual OEMs and countries also have their rules regarding colour10Karsten Mhlberg,December 2015PAINT SYSTEMSSpecifications:Who Decides12Towers:Generally OEMs decide(Vestas,Siemens,GE)Transit
8、ion pieces/monopiles:Generally owners decide,in consultation with TP/MP makers.Towers and TPs/MPs made by different companies,with different traditions and different ways of doing things.Systems overview:Offshore wind turbine towersAreaEnvironmentDFT rangeCoatsZinc primerNORSOK Ed 6ExteriorC5-M(CX)2
9、80-400m3-4(Sealer)All:TSZ or Epoxy zincSystem 1280m,3 coats w.epoxyzincInteriorC4200-345m2-3All:Epoxy zincISO 12944:240-32013Exterior area:Mostly 4 coat duplex systems between 320-380m.Interior area:Mostly 2 coat epoxy-zinc+epoxy systems at 240.Dehumidification during service.Compared to NORSOK Ed 6
10、:Mostly higher DFT,more coats and the majority uses duplex systems on the exterior.Severity of ISO 12944-9(2018)test scheme and long term offshore service cautions OEMs to specify conservatively.Siemens Offshore SystemsZPS 1009606:90/10 as always on offshoreExterior:C5-M High ver 1.1 or 1.2 TSM(110-
11、130)+2 x 47140/4774D(120/120)+55213/55613(50-60)Interior:C4 High Ver 1.1 17360(60)+2x 47140/4774D(100/100)So:Exterior=Duplex(TSM/2EPOX/PU)27 year track record,Interior:standard ZnEp+Ep too,track record,and need C4 for internal due to harbour storage etc.Future direction:Midcoat:4774D only Why:Better
12、 track record,more robustPrimer:1736G only,faster drying,better crack resistance Topcoat:5561B only Lower VOC,standard shadeBut:This will take time,Siemens needs a lot of time to change things due to recent mergers.Gamesa have changed to 1736G 4774D system already.Rolling out in 2019-20.14Vestas off
13、shore systemsTPS 0001-4565 V04:Exterior:TSM(60)+Sealer 4774D(20)+2 x 4774D(100/100)+5561B(70)Interior:17360/G(50)+1 4774D(190)90/10 as always on offshoreSo:Exterior=Duplex(TSM/2EPOX/PU)27 year track record,Interior:standard ZnEp+Ep too,track record,and need C4 for internal due to harbour storage etc
14、.Evaluation:vestas spec somewhat more in line with what we have learned over 27 years,thinner TSM and thicker topcoat.Former sufficient,latter needed see Vindeby.15Systems overview:Offshore transition piecesAreaEnvironmentDFT rangeCoatsTypeNORSOK Ed 6ExteriorSplash zoneIm2(Im4)600-1500m2-4Epoxies(PU
15、 topcoat)System 7a2x300mExterior SubmergedIm2(Im4)600-1500m2As above(Cathodic prot.)System 7b2X175mInteriorC4240-345m2-3Zinc epoxy+Epoxy(PU)ISO 12944-5:240-32016Exterior areas:Maker/Owner specifications generally above NORSOK requirements either in terms of system DFT or number of coats or both.Seve
16、rity of ISO ISO 12944-9(2018)test scheme and long term offshore service cautions makers to specify conservatively.Mainly High VS or solvent free immersion grade epoxies used.Only Germany uses zinc epoxy containing systems.Exterior:Move away from PU topcoats to yellow coloured epoxy topcoats.Interior
17、 areas:Interior area:Mostly 2 coat epoxy-zinc+epoxy systems at 240.(Like towers)Dehumidification during service.Systems overview:Offshore TPs&monopilesAreaEnvironmentDFT rangeCoatsTypeNORSOK Ed 6ExteriorSplash zoneIm2(Im4)600-1500m2-4Epoxies GF(PU topcoat)System 7a2x300mExterior SubmergedIm2(Im4)600
18、-1500m2As above(Cathodic prot.)System 7b2X175mInteriorAbove airtight platformC4240-345m2-3Zinc epoxy+Epoxy(PU)ISO 12944-5:240-320InteriorBelow airtight platformC4350-650m2EpoxiesSystem 7b17Exterior areas:Maker/Owner specifications generally above NORSOK requirements either in terms of system DFT or
19、number of coats or both.Mainly High VS or solvent free immersion grade epoxies used.Only Germany uses zinc epoxy containing systems.Exterior:Move away from PU topcoats to yellow coloured epoxy topcoats.Interior areas:Interior area:Mostly 2 coat epoxy-zinc+epoxy systems at 240.(As towers)Dehumidifica
20、tion during service.Underwater part of signal mast:CP protected18Example of how immersed structures are often protected by CP+corrosion allowance rather than coatings.COST OF OFFSHORE FAILURECost of offshore wind-turbine paint system failures9 March 2018Is enormous,for the following reasons Low pace
21、:All work must be done manually:No blasting and no spray painting allowedMost work must be done suspended from nacelleNo work allowed in case off strong winds(force 5)or high waves(+1 m)Weather breaks:Numerous due to bad weather Mobilized equipment and manpower must be paid continuouslyApproximate c
22、ost:Mobilization cost Thereafter 2000-5000 USD/m2Real life examplesArklow bank+3,000,000 EUR for 7 transition pieces(2010)Bard Offshore One,2011 repairs 4,960 EUR/m220Why offshore wind-turbine paint failures are expensive?9 March 2018Equipment:Ships:USD 3-5,000/Day(If available)Access platforms USD
23、500-1000/day Both ships and platforms come with specialized personnelManpower:Working at heights:GWO&IRATA 3 certificates requiredDaily salary of IRATA III personnel:USD 400-600 x plus agents fees(2-4 people needed)21Work permits:Weather dependentWave height(max 1 m)Wind velocity(max F5)Turbine shut
24、down!An ounce of prevention is worth a stone of cure 9 March 2018Preventing on-site paint system failures=Only viable optionCost of repairs prohibitiveOnshore/offshore wind turbine difference:Paint system(Duplex system)Approach to offshore painting:Quality driven,not cost/pace drivenRight first time
25、Reed out bad habits of old22LIFETIMENN09.03.2019Offshore reference:VindebyHistory:First offshore wind-park in the world,deployed in 1991Hempel provided the coatings for the wind-parkInspected by Hempel in 2017 at de-commissioning Environment:C5-M(CX)Service time:25 yearsStructure:Wind turbine towerP
26、aint system:TSM 120m+Hempadur 4523 100m+Hempadur 4520 100m+Hempathane 5521 50mCondition:Very good,despite poor application(many pinholes,sagging).Stripes of partial topcoat erosion in the direction of the prevailing winds.24Offshore reference:Vindeby2510/2017 Nyborg,DenmarkOffshore reference:Vindeby
27、 Follow up investigationRust creep at mechanical damages:Practically none prevented by TSMChloride diffusion to substrate:None,stopped at topcoat levelAdhesion:Substrate-primer adhesive break(100%):10.9 14.4 Mpa(2)Topcoat cohesive break(100%):15.5 17.9 Mpa(2)Topcoat:Erosion in prevailing wind direct
28、ion:On average 25m over just as many years.Photodegradation:Loss of colour and gloss in certain areas of maximum sunlight exposureConclusions:Duplex system performed well on the exteriorPure barrier system performed well on the inside Cannot recommend it though due to transport,storage and set-up da
29、mage they could have been lucky!TSM can be reduced:60-80m appropriateTopcoat DFT should be increased:80m appropriate 26Offshore wind-turbine painting gone sour:Hornsrev(Denmark)Environment:C5-M(CX)Service time:17 yearsStructure:Transition piecesPaint system:Hempel:2 x Hempels High Protect 35650,meas
30、ured DFT 1000-1300Competitor:2 x Epoxy,measured DFT 350-500 applied wet-in-wetCondition:Hempel(left):Very good condition,with the exception of a few areas of mechanical damage Competitor(right):TPs exhibited complete coating system failure after 1-2 years27Lessons from Hornsrev project9 March 2018Competitor breakdown characteristics:General corrosion to steelWidespread pinpoint rustingPossible causes:Application failure:Under-thickness leading to insufficient barrier protection28Close up of competitor TP Hempel on-site inspections in 2004(Left)and 2014(Right)