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Coating degradation on Army ground systems represents a significant maintenance cost and effort. The objective of this proposed work is to develop a predictive model for coating degradation and subsequent substrate corrosion on Army ground assets. Provided with a better understanding of the root causes, steps can be taken to reduce corrosion impacts on Army materiel.
The research describes the effort to develop a predictive model for coating degradation and substrate corrosion on Army assets. The model incorporates the learning from field surveys of over 15,000 assets and 250,000 components; coating performance in standardized testing; and observations of coating condition as-applied to fielded items. The model outputs would provide a basis to (1) support a Commodity Manager to determine repaint intervals, optimizing expenditures and (2) develop new products / processes (impacting coating performance) increasing life of an asset protective coating system.
When it comes to a bridge structure with a serviceable Organic Zinc / Epoxy / Urethane (OZ/E/U) coating system, there is no golden answer on the most cost-effective maintenance painting strategy. Depending on the severity and amount of corrosion and coating breakdown on the structure, planned maintenance surface preparations range from spot power tool cleaning and spot painting to a full SSPC-SP 10 media blast and full recoating operation.
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External corrosion on offshore O&G platforms is one of the biggest threats to asset integrity and its management is a large operational expense. Many operators now implement risk-based assessment (RBA) programs where all equipment is assessed periodically with the aim to reduce operational costs while maintaining integrity. Regulatory codes for offshore platforms in the GoM require a visual inspection of all pressure equipment and piping every five-years. In practice, this can equate to approximately 20% of equipment being inspected per year on a large-sized offshore platform (i.e., a topside weight of around 10,000 tons), with a rolling five-year inspection plan to balance the inspection workload evenly through time.
Oil and gas production in a CO2 saturated environment is known to lead to corrosion due to dissolved carbonic acid. However, when the conditions are favorable, a protective FeCO3 layer can also form which reduces the material degradation of the underlying steel by up to ten or a hundred times.1 The formation of FeCO3 is possible via the reaction shown in equation 1.