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Case Study On The Failure Of Polyurea Elastomer (PU) Coating in a Sea Water Storage Tank

Picture for Case Study On The Failure Of Polyurea Elastomer (PU) Coating in a Sea Water Storage Tank
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Protective coatings are widely used for shielding metal surfaces against service-induced degradations. Immersion-grade coatings protect the metal surfaces by hindering the interaction of steel (i.e., substrate) with service thereby providing corrosion and even abrasion resistance. Coatings nowadays are the most efficient method to shield metals and thus has been widely engaged among various protective techniques.

Product Number: 51323-19160-SG
Author: Ahmad Raza Khan Rana, George Jarjoura, Syed Umair Niaz Bukhari
Publication Date: 2023
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$20.00
$20.00

Coating system of a seawater storage tank failed during service at the humid south gulf coastline. The failure occurred during the summer of 2022 after only 14 months of service. The tank had an acknowledged life expectancy of 15 years. An investigation team was deployed to investigate the root causes of the coating failure. In this case study, a comprehensive investigation was conducted to discover the reasons behind the premature failure of the sprayed PU (polyurea) elastomer coating on a water storage tank during a turnkey project in the Arabian Gulf region. Visual inspections alongside longitudinal seams of shell courses revealed rust stains as well as blistering and delamination. DFT (Dry film thickness) checks revealed thickness variations beyond specified limits. Pull-off adhesion tests on the as-applied coating revealed inter-layer (i.e., cohesive) failure. In addition, the holiday checks revealed pin-holes near longitudinal weld seams. On the other hand, the FTIR (Fourier-transform infrared) spectrum of the applied coating was found in close resemblance with the polyurethane spectrum. Whereas, the water resistance test did not reveal significant deformation. The failure mechanism leading to the in-service failure of the applied coating is explained.

Coating system of a seawater storage tank failed during service at the humid south gulf coastline. The failure occurred during the summer of 2022 after only 14 months of service. The tank had an acknowledged life expectancy of 15 years. An investigation team was deployed to investigate the root causes of the coating failure. In this case study, a comprehensive investigation was conducted to discover the reasons behind the premature failure of the sprayed PU (polyurea) elastomer coating on a water storage tank during a turnkey project in the Arabian Gulf region. Visual inspections alongside longitudinal seams of shell courses revealed rust stains as well as blistering and delamination. DFT (Dry film thickness) checks revealed thickness variations beyond specified limits. Pull-off adhesion tests on the as-applied coating revealed inter-layer (i.e., cohesive) failure. In addition, the holiday checks revealed pin-holes near longitudinal weld seams. On the other hand, the FTIR (Fourier-transform infrared) spectrum of the applied coating was found in close resemblance with the polyurethane spectrum. Whereas, the water resistance test did not reveal significant deformation. The failure mechanism leading to the in-service failure of the applied coating is explained.

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Evaluation of the Effect of Welding Process on the Performance of an Inorganic Industrial Coating for Soil-side Application of Above Ground Storage Tank Bottoms

Product Number: 51323-19186-SG
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Protection of aboveground water storage tank bottom plates against soil side corrosion is an important concern for the oil and gas industry, particularly when considering long-term continuous operation requirements for these assets. Corrosion of the tank bottom plates is mainly due to the formation of galvanic corrosion cells on the soil side. This galvanic corrosion cell formation is more pronounced if the tank content is stored at elevated temperature and/or located in aggressive soil.
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Product Number: 51323-19193-SG
Author: Ahmad Raza Khan Rana, George Jarjoura, Syed Umair Niaz Bukhari
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A remarkable amount of financial loss is incurred every year because of premature failures of paints and coatings. The budget to repair such failures extremely outweighs the initial cost of coatings, since excessive engineering may be looked-for to access the deteriorating areas of a coating system. Additional accountability may also be anticipated if a facility stops operation for the essential repairs to be made.
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09022 How Not to Perform a Failure Analysis

Product Number: 51300-09022-SG
ISBN: 09022 2009 CP
Author: Mark S. Schilling and Randy Nixon
Publication Date: 2009
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This paper discusses a classic example where the facts surrounding the failure of a lining system were ignored and undue reliance was placed on laboratory analysis. This “blind faith” in analytical data without a sound causal theory caused the failure analysts to disregard or overlook the obvious.
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