Coating Performance Standard A Review PCE - PSPC Workshop Amsterdam February 2007 Session 1

Objectives To provide an overview of the IMO Coating Performance Standard for Water Ballast Tanks To identify opportunities for –FP7 Projects –Business due to the requirements of the standard

Objective 1 To provide an overview of the IMO Coating Performance Standard for Water Ballast Tanks …..but first we should look at who does what now…… The Parties involved

The Parties Involved In all new building contracts today for building and painting a ship the parties involved are:

The Parties Involved In all new building contracts today for building and painting a ship the parties involved are: –Ship-owner –Shipyard + Painting Contractor –Coating Manufacturer

The Parties Involved In all new building contracts today for building and painting a ship the parties involved are: –Ship-owner –Shipyard + Painting Contractor –Coating Manufacturer What does each party expect?

The Parties Involved Ship-owner :

The Parties Involved Ship-owner : –A vessel built to specification at an agreed price and delivered at the agreed time –Coatings to last as long as possible

The Parties Involved Shipyard :

The Parties Involved Shipyard : –To build and deliver vessels at the agreed price and time making maximum use of its assets –To make a profit in doing so ( in most cases!) –The painting contractor is also wanting to make a profit –Coatings to last at least 12 months…..!!??

The Parties Involved Coating Manufacturer :

The Parties Involved Coating Manufacturer : –To supply coatings to the shipyard for use on the vessel that will be applied to an agreed specification and give the desired performance –Make a profit –Obtain repeat business after the vessel has been delivered via dry-dock supply, sea stores etc

The Parties Involved Do all the expectations match?

The Parties Involved ProductivityPerformance ShipyardShip-owner

The Parties Involved At the contract stage all parties agree to the painting specification which covers: The Coating System Surface Preparation Environmental Conditions Drying/curing/overcoating Times Inspection Requirements + ?

The Parties Involved At the contract stage all parties agree to the painting specification which covers: The Coating System Surface Preparation Environmental Conditions Drying/curing/over-coating Times Inspection Requirements + A Guarantee

The Parties Involved The Performance Standard for protective Coatings (PSPC) covers all of these aspects (except guarantee but has a target life of the system of 15 years) –So why the need for the PSPC?

The Parties Involved The specification is in many ways a compromise: –It has to meet with the yards building procedures and productivity requirements –The shipyard is the customer of the coating manufacturers and they have to be competitive on standards as well as price The PSPC is in effect making the compromise redundant

The Parties Involved Roles and Responsibilities

The Parties Involved Roles and Responsibilities –Ship-owner Verifying that the agreed specification is met. This usually means spot checks during the process or delegating the responsibility of all inspections to a ‘paint consultant’

The Parties Involved Roles and Responsibilities –Shipyard

The Parties Involved Roles and Responsibilities –Shipyard Carrying out the specification and ensuring the standards are met - usually via the QC department

The Parties Involved Roles and Responsibilities –Coating Manufacturer

The Parties Involved Roles and Responsibilities –Coating Manufacturer: Supplying paint of the required quality Giving advice when needed - NOT Supervision of the work Verifying that the specification is being met which is important especially from a guarantee perspective

The Parties Involved Guarantee: –Who gives it/them and to whom? –Against what? –Duration

The Parties Involved Guarantee: –The coating supplier gives a guarantee to the shipyard for 12 months –The coating supplier may also give a further guarantee to the ship- owner of up to, typically, another (max) 4 years

The Parties Involved Guarantee: –The shipyard gives a guarantee to the ship-owner for, usually, 12 months –The shipyard undertakes to correct any fault at their cost in that 12 months but will seek to recover any significant costs from the coating supplier

The Parties Involved Guarantee terms: –Guarantees are normally against visible corrosion –They may also include a guarantee against blistering –They may only reimburse the costs of the coating - ‘paint only guarantees’ –They may include labour to effect the repair - ‘paint and labour guarantees’

The Parties Involved Guarantee –The cost of repairing a ballast tank is ~ US$60 per square metre –The price of paint supplied for repair is ~ 10% of the total Consequently anything that improves standards in the ballast tank coating process is welcomed by the coating manufacturer!

The Parties Involved Guarantee ……So will anyone give a guarantee beyond 5 years for a system with a target life of 15 years…?

The Parties Involved …… how will the Performance Standard for Protective Coatings alter what happens today….?

Coating Performance Standard Review What is the proposed Coating Performance Standard ? What are its aims ? When will it enter force and who will it affect? What are the main opportunities ?

Coating Performance Standard Review The Performance Standard for Protective Coatings (PSPC) provides the technical requirements for protective coatings in dedicated sea water ballast tanks of all types of ships of 500 gt and greater and double sided skin spaces on bulk carriers of 150m and greater in length. It will be mandatory and is intended to be included as amendments to SOLAS regs II-1/3-2 and XII/6 It is also recommended to be applied where possible to items, not integral to the structure e.g. ladders, platforms

Coating Performance Standard Review Solas II-1/3-2 currently requires seawater ballast tanks to be coated at new building and is mandatory. It does not specify details of the coating, inspection, etc. [Non-mandatory guidelines for the selection, application and maintenance of corrosion prevention systems are contained in Resolution A.798(19)] Solas XII/6-3 extends the above to seawater ballast tanks and double skin spaces of bulk carriers of 150m in length and greater (entered into force July 2006) and refers to performance standards to be adopted in future

Coating Performance Standard Review Aims of the PSPC –to provide a 15 year life for ballast tank coatings over which it is defined as in being ‘good’ condition. –‘Good’ condition is defined in resolution A.744(18) and is “ minor rust spotting affecting < 3% and < 20% of welds and edges” –Better coating systems with reduced maintenance –Improved safety at sea

Coating Performance Standard Review Aims of the PSPC

Coating Performance Standard Review Aims of the PSPC

Coating Performance Standard Review Aims of the PSPC

Coating Performance Standard Review Aims of the PSPC –Further work is underway to develop a draft standard for: Void spaces of all ships Cargo tanks of oil tankers Guidelines for maintenance and repair for protective coatings Standards for protection of permanent means of access - not part of structural strength elements

Coating Performance Standard Review Entry into force

Coating Performance Standard Review Entry into force –The proposals were adopted at the Marine Safety Committee (82) meeting on December 8th 2006 in Turkey

Coating Performance Standard Review Entry into force The proposals will apply to the aforementioned types of vessels: –For which the building contract is placed on or after 1st July 2008, or –In the absence of a building contract, the keels of which are laid or which are at a similar stage of construction on or after 1st January 2009, or –The delivery of which is on or after 1st July 2012

Coating Performance Standard Review Entry into force However IACS are applying the proposals on ratification to tankers and bulkers under the Common Structural Rules (CSR) from December 8 th 2006 It is expected that the first new building classed under the above rules will begin building in the second half of 2007

Coating Performance Standard Review Affected Parties

Coating Performance Standard Review Affected Parties –Ship-owners/operators of all vessels > 500 gt and bulkers in the prescribed size range –New building shipyards/contractors –Coating manufacturers –Administration or Recognised Organisations

Coating Performance Standard Review Ship-owners/operators of tankers and bulkers in the prescribed size range: –It is expected that new building prices will increase by up to 10% –Increased documentation to be on board in the form of a Coating Technical File (CTF) which will, in future, also record maintenance carried out but… –Reduced maintenance and through life costs should be a benefit

Coating Performance Standard Review New building Shipyards: –Construction times are likely to increase with potential associated drop in productivity –Increased manpower may be required with increased inspection times likely –Possible investment in new facilities? –Extra training for QC staff to appropriate standard (Frosio level III (red), NACE II or equivalent) –Yards are responsible for the production of the CTF

Coating Performance Standard Review New building Shipyards: –Today the surface preparation and coating process is considered by most shipyards as a ‘bottleneck’ in the process –The coating of a block can take ~ 5+ days during which the block is effectively ‘dead’ –The ballast coatings may only be 2 coats but an antifouling scheme may consist of up to 6 coats

Coating Performance Standard Review New building Shipyards: –Steel Preparation –Inspect –Surface Preparation –Clean –Inspect –Coat –Inspect –Stripe –Coat –Stripe –Inspect The time to carry out this work may increase

The Parties Involved Productivity Performance ShipyardShip-owner You?

Coating Performance Standard Review Coating Manufacturers: –Obtaining approval of coatings – including over various shop primers –Preparation of new data sheets –Training of technical teams to appropriate standard –Possible increase in staff levels - higher costs?

Coating Performance Standard Review Recognised Organisation or Administration –Auditing of the standard and verification of compliance –Training of surveyors in the PSPC

Coating Performance Standard Review Main Elements of the PSPC:

Coating Performance Standard Review Main Elements of the PSPC: –Design of a specification and coating system –Coating System approval –Definition of inspection procedures –Production of a Coating Technical File (CTF) which records all aspects of the process –Verification of compliance

Coating Performance Standard Review Definition of inspection procedures: –Qualification required for inspectors (Frosio level III (red), NACE Level II or equivalent) –Stages of the process when inspection and/or monitoring is required –Recording of inspection details

Coating Performance Standard Review Production of a Coating Technical File (CTF) which records all aspects of the process and will contain: –Statement of compliance or Type approval of coating –Documented performance records of the coating and criteria for selection –Specification –Technical data sheet supplying all data needed –Shipyard work ( and owner) records - location, times, surface preparation, environmental conditions etc –Inspection procedures and repair of coating during construction (and also in-service maintenance) –Coating log issued by the coating inspector –Shipyards inspection report

Coating Performance Standard Review Verification of compliance to confirm : –Data sheet and Statement of Compliance certificate of coating or type approval certificate complies with PSPC –Coating supplied is consistent with above –Inspectors are qualified –Reports of the surface preparation / application process are compliant with data sheet and certificate of type approval/statement of compliance –Monitoring of implementation of inspection requirements –CTF

Objectives To provide an overview of the IMO Coating Performance Standard for Water Ballast Tanks To identify opportunities for –FP7 Projects –Business due to the requirements of the standard