1、 Guidance Notes on Maintenance and Repair of Protective Coatings GUIDANCE NOTES ON MAINTENANCE AND REPAIR OF PROTECTIVE COATINGS MAY 2017 American Bureau of Shipping Incorporated by Act of Legislature of the State of New York 1862 2017 American Bureau of Shipping. All rights reserved. ABS Plaza 1685
2、5 Northchase Drive Houston, TX 77060 USA Foreword Foreword A protective coating is the most efficient way to preserve steel structural strength. However, coatings will deteriorate over time during service. In order to maximize service life with reduced life-cycle cost, it is critical to maintain and
3、 repair the coating at an early stage, before accelerated corrosion due to coating deterioration occurs. It is a regulatory requirement for ships to comply with the IMO Performance Standards of Protective Coatings (IMO PSPC) for the goal, as a minimum, of 15 years of useful coating life in “GOOD” co
4、ndition. These Guidance Notes provide guidelines of coating maintenance and restoration of ballast tanks and cargo oil tanks in order to reach the PSPC goal as a minimum. IMO Performance Standards of Protective Coatings (IMO resolutions MSC.215(82) and MSC.288(87), hereinafter referred to as “IMO PS
5、PC”) set out coating standards for new construction of seawater ballast tanks and crude oil tanks. The coatings applied in accordance with those PSPC standards are expected to have a target useful coating life of 15 years, over which time the coating system is intended to remain in “GOOD” condition.
6、 However, the actual useful life will vary, depending on numerous variables including actual conditions encountered in service. The existing ABS Guidance Notes on the Application and Inspection of Marine Coating Systems published in January 2017 were developed to help the shipyards implementation of
7、 adopted IMO PSPCs for dedicated seawater ballast tanks and crude oil tanks during new constructions. These newly developed ABS Guidance Notes on Maintenance and Repair of Protective Coatings cover recommendations on maintenance and repairs of the PSPC coatings in service, which help the ABS Surveyo
8、rs, the shipyards, and ship operators assess the coating in-service maintenance and repairs. ABS Nautical Systems has been integrated with ships Hull Manager to assist ship operators to assess and monitor the in-service coating conditions to meet the requirement of the ABS HIMP Notation issued. This
9、 guidance is in line with Hull Manager of ABS Nautical Systems. The purpose of these Guidance Notes is to assist Surveyors, shipowners, ship managers, shipyards, flag Administrations, and other interested parties in maintaining the PSPC-related certification for compliance with PSPCs in relation to
10、coating condition assessment, maintenance, and repair of protective coatings of seawater ballast tanks and crude oil cargo tanks. These Guidance Notes become effective on the first day of the month of publication. Users are advised to check periodically on the ABS website www.eagle.org to verify tha
11、t this version of these Guidance Notes is the most current. We welcome your feedback. Comments or suggestions can be sent electronically by email to rsdeagle.org. Terms of Use The information presented herein is intended solely to assist the reader in the methodologies and/or techniques discussed. T
12、hese Guidance Notes do not and cannot replace the analysis and/or advice of a qualified professional. It is the responsibility of the reader to perform their own assessment and obtain professional advice. Information contained herein is considered to be pertinent at the time of publication, but may
13、be invalidated as a result of subsequent legislations, regulations, standards, methods, and/or more updated information and the reader assumes full responsibility for compliance. This publication may not be copied or redistributed in part or in whole without prior written consent from ABS. ii ABSGUI
14、DANCE NOTES ON MAINTENANCE AND REPAIR OF PROTECTIVE COATINGS .2017 Table of Contents GUIDANCE NOTES ON MAINTENANCE AND REPAIR OF PROTECTIVE COATINGS CONTENTS SECTION 1 General 1 1 Background . 1 3 Scope and Application 1 SECTION 2 Definitions . 2 1 Maintenance . 2 3 Repair 2 5 Coating Conditions 2 7
15、 Areas under Consideration and Critical Structural Areas . 4 TABLE 1 “GOOD”, “FAIR”, and “POOR” Coating Conditions 3 TABLE 2 Inspection Grading Criteria for the ABS Hull Inspection and Maintenance Program (HIMP) 3 SECTION 3 Areas under Consideration . 5 1 General . 5 3 Coated Areas of Crude Oil Carg
16、o Tanks in Oil Tankers . 5 3.1 Minimum Areas Coated . 5 3.3 Deck Head with Upper Transverses and Longitudinal Bulkheads 6 3.5 Bottom Plating with Lower Transverse and Longitudinal Bulkheads 6 3.7 Transverse Bulkheads (Upper Forward and Aft) . 6 3.9 Swash Bulkheads 6 3.11 Stringers 6 5 Coated Areas o
17、f Ballast Tanks in Oil Tankers 7 5.1 Typical Zones 7 5.3 Single Hull Tanker Wing Ballast Tanks. 7 5.5 Double Hull Tanker Double Bottom Ballast Tank . 9 5.7 Double Hull tanker Double Hull Side Ballast Tank 9 5.9 Fore Peak Tanks . 10 5.11 After Peak Tanks . 10 ABSGUIDANCE NOTES ON MAINTENANCE AND REPA
18、IR OF PROTECTIVE COATINGS .2017 iii 7 Coated Areas of Ballast Tanks in Vessels other than Oil Tankers . 10 7.1 General 10 7.3 Topside Tanks . 11 7.5 Hopper Tanks 11 7.7 Double Bottom Tanks 12 7.9 Side Tanks . 12 7.11 Fore Peak Tanks . 12 7.13 After Peak Tanks . 12 9 Critical Structural Areas 13 9.1
19、General 13 9.3 Critical Areas in a Double Hull Tanker . 13 9.5 Critical Areas in a Single Hull Tanker 14 9.7 Typical Critical Areas in a Topside Tank 15 9.9 Typical Critical Areas in a Cargo Hold . 15 TABLE 1 Areas for Ballast Tanks other than Double Bottom . 10 FIGURE 1 Minimum Coated Areas of Typi
20、cal VLCC Tanks 6 FIGURE 2 Typical Zones for a Tank 7 FIGURE 3 Areas under Consideration for a Wing Ballast Tanks of a Single Hull Tanker . 8 FIGURE 4 Areas under Consideration for Ballast Tanks of a Double Hull Tanker 9 FIGURE 5 Areas under Consideration for a Fore Peak Tank and an Aft Peak Tank 10
21、FIGURE 6 Topside Tanks . 11 FIGURE 7 Hopper Tanks 12 FIGURE 8 Typical Critical Areas in a Double Hull Tanker . 13 FIGURE 9 Typical Critical Areas in a Single Hull Tanker . 14 FIGURE 10 Typical Critical Areas in a Topside Tank 15 FIGURE 11 Typical Critical Areas in a Cargo Hold 15 SECTION 4 Survey Re
22、commendation 16 1 Scope 16 3 Cargo Tank Entry 16 5 In-service Condition Monitoring 16 7 Frequency of Inspections 17 TABLE 1 Survey Frequency for Ballast Tanks and Combined Cargo/Ballast Tanks in the Various Previous Survey Conditions for Single and Double Skin Bulk Carriers 17 TABLE 2 Survey Frequen
23、cy for Ballast Tanks for Double and Non-Double Hull Tankers ESP and Chemical Carriers ESP . 18 TABLE 3 Survey Frequency of Cargo Holds in Bulk Carriers 18 FIGURE 1 Single Side Skin Bulk Carrier Typical Areas in Way of Cargo Holds Required to be Coated . 18 iv ABSGUIDANCE NOTES ON MAINTENANCE AND REP
24、AIR OF PROTECTIVE COATINGS .2017 SECTION 5 Assessment Scales of Coating Conditions . 19 1 General . 19 3 Scattered Coating Failures Assessment Scale. 19 5 Localized and Scattered Coating Failures Assessment Scale . 21 7 Linear Coating Failure Assessment Scale 23 9 Examples of Coating Breakdown Failu
25、res 23 9.1 Breakdown on Flat Areas 23 9.3 Breakdown on Welds and Edges 24 FIGURE 1 Diagrams of Scattered Coating Breakdown for the Areas under Consideration 20 FIGURE 2 Diagrams for Localized and Scattered Coating Failures in Corners . 21 FIGURE 3 Assessment Scale of Failures (IACS Rec. 87) . 22 FIG
26、URE 4 Linear Extent Diagrams 23 FIGURE 5 Coating Breakdown on Flat Area 23 FIGURE 6 Coating Breakdown on Welds and Edges 24 SECTION 6 Coating Maintenance . 27 1 General . 27 3 Process Considerations 27 5 Recommended Process 27 TABLE 1 Recommended Maintenance 28 SECTION 7 Coating Repair 29 1 General
27、. 29 3 Process Considerations 29 5 Repair Process . 29 7 Recommended Repair 30 TABLE 1 Recommended Medium and Long-term Repairs of PSPC Ballast Tank Coatings . 30 TABLE 2 Recommended Short-term Repair of PSPC Crude Oil Tank Coatings 31 SECTION 8 Coating Technical File (CTF) . 32 1 General . 32 3 CTF
28、 Maintenance . 32 3.1 Maintenance 32 3.3 Repairs 32 ABSGUIDANCE NOTES ON MAINTENANCE AND REPAIR OF PROTECTIVE COATINGS .2017 v APPENDIX 1 Considerations for Coating Maintenance and Repair . 34 1 General . 34 3 Safety 34 5 Staging 35 7 Tank Cleaning and Steel Surface Cleaning 35 9 Salt Contamination
29、36 11 Rust Scale . 36 13 Pitting 37 15 Temperature, Humidity, and Condensation 37 17 Ventilation . 39 19 Coating Systems and Coating Applications 40 21 Cathodic Protection . 40 FIGURE 1 Ship Repair Safety 34 FIGURE 2 Scaffolds and Staging . 35 FIGURE 3 Surface Preparation 36 FIGURE 4 Typical Pitting
30、 Corrosion . 37 FIGURE 5 Coating Cracking . 38 FIGURE 6 Coating Pinhole Defects . 38 FIGURE 7 Ventilation Arrangement . 39 FIGURE 8 Stripe Coating . 40 FIGURE 9 Anodes in Ballast Tanks . 41 APPENDIX 2 ABS Nautical Systems Hull Manager 42 1 Enabling Comprehensive Asset Management 42 3 NS Hull Manager
31、 Capabilities . 42 3.1 One-click Access to Structural Health 42 3.3 Inspection Scheduling 42 3.5 Anomaly Reporting 42 3.7 NS Software Integration . 42 5 3D Visualization 42 5.1 Enhanced Tools for Planning and Management of Asset Structural Condition, Maintenance, and Repair . 43 5.3 Key Features . 4
32、3 APPENDIX 3 References 44 vi ABSGUIDANCE NOTES ON MAINTENANCE AND REPAIR OF PROTECTIVE COATINGS .2017 Section 1: General SECTION 1 General 1 Background Two coating performance standards for protective coatings (PSPC) have been mandated from SOLAS regulations II-1/3-2 Year last coated, either delive
33、ry date or latest repair Coating name/type, manufacturer and product identification used Last repaired Surface area; designation and size Coating condition (GOOD, FAIR, or POOR) Pitting corrosion Yes/No Amount of rust scale and coating breakdown (in m2(ft2) or % of areas under consideration) Access
34、arrangement condition Sounding pipe condition Vent pipe condition 16 ABSGUIDANCE NOTES ON MAINTENANCE AND REPAIR OF PROTECTIVE COATINGS .2017 Section 4 Survey Recommendation Ballast pipes condition, in the case of ballast tanks Other comments (such as structural damage, mechanical damage, location,
35、and extent) Bellmouth condition and erosion underneath Conditions of coatings of Permanent Means of Access (PMA) A copy of the latest standardized report should be maintained on board for use of the owner. 7 Frequency of Inspections The coating system in ballast tanks should be examined in connectio
36、n with: Intermediate Surveys for tankers exceeding 5 years of age Special Surveys for all tankers It is recommended that all ballast tanks, especially for vessels over six years of age, are inspected at least annually by the crew. The condition of the coating in ballast tanks is assigned and categor
37、ized as “GOOD”, “FAIR”, or “POOR”, based on visual inspection and estimated percentage of areas with coating failure and rusty surfaces. The frequency of inspections for ballast tanks of single and double skin bulk carriers (according to Section 7-3-2 of the ABS Rules for Survey After Construction (
38、Part 7) and IACS UR Z10.2 and Z10.5) is shown in Section 4, Table 1. TABLE 1 Survey Frequency for Ballast Tanks and Combined Cargo/Ballast Tanks in the Various Previous Survey Conditions for Single and Double Skin Bulk Carriers Ballast Tanks or Combined Cargo/Ballast Tanks Inspection during Periodic
39、al Survey Coating Condition GOOD S I S I S I S FAIR S I S I S A* A* I A* S POOR S A A I A S A A I A S A A I A S Vessel Age 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 S: Special Survey: An overall survey of all tanks and spaces is to be carried out. A ballast tank or a combined cargo/ballast tank is
40、to be examined at subsequent annual intervals where the hard protective coating is found to be in POOR condition. I: Intermediate Survey: For vessels with 5-10 years, overall survey of a minimum of three (3) representative ballast tanks, including fore and aft peak tanks, are to be surveyed. Where a
41、 hard protective coating is found in POOR condition, the examination is to be extended to other ballast tanks of the same type. For vessels 10 years, overall survey of all ballast tanks is to be carried out no matter what coating condition. The tanks in question are to be internally examined at each
42、 subsequent Annual Survey. Thickness measurements are to be carried out as considered necessary by the Surveyor. A: Annual Survey for Vessels over 5 Years of Age: Ballast tanks or combined cargo/ballast tanks other than double bottom tanks, where a hard protective coating was found in POOR condition
43、 at previous surveys. Double bottom tanks with hard coatings in POOR condition and with substantial corrosion. A*: Annual Survey for Vessels over 15 Years of Age: minimum 3 ballast tanks or combined cargo/ballast tanks other than double bottom tanks (one forward, one amidships, one aft) within the c
44、argo hold area and fore and aft peak tanks, where FAIR coating conditions were identified at previous surveys. The frequency of inspections for ballast tanks for tankers and chemical carriers (according to Section 7-3-2 of the ABS Rules for Survey After Construction (Part 7) and IACS UR Z10.1, Z10.3
45、, and Z10.4) is shown in Section 4, Table 2. ABSGUIDANCE NOTES ON MAINTENANCE AND REPAIR OF PROTECTIVE COATINGS .2017 17 Section 4 Survey Recommendation TABLE 2 Survey Frequency for Ballast Tanks for Double and Non-Double Hull Tankers ESP and Chemical Carriers ESP Ballast Tanks or Combined Cargo/Bal
46、last Tanks Inspection during Periodical Survey Coating Condition GOOD S I S I S I* S FAIR S A A I A S A A I A S A A I A S POOR 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Vessel Age 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 S: Special Survey: An overall survey of all tanks and spaces is to be carrie
47、d out. A ballast tank or a combined cargo/ballast tank is to be examined at subsequent annual intervals where the hard protective coating is found to be in less than GOOD condition. I: Intermediate Survey: For vessels with 5-10 years of age, all ballast tanks and combined cargo/ballast tanks are to
48、be examined. The tank is to be examined at subsequent annual intervals where the hard protective coating is found to be in less than good condition. For vessels over 10 years, overall survey requirements of the previous Special Periodical Survey is needed. A: Annual Survey for Vessels over 5 Years o
49、f Age: Ballast tanks or combined cargo/ballast tanks, where a hard protective coating was found to be in less than GOOD condition at previous surveys. The frequency of overall and close-up inspections for cargo holds of single and double skin bulk carriers (according to Section 7-3-2 of the ABS Rules for Survey After Construction (Part 7) and IACS UR Z10.2 and Z10.5) is listed in Section 4, Table 3. The typical coated areas of a cargo hold are shown in Section 4, Figure 1. TABLE 3 Survey Frequency of Cargo Holds in Bulk Carriers Cargo Hold I
