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NATIONAL PAINT & COATINGS ASSOCIATION INTERNATIONAL MARINE & OFFSHORE COATINGS EXPO June 2007 Mr. Mark Ingle, P.E. (202) 781-3665 Inglemw@navsea.navy.mil
OBJECTIVES
Summarize Naval Sea Systems Command (NAVSEA) reorganization
changes in key coatings & corrosion control staff.
R&SE Director
Competency Domain Manager (CDM) Ship Integrity & Performance Michael R. Kistler Deputy CDM
SEA 05P
SEA 05PB
SEA 05P1
SEA 05P2
SEA 05P21
Surface Ships Structural Integrity Dept. Head David A. Qualley (Acting) Materials Department Head Jon Fallick
SEA 05P24
SEA 05P22
Pre-decisional
SEA 05P25
SHIP INTEGRITY & PERFORMANCE (SI&P) Corrosion Control & Coatings Organization
Corrosion Control Dept. Head Beau E. Brinckerhoff (Acting)
Senior Engineer, Coatings Mark Ingle Senior Engineer, Cathodic Protection Andrew Seelinger Engineer, Non-skid & Decking Mike Evans Engineer, Tank Coatings VACANT Engineer, Topside & Freeboard Coatings VACANT
Pre-decisional 4
DDG LHD
F-76 fuel cost increased By 50% from $1.47/gal in 2005 TO $2.21/gal in 2006
NAVSEA collecting data on commercial fleets that are paying a premium price for foul-release coatings to realize fuel savings. One vendor claims 6% fuel savings. Another vendor claims 2% fuel savings. NAVSEA conducting additional demonstrations on foul-release; can we measure cost savings on Navy & U.S. Coast Guard (USCG) craft.
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Local water-quality issues in ports with military & civilian ships leading to new domestic regulations.
San Diego violates federal water quality standards California evaluating new regulations. San Diego Regional Water Quality Board issued a 20-year plan to phase out copper-bearing paints. Puget Sound Naval Shipyard (PSNS) has had NOVs for copper discharge from drydocks. Hull-coating leachate is identified UNDS discharge. NUMERICAL UNDS COPPER EMISSION LIMIT TO BE PROPOSED IN 2007.
ALUMINUM
FLEXIBLE 8
Phase I
Phase II
Phase III
DoD Rule
Negotiation
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From Provide Qualification Application to NAVSEA NAVSEA Application Review Entry Criteria- perquisites For the Navy to consider product General Criteria- Required Tests/inspections to Qualify product
Fail
Modify Product
Pass
Pass
Resistance to Tropical Biofouling Organism Attachment PANEL TEST (12 months or 24 months) Fail
Correct Facility Deficiencies
Fail
Modify Product
DCMA Audit
Pass
Conduct Product Testing Ablation/erosion rate Volatiles Nonvolatile Vehicle Toxicity Flash Point Consistency Metal ( Pb) Content Dry Times Sag Resistance Condition in Container Color Partially full container Spraying properties Brushing properties Rolling properties Pressure cycling
Resistance to Tropical Biofouling Organism Attachment SHIP PATCH TEST Government (Minimum 12 months) Or Commercial (Minimum 24 months)
Modify Product
Fail
Modify Product
Pass Resistance to Tropical Biofouling Organism Attachment SHIP FULL TEST Government (Minimum 12 months) Or Commercial (Minimum 24 months) Pass
Modify Product
Fail
Modify Product
Unacceptable
NEHC Review Complete Performance Testing
Acceptable
Accelerated Storage Stability (30 days) Recoatability (3 months) Shelf Life (24 months) Start
Fail
Compile Submission Package
2 months
4 months
14-28 months
26-52 months
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38 months Minimum
Current cycle is 73-months 12-year life-cycle extension already authorized for CVN, LHD, and LHA test ships. NAVSEA authorized docking extension for all ships using Condition Based maintenance. Navy antifouling coating system applied with three coats of antifouling paint (red/black/red) to achieve 12-year cycle. Navy antifouling coatings must withstand service life that includes: - 55% inactivity pier-side, - Diver cleaning of coatings, - Brief dockings for specific repairs.
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TECHNICAL:
Coatings must satisfy Navy operating cycle. Goal is for coating to last for 12-years without hull cleaning (or with no more cleaning than current products). Vendors must commit resources to register and sell coatings in the United States.
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OPTION 1: NON-COPPER DEVELOPMENTAL COATINGS. NOT EPA REGISTERED. SHORT HALF-LIFE (e.g., 10-hour) BIOCIDES.
OPTION 2: LOW-COPPER CO-BIOCIDE COATING COMMERCIAL PRODUCTS SOME CO-BIOCIDES, NOT EPA REGISTERED. SHORT HALF-LIFE (e.g., 10-hour) BIOCIDES. BEST OPTION 2 PRODUCTS Dont currently meet Navy needs.
MIL-PRF-24647D INCLUDES CATEGORY. International Intersleek included on MIL-PRF-24647D Qualified Products List Two other products in qualification testing.
MIL-PRF-24647D category One vendors products failed ship test Two vendors products under smallscale tests
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Option 1
I-11-2
6 Mon. May-05
I-11-2
12 Mon. Nov-05
I-11-2
18 Mon. May-06
I-11-2
24 Mon. Nov-06
6 Mon. Jul-04
12 Mon. Jan-05
18 Mon. Jul-05
24 Mon. Jan-06
MIL-PRF-24647 control
I-1d-1
I-1d-1
I-1d-1
I-1d-1
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Option 1 - Coating 2
Cu Ablative Control 1
Cu Ablative Control 2
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15
20 Months
25
30
35
40
45
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Percent Fouling
Soft Fouling
Hard Fouling
100 90 Percent Remaining Fouling 80 70 60 50 40 30 20 10 0 1 2 3 4 5 6
MIL-PRF-24647D
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11
12
Exposure Cycle
% Remaining @ 20 kts
% Remaining @ 30 kts 18
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USS JOHN PAUL JONES (Option 1 & 2) USS RENTZ (Option 1 & 2) USS AVENGER (Option 1) USCG MARLIN (Option 1 & 2) USCG KNIGHT ISLAND (Option 1 test patch)
USCG 41 UTILITY BOAT (Option 1) USCG 41 UTILITY BOAT (Option 1) USCG 41 UTILITY BOAT (New Option 3) USCG MATINICUS (Option 1 & 2) USCG CUSHING USCG 47 LIFEBOAT (Option 1) 22 (Option 1)
Option 1 Coating
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Control
ANTIFOULING COATING TESTING USS JOHN PAUL JONES (DDG-53) PATCH TEST INSTALL
TEST COATING (TWO COATS, ONE BLACK AND ONE RED) BRA 640 COPPER ABLATIVE COATING EPOXY PRIMER STEEL HULL
INSTALLED TEST PATCHES OF OPTION 1 & OPTION 2 COATINGS, ALSO INSTALLED BILGE KEEL PANELS OF MORE DEVELOPMENTAL OPTION 1 & OPTION 2 SYSTEMS.
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ANTIFOULING COATING TESTING New, Option 3 Product May Perform Well on Lower Speed Ships
New Option 3 Product Introduced to Navy and Commercial industry in May 2007. Fluorinated polymer with silicone resin. Amphiphillic surface (i.e., with mixed hydrophobic and hydrophillic areas) inhibit organism settlement and adhesion. Surface is smoother than conventional silicone-based Intersleek 425. Option 3 vendor reporting that vessels with speeds in excess of 10 knots can achieve > 6% fuel savings because amphiphillic coating is smoother and has a lower coefficient of friction than standard Intersleek. NAVSEA testing Option 3 on test panels and on patches on U.S. Coast Guard 47-foot lifeboat based in Fort Pierce, FL. Coating to be installed in June 2007.
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Backup slides
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NAVSEA GOAL IS TO ADOPT NEW, ADVANCED COATING SYSTEMS FOR FLEET-WIDE IMPLEMENTATION. CURRENT U.S. NAVY FLEET UNDERWATER-HULL AREA,
99% COATED WITH COPPER ABLATIVE 12,434,472 ft2 or 1,155,200 m2 FOUL-RELEASE COATING APPLIED TO 26,635 ft2 or 2,660 m2
EFFECTIVE, COPPER-FREE OR REDUCED COPPER ANTIFOULING COULD BECOME U.S. NAVY STANDARD. 31
(156,707 kg/yr)
Other <1% 691 lbs (314 kg) Hull Coating Leachate 64% 216,657 lbs (98,274 kg)
VOC < 400 g/l Cu RELEASE < 10 ug/cm2/day OR 50% OF ABC-3/BRA-640 OR NO COPPER SUPPORT 12-year DOCKING WITHOUT CLEANING COATING THAT MEETS NAVSEA NEEDS
APPLICABLE USING NAVY STANDARD EQUIPMENT (COMPARABLE TO ABC-3, BRA-640, HEMPEL OLYMPIC)
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APPLICABLE USING NAVY STANDARD EQUIPMENT CAN USE HIGH-SOLIDS PUMPS. CANNOT HAVE NUMEROUS EXTRA COATS OR DRY TIME.
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FFG
DDG
KEY POINT: CLEANING CAN REMOVE 30% TO 51% OF ONE ENTIRE COAT OF ANTIFOULING PAINT.
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