APPLICATION OF COATING ON LNG TANK

Ranto Manullang
Sr. Engineer - PT Badak NGL

Workshop : Design, Standard, Pemeliharaan dan Aplikasi Coating di Industri Minyak dan Gas PERTAMINA
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ABSTRACT

Structural steels in plant require timely painting maintenance, not only for good appearance, but the main function is to
maintain the integrity of the steel and to protect the plant investment. Unhappily, there is no easy rule for proper painting
maintenance. Decisions on the frequency and extent of repainting and the type of coating system to be used depend on a
number of factors.

Protection against corrosion and loss of structural identity is often the primary purpose of maintenance painting. When
structure in public view, appearance is often a factor. Public safety and the protection of employees and visitors are
sometimes important concerns. While protection and appearance are two most common reasons for painting, safety or
identification may also be important. If we decide that protection is our main goal, and appearance doesn’t matter, our
maintenance painting will be affected.

LNG Tank, one of equipment that categorized as important in LNG Plant, of course, will also need a coating protection.
Location of LNG Tank in Badak LNG Plant is close enough to the shore. The outer shell (wall) material is carbon steel SA
283 Gr. C. The carbon steel material is known prone to seawater corrosion if unprotected. So that, as part of maintenance
strategy, the LNG Tanks need to be protected by coating to avoid corrosion condition occurs on the outer shell that will
cause metal failure of outer tank shell.

Currently, PT Badak is performing re-painting activity on LNG Tank 24D-5 for the second time. This LNG Tank has been
in operation since 1982 and the first re-painting was done in 1987. In this paper, we will share our experience to carry out
painting activity on the LNG Tank 24D-5.
 Coating Seminar & Workshop

PT BADAK NATURAL GAS LIQUEFACTION

Bontang – East Kalimantan-Indonesia

Application of Coating on
Badak LNG Tank 24D-5

Ranto Manullang
Yulius Manurung

Engineering & Research Division PT PERTAMINA (Persero)

 Coating Seminar & Workshop 2
AGENDA

••INTRODUCTION
••REASON FOR COATING THE TANK
••REASON FOR RE-COATING THE TANK
••COATING SELECTION
••APPLICATION OF COATING ON 24D-5
••CONCLUSION

Engineering & Research Division PT PERTAMINA (Persero)

 3
INTRODUCTION
Coating Seminar & Workshop

„PT BADAK have 6 LNG Tanks and 5 LPG Tanks

„Material of the tank outer shell is Carbon Steel SA 283 Gr. C

„All tanks are located close enough to the seashore

„One of the best method to prevent external corrosion is by coating

24D-5

Engineering & Research Division PT PERTAMINA (Persero)

 4
REASON FOR COATING THE TANK
Coating Seminar & Workshop

The Tank located Carbon Steel

close enough to material has less
the seashore resistance to
seawater
corrosion IF METAL
FAILS

Corroded area on
the tank is difficult
to be repaired on-
line due to safety
reason

Protective coating is
very important to Esthetic side
protect outer wall (Good Looking)
from corrosive • High Humidity
environment • Marine Environment
• Air Pollution

Engineering & Research Division PT PERTAMINA (Persero)

 REASON FOR RE-COATING THE TANK
Coating Seminar & Workshop 5

• Existing coating of the outer shell tank was

maintained by cleaning and spot coating during
period of 1987 – 2004 :
- 5 Times cleaning with water
- 2 Times for spot coating

• The Last Condition :

Existing coating was damaged on the most exterior
surfaces of the tank
Spot repair for extending the coating life is technically
almost impossible due to existing bonding strength of the
primer coating to base metal has already weakened and
also the new coating would not be 100% compatible due to
different type of coating

Engineering & Research Division PT PERTAMINA (Persero)

 PAINTING DEFECT TYPE ON 24D-5 Coating Seminar & Workshop 6

Peel off /
crack corroded

Blister then
touch up chalking
Engineering & Research Division PT PERTAMINA (Persero)
 PAINTING DEFECT TYPE ON 24D-5 Coating Seminar & Workshop 7

Fungi +
Carbon from
Flare

Peel off /
corroded

Engineering & Research Division PT PERTAMINA (Persero)

 COATING SELECTION Coating Seminar & Workshop 8

• Criteria of Coating
– Life time at least 15 years
– Ease in maintenance
– Compatible
• Refer to PT Badak Specification
– PTB SPEC No. 01
• Coating of steel to protect atmospheric corrosion and located close to the
shore
• Applied coating system has demonstrated excellent performance
– Generic Name
• Primer Coat : Inorganic Rich Zinc Silicate (65µ DFT)
• Second Coat : High Build Epoxy (125µ DFT)
• Top Coat : High Gloss Polyurethane (50µ DFT)
• Open Bid Selection
Product name that meet PTB Spec. : Trimitz, Carboline, Hempel, Jotun.
Selected by the lowest price : Trimitz
• Familiar Product Name in PT Badak
Dimet, Carboline, Hempel, Jotun, and Trimitz

Engineering & Research Division PT PERTAMINA (Persero)

 PT BADAK SPECIFICATION Coating Seminar & Workshop 9

SPEC NO 01 SPEC NO 02 SPEC NO 03

Steel, Atmospheric Pollution Steel Temp below 80 °C Steel Temp 80 – 200 °C
Abrasive blast to SA 2.5 Wash down with fresh water Abrasive Blast to SA 2.5
1 coat Inorganic Zinc Primer 65µ Abrasive blast to SA 2.5 1 coat Inorganic Zinc Primer 65 µ
1 coat High Solid Epoxy (125 µ DFT) 1 coat High Solid Epoxy 125 µ DFT 1 coat Silicon Acrylic Aluminum
1 coat Aliphatic Polyurethane 50 µ 1 coat Aliphatic Polyurethane 50 µ (100 µ DFT)

SPEC NO 04 SPEC NO 05 SPEC NO 06

Steel Temp 200 – 500 °C Steel immersion in Demin Steel under cold insulation
Abrasive blast to SA 2.5 Water Submersion Clean with high pressure water
2 coat Silicon Aluminum Abrasive blast to SA 2.5 Abrasive blast to SA 2.5
(50 µ DFT) 1 coat Inorganic Zinc Primer 65 µ 1 coat Inorganic Zinc Primer 65 µ
1 coat Epoxy Phenolic Amine 350 µ 1 coat High Solid Epoxy 200 µ

SPEC 07 SPEC NO 08 SPEC No 09

Steel in sweating lines & low Exterior pump casing and Steel in diluted acid / caustic
temperature MCC Wash down with high pressure
Wash down with fresh water Remove rust, grease and other Abrasive blast to SA 2.5
Wet abrasive blast to SA 2.5 contaminants with cleaner 1 coat Non Inhibitive Epoxy Primer
2 coats High Solids Epoxy 200 µ DFT 1 coat Inhibitive Epoxy Primer 50 µ (75 µ DFT)
2 coats Aliphatic Polyurethane 90 µ 2 coats High Build Epoxy 325 µ DFT
Engineering & Research Division PT PERTAMINA (Persero)
 Coating Seminar & Workshop 10

ESSENTIAL CRITERIA TO MEET PTB SPEC.

GENERIC NAME ESSENTIAL CRITERIA

Inorganic Rich Zinc Silicate Total Zinc Dust ≥ 86 % weigh

High Build Epoxy Solid Content ≥ 83 %
Self Priming
Aliphatic Polyurethane Glossy ≥ 90 %
Silicone Acrylic Aluminum Continuous Temperature Resistance = 200 °C
Silicone Aluminum Continuous Temperature Resistance = 500 °C
Final Cure Temperature ≤ 250 °C
Epoxy Phenolic Amine Solid Content ≥ 56 %
Self Priming
Inhibitive Epoxy Primer Solid Content ≥ 50 %

Engineering & Research Division PT PERTAMINA (Persero)

 Coating Seminar & Workshop 11

PRODUCT EQUIVALENT OF PAINTING MATERIAL

GENERIC NAME DIMET CARBOLINE TRIMITZ

Inorganic Rich Zinc Silicate Dimetcote 9 Carbozinc 11 Trimitz ZS 87-800
High Build Epoxy Amerlock 400 Carbomastic 801 Trimitztic - 480
Aliphatic Polyurethane Amercoat 450 GL Carboline 134 HS Trimitzthane
Gloss - 580
Silicone Acrylic Aluminum Amercoat 1999 Carboline 1248 Trimitz Silicryl -
680
Silicone Aluminum Amercoat 878 Carboline 4631 Trimitz Silicone
HR -670
Epoxy Phenolic Amine Amercoat 90 Carboline Trimitzpox
Phenoline 368 Phenolic - 494
Zinc Rich Primer Amercoat 160 Carboline 676 Trimitzprime
Zinc - 430
Inhibitive Epoxy Primer Amercoat 64 Carboline 191 Trimitzpox Lining
Primer Primer - 404

Engineering & Research Division PT PERTAMINA (Persero)

 Coating Seminar & Workshop 12

PRODUCT EQUIVALENT OF PAINTING MATERIAL

GENERIC NAME DIMET JOTUN HAMPEL
Inorganic Rich Zinc Silicate Dimetcote 9 Resist GTI Galvosil 15701
High Build Epoxy Amerlock 400 Jotamastic 87 Hempadur 45159
Aliphatic Polyurethane Amercoat 450 GL Hempathane Hardtop As
Enamel 55109
Silicone Acrylic Aluminum Amercoat 1999 Fail to meet Jatocote 710
essential criteria
Silicone Aluminum Amercoat 878 Silicone Solvalitt
Aluminum 56910 Aluminum
Epoxy Phenolic Amine Amercoat 90 N/A N/A
Zinc Rich Primer Amercoat 160 N/A N/A
Inhibitive Epoxy Primer Amercoat 64 Penguard Primer N/A

Engineering & Research Division PT PERTAMINA (Persero)

 APPLICATION OF COATING ON 24D-5 Coating Seminar & Workshop 13

•SURFACE PREPARATION
Primary Functions
•To provide a surface that can be easily wetted for good coating adhesion
•To clean the surface of material that will induce premature failure of coating
Method Selected
Wet Abrasive Blast Cleaning
•Remove soluble corrosion product from deeply corroded or pitted steel more
effective than dry blast
•From safety aspect, wet blasting more safely when working in potentially
flammable areas
•Use Silica Sand (Cl- 50 ppm)
•Inhibitor (Nalco 918) + Fresh Water

Specification for Surface Roughness

•SA 2.5 (Near-white metal blast)
•Reference = Steel Structures Painting Council (SSPC-SP10)
•No surface preparation will be permitted for proceeding the coat work
except it has been accepted by PT Badak QA Inspector
Engineering & Research Division PT PERTAMINA (Persero)
 APPLICATION OF COATING ON 24D-5 Coating Seminar & Workshop 14

SPECIFICATION FOR SURFACE ROUGHNESS

• Category of rust LNG Tank is Type A
• To compare the actual profile with reference profile
• Using Keane Tator Surface Profile Comparator
SA 2.5

CATEGORY OF RUST REFERENCE PROFILE

TYPE A

Zoom Result

ACTUAL Keane Tator Comparator

Engineering & Research Division PT PERTAMINA (Persero)
 APPLICATION OF COATING ON 24D-5 Coating Seminar & Workshop 15

•SANDBLASTING EQUIPMENT
Inhibitor
Nozzle

Sandblast
Nozzle

Sand for
blasting
Inhibitor
Sandblast (Nalco)
Pot mix with
water

Engineering & Research Division PT PERTAMINA (Persero)

 APPLICATION OF COATING ON 24D-5 Coating Seminar & Workshop 16

•SANDBLASTING PROCESS AT DOME TANK AND SHELL

Sandblast at Sandblast at
Dome Tank Dome Tank

Sandblast at Shell
using Gondola

Engineering & Research Division PT PERTAMINA (Persero)

 APPLICATION OF COATING ON 24D-5 Coating Seminar & Workshop 17

•COATING EQUIPMENT
Air Spray Pot
Use on certain area
Pressure = 45 Psi

Airless Spray

Provided with
screen 80 mesh
Pressure = 4500 Psi

Thinner Consume

Hydraulic Pump
Engineering & Research Division PT PERTAMINA (Persero)
 APPLICATION OF COATING ON 24D-5 Coating Seminar & Workshop 18

•COATING PROCESS
•Coating Condition Requirement
•Relative humidity less than 88 %
•Dew point is above 3 °C of the metal substrate temp.
•Metal temperature should be 10 – 49 °C
•No rain or fog
Check
dry/wet bulb
to get dew
point and RH

Measurement of metal
surface temp. before
painting
Engineering & Research Division PT PERTAMINA (Persero)
 APPLICATION OF COATING ON 24D-5 Coating Seminar & Workshop 19

•COATING PROCESS
Primer Coat
•Cleaning and Drying after blasting
•Apply Primer Coat and Check WFT
•Check DFT (65 µ )
•Primer must be applied on the same
day as finish blast and cleaning
Second Coat
To measure WFT
•Drying time of primer coat should
follow manufacturer specification
before continuing to second coat
•Cleaning
•Apply Second Coat and Check WFT
•Check DFT (125 µ )
Top Coat
•Cleaning
•Apply Top Coat and Check WFT
•Check DFT (50 µ )

Engineering & Research Division PT PERTAMINA (Persero) To measure DFT

 APPLICATION OF COATING ON 24D-5 Coating Seminar & Workshop 20

•COATING PROCES
Shell

Dome
Repair Primer Coat

Primer Coat Process Cleaning before Second Coat Second Coat Process

Engineering & Research Division PT PERTAMINA (Persero)

 APPLICATION OF COATING ON 24D-5 Coating Seminar & Workshop 21

•COATING RESULT
•Acceptance Criteria
• Compile with PTB DFT Specification
• No pinhole
One of the causal factor is water in the coat / paint due to lack of
separators between the compressor and the coat spray
• No coating peel off
Coating to soon after a rainfall
Moisture condensing on the surface when the surface temperature is
below the dew point
Improper surface preparation
• No sagging
Too much paint applied per coat
Too much thinner added to paint
Improper spray technique
• No Bubbling
A bubble sign appear during coating process due to there is a porous on
the surface of metal that cause air trapped
Engineering & Research Division PT PERTAMINA (Persero)
 APPLICATION OF COATING ON 24D-5 Coating Seminar & Workshop 22

•COATING RESULT
Primer Coat

Second Coat

Engineering & Research Division PT PERTAMINA (Persero)

 APPLICATION OF COATING ON 24D-5 Coating Seminar & Workshop 23

MONITORING OF COATING APPLICATION AND RESULT

DAILY PAINTING REPORT PT. TRIMITZ COATING
PROJECT NO. C-04003 REPORT NO. : 027

LOCATION : OWNER : PAGE :

TANGKI LNG 24D-5 PT. BADAK NGL
SPECIFICATION NO. : ITEM : DATE : 16 Agustus 2004
DOME & SHELL

AMBIENT CONDITION SURFACE PREPARATION

Time 09.00 11.00 14.00 17.15 Rust Grade

o o o o o
Dry Bulb C 31 C 30 C 32 C 30 C Date 16 AGUSTUS 2004
o o o o o
Wet Bulb C 27 C 25 C 27 C 25 C Methode WET BLASTING
Relatif Humidity 75 % 65 % 68 % 65 % Start Time 07.45 Stop Time 15.00
o o o o o
Dew Point C 26 C 23 C 25.5 C 23 C Standard SSPC SP 10
o o o o
Steel Temp. 30 C 33 C 35 C 31 C
Remark

APPLICATION

Coat Number Primer coat Intermediate Coat Top Coat

Date 16 AGUSTUS 2004
Time 16.30-17.30
Method Application SPRAY
Product Name TRIMITZ ZS 87
Colour GREY
Batch No. Part A 4E+06
Batch No. Part B 4E+06
Thinner No. & % 4E+06
Dry Film Thickness 71 65 80 73
72 63 60 71
74 61 62 65
60 64 61 63
Remark

APPROVAL
QC. CV. AMELIA P.L. QC. PT TRIMITZ COATING PT. BADAK NGL

Engineering & Research Division PT PERTAMINA (Persero)

 APPLICATION OF COATING ON 24D-5 Coating Seminar & Workshop 24

•MONITORING OF COATING RESULT

Total area of Dome = 5,566 m2

Total area of Shell = 8,289 m2

Engineering & Research Division PT PERTAMINA (Persero)

 APPLICATION OF COATING ON 24D-5 Coating Seminar & Workshop 25

• INSPECTION OF COATING RESULT

PRIMER COAT
DFT Check Need to add coating

Bottom Shell
DFT Result = 61 µ
PTB Spec = 65 µ
DFT average

Engineering & Research Division PT PERTAMINA (Persero)

 CONCLUSION Coating Seminar & Workshop 26

To extent the coating life, the following

subject should be considered :

The coating should be maintained properly

• Propose to clean the tank with water every year periodically
• Propose to survey the coating condition every 5 years
• Propose to perform spot coating by touch up method soon
after some coating damaged was observed
• Propose to perform re-coating every 15 years

Engineering & Research Division PT PERTAMINA (Persero)

 CONCLUSION Coating Seminar & Workshop 27

To obtain good coating result, the following

subject should be considered :

– Surface Preparation
– Coating Condition (T, Rh,Dew Point)
– Coating Material
– Monitoring (Inspection) during application
– Coating Equipment

Engineering & Research Division PT PERTAMINA (Persero)

 Coating Seminar & Workshop 28

Terima kasih

Engineering & Research Division PT PERTAMINA (Persero)