Evaluation of “Spot and Sweep” Blasting as a Cost Effective ... - NSRP

Evaluation of “Spot and Sweep”Blasting as a Cost Effective methodof Underwater and Outer HullSurface PreparationStephen CogswellBAE Systems Southeast ShipyardsNon-Export Controlled Information – Releasableto Non-US Persons: DSEA-S2-2010-0118

Spot and Sweep, in progressNon-Export Controlled Information – Releasableto Non-US Persons: DSEA-S2-2010-0118

Concept• Reduce Total Ownership Cost of cleaning andpainting underwater hulls on US Navy ships byleaving in-tact anti-corrosive on the hullduring re-painting• This paper is a result of the work beingaccomplished by the NSRP SurfacePreparation and Coating Panel project team:Steve Cogswell, Pete Ault, Gordon Kuljian &John Odwazny.Non-Export Controlled Information – Releasableto Non-US Persons: DSEA-S2-2010-0118

Spot & Sweep to well adhered Epoxy½ & ½ , spot & sweep/fullremoval, edge check in progressSpot & Sweep, DFT in tact epoxy7 to 15 milsNon-Export Controlled Information – Releasable toNon-US Persons: DSEA-S2-2010-0118

Spot & Sweep to well adhered EpoxySpot & Sweep, robotic headSpot & sweep, robotic headNon-Export Controlled Information – Releasable toNon-US Persons: DSEA-S2-2010-0118

Project Goals• Demonstrate commercial technology on USNavy ships– Document performance issues– Identify process refinements– Determine life cycle cost impact• Develop NSI 009-32 language– Process requirements– Objective Quality Evidence (OQE)Non-Export Controlled Information – Releasableto Non-US Persons: DSEA-S2-2010-0118

Phase One, Commercial repair. 80K sqftaccomplished in 6 days, full removal prior toapplication of IntersleekFull coating removalFull coating removalNon-Export Controlled Information – Releasable toNon-US Persons: DSEA-S2-2010-0118

“Commercial Ship”Full removal to bilge keelFull removal to keel blocksNon-Export Controlled Information – Releasable toNon-US Persons: DSEA-S2-2010-0118

Adhesion testing over Spot and SweepArea was prepared after spot and sweep for the dolly tomeasure any impact/fracturing from the UHPwaterblast2189 psi, no impactNon-Export Controlled Information – Releasable toNon-US Persons: DSEA-S2-2010-0118

USS KLAKRING (FFG 42)• Demonstration in February, 2011– BAE Systems Southeast Shipyards, Jacksonville FL– Existing coating applied in November, 2002– Performed on freeboard and underwater hull– Data collected• Production rates• Adhesion of coating before and after cleaning• Extent of coating removedNon-Export Controlled Information – Releasableto Non-US Persons: DSEA-S2-2010-0118

USS Klakring (FFG-42) Spot & SweepThe surfaceSpot and sweep to existing welladhered epoxy coatingNon-Export Controlled Information – Releasable toNon-US Persons: DSEA-S2-2010-0118

Chariot RoboticsArticulating robotic head makinga turn.Vertical, cutting pathNon-Export Controlled Information – Releasable toNon-US Persons: DSEA-S2-2010-0118

Flow Hydro Cat½ & ½, Chariot(left), Flow (right)Hydro Cat tracking verticallyNon-Export Controlled Information – Releasable toNon-US Persons: DSEA-S2-2010-0118

Existing LSA >80 mils> 80 mils > 80 milsNon-Export Controlled Information – Releasable toNon-US Persons: DSEA-S2-2010-0118

Adhesion values, Spot & Sweep2 coats AC – 1007 psi 1 coat AC- 1356 psiNon-Export Controlled Information – Releasable toNon-US Persons: DSEA-S2-2010-0118

Adhesion Values, Spot & Sweep1 st and 2 nd AC, cut through 2030 psiNon-Export Controlled Information – Releasable toNon-US Persons: DSEA-S2-2010-0118

Paint, in progressNon-Export Controlled Information – Releasableto Non-US Persons: DSEA-S2-2010-0118

Hull Plating from the Side shellretained for Laboratory testingNon-Export Controlled Information – Releasableto Non-US Persons: DSEA-S2-2010-0118

USS SHOUP (DDG-86)• Tentative demonstration- limited square footage– Todd Shipyards– August, 2011– Scope limited to underwater hull, (TBD)Tentative demonstration 100% Spot and Sweep onMSC vessel Gulf CoastNon-Export Controlled Information – Releasableto Non-US Persons: DSEA-S2-2010-0118

Technical Issues to Overcome• “Crop Circles” create aesthetic concerns• Equipment which attaches with magnets maybe of concern to the Navy• Criteria for inspectors is subjective• OQE is limitedNon-Export Controlled Information – Releasableto Non-US Persons: DSEA-S2-2010-0118

Initial Inspection criteria and OQE3.7 Change the requirements of Column A (surface preparation) of Table One, Line 4 called out in 3.3 and accomplish alternativesurface preparation as follows:3.7.1 Remove all antifouling coating and remove approximately 1/2 of the thickness of the current epoxy tie coat thickness fromthe areas listed in 1.2.1 with the following exceptions: APU cavities and fairing plates, sea chests and hull openings up to valveflanges and sea chest strainers which will be prepared in accordance with 3.3.3.7.2 Smoothly feather or transition from areas of bare metal to the retained epoxy primer/tie coat in areas of sharp or "step"transition between bare metal and paint.3.7.3 Remove all rust and fouling from areas of bare metal to create a SSPC SP-12, WJ2M or WJ2L level of surface cleanliness inaccordance with 009-32, Change 1 of 2.1.3.7.4 Upon completion of the surface preparation of the areas listed in 3.7.1 apply one coat of antifouling primer, in accordancewith 009-32 of 2.1 including Table One, Line 4, Column B , Minimum DFT: 7-mils, Maximum DFT: 16-mils.4.2 There shall be no more than two colors of paint visible in any area of retained coating. Inspectors shall observe the red primeradjacent to any bare metal areas and then continue observations into the bulk of the retained epoxy. Dark gray epoxy may beretained on top of the red primer, but any visual evidence of additional coats of red or black paint on top of the gray shall be causefor closer inspection. Upon closer inspection, a solvent-wipe test with a white rag shall be conducted using the antifouling coatingclean-up solvent. If the solvent wipe test shows color transfer onto the rag, the area shall be rejected. Rejected areas shall becleaned again until no color transfers to the rag.4.3 There shall be no areas of sharp transition or steps between bare metal and paint. Any such areas shall be inspected andtested with a dull putty knife to determine adhesion. If the paint flakes or can be dislodged, the area shall be rejected and cleanedagain to remove the loose paint.Non-Export Controlled Information – Releasableto Non-US Persons: DSEA-S2-2010-0118

Draft Requirement• Draft requirement currently being developedfrom Lessons Learned during the Demo(s).• Shall be written in language ready for theStandard Item 009-32.Non-Export Controlled Information – Releasableto Non-US Persons: DSEA-S2-2010-0118

DRAFT- PROCESS FOR SPOT AND SWEEP BLAST DEMONSTRATION1. The spot and sweep process preformed by the Chariot Robotics unit (or equivalent) may beused for all areas of the underwater-hull and freeboard on approved surface ships. For areas notprepared using the Chariot Robotics or equivalent; Ultra High Pressure (UHP) lances, abrasiveblasting, may be used to create either an SSPC SP-12 WJ-2/M surface or an SSPC SP-10 surface.SSPC SP-3 Power tool cleaning may be authorized for fairing in the spot and sweep surface asrequired.2. The contractor shall inspect the existing coating on the hull and shall determine the sequenceof the epoxy coatings currently on the hull prior to blasting. The anticipated sequence is redprimer followed by gray epoxy tie coat. The contractor shall note these colors for use inNAVSEA inspection of the hull prior to application of the first coat of epoxy primer.3. The Chariot Robotics unit (or equivalent) shall be set up to accomplish the following:(a) Remove all rust and fouling from areas of bare metal to create a SSPC SP-12, WJ-2/Msurface condition in accordance with specified NAVSEA Standard Item 009-32, FY 12 Change 1processes.(b) Remove all antifouling coating and remove approximately 1/2 of the thickness of the currentepoxy tie coat thickness from the underwater hull area.(c) Remove all silicone alkyd, regardless of coating thickness, and remove approximately 1/2 ofthe thickness of the current epoxy topcoat from the freeboard area.(d) Smoothly feather or transition from areas of bare metal to the retained epoxy primer/tie coat.Areas of sharp or "step" transition between bare metal and paint shall be noted by the NAVSEArepresentative for detailed inspection. *under review: Feather edges where the Chariot Roboticsunit (or equivalent) leave behind markings in the existing paint (concentric circle areas whichsome describe as “crop circles”).

4. Upon completion of standard zones or work areas, in accordance with current, standardcontractual requirements, the contractor shall inform the NAVSEA representative when they areready to apply the first coat of primer to the zone or work area. NAVSEA representative shallconduct all standard data reviews and inspections on bare metal areas in accordance withspecified Standard Item 009-32 requirements. Areas of retained paint shall be visually inspectedand shall satisfy the following:(a) There shall be no more than two colors of paint visible in any area of retained coating.Inspectors shall observe the red primer adjacent to any bare metal areas and then continueobservations into the bulk of the retained epoxy. Gray epoxy may be retained on top of thered primer, but any visual evidence of additional coats of red or black paint on top of the grayshall be cause for closer inspection. Closer inspection shall be conducted from a minimumdistance of 3 feet. Upon closer inspection, a solvent-wipe test with a white rag shall beconducted using the antifouling coating clean-up solvent. If the solvent wipe test showscolor transfer onto the rag, the area shall be rejected. Rejected areas shall be cleaned againuntil no color transfers to the rag.(b) There are no areas of sharp transition or steps between bare metal and paint. Any such areasshall be inspected and tested with a dull putty knife to determine adhesion. If the paint flakesor can be dislodged, the area shall be rejected and cleaned again to remove the loose paint.(c) *Under review Effort will be needed to smooth out the transition areas where partial blastedareas occur next to bare steel blasted areas. Sharp edges shall be removed in accordance withSSPC SP-3 and the areas feathered for a smooth transition.(d) Measurements of existing DFT shall be recorded for historical purposes in accordance withSSPC PA-2.

5. Upon approval of the surface preparation, the contractor shall apply one coat of AC primer, inaccordance with established Standard Item 009-32 requirements to all areas in the zone or workarea (i.e., bare metal and retained epoxy primer) to achieve the specified 5-7 mil dry filmthickness. The contractor is not obligated to apply a thin or varied primer thickness whentraversing areas between bare metal and retained epoxy. Again following standard practices,SUPSHIP shall inspect the zone or work area coating thickness. Because the coating thicknessretained will vary notably, DFT readings shall be taken and recorded; however high DFTreadings shall not be means for rejection, such readings shall only be taken for documentationpurposes. In place of DFT readings for determining proper coating thickness, WFT readingsshall be taken and recorded on each coat to confirm proper coating thickness (i.e. follow the 009-32 requirement for taking WFT readings in place of DFT readings for accept/reject criteria). Allother QA requirements of 009-32 shall be accomplished.6. Once the primer has cured to overcoat the surface area shall be inspected for edge lifting of theremaining epoxy that was over coated. This inspection shall be conducted at a maximumdistance of 15 feet. The curing epoxy primer will lift any loose edges of the existing coating as itcures that may not have been visible during the initial surface preparation inspection. Theseareas shall be prepared in accordance with SSPC-SP-3 and primed.7. For underwater hull areas, apply second or tie coat of epoxy and first coat of antifouling inaccordance with Standard Item 009-32 requirements (using WFT readings).8. For underwater hull areas, apply complete antifouling system in accordance with StandardItem 009-32 requirements and note final coating thickness. Again, use WFT readings in place ofDFT readings for determining proper coating application, with DFT readings being recorded fordocumentation purposes.9. For freeboard areas, apply second coat of epoxy then the topcoat in accordance with StandardItem 009-32 requirements (using WFT readings).10. The contractor and NAVSEA representative shall retain time, cost, or productivity metrics toreport to NAVSEA and to be used to provide supporting data for any future Standard Item 009-32 proposal to incorporate spot and sweep processes.

Potential Cost Savings to the Fleet• Defining the cost savings is a deliverable of theproject due Dec. 31, 2011.– Schedule and budget savings measured against the lifecycle of the coating system to docking evolutions.– Freeboard preservation may be the land ofopportunity. Non Critical, often top coated foraesthetics only. Easily inspected. Greater than doublethe square footage over the UWH. Cost per squarefoot for surface preparation freeboard and UWH areclose.Non-Export Controlled Information – Releasableto Non-US Persons: DSEA-S2-2010-0118

QUESTIONSSpecial thanks to the project Team:Chariot Robotics; John Odwazny, Gordon KuljianElzly technologies; Pete AultNAVSEA: Mark Ingle, David CisconLast but not least: SERMC; Bob George, Art Williams & theCommand of FFG-42Non-Export Controlled Information – Releasableto Non-US Persons: DSEA-S2-2010-0118