Segment Industrial

Thermal Sprayed Aluminium Competences@Bilfinger

KIC Meeting on 15th of October 2015

C.H. den Adel

Definition and Application of TSA
Basic information about Thermal Sprayed Aluminium

Thermal Sprayed Aluminium is a coating process in which melted aluminium is sprayed onto
DEFINITION OF TSA a surface of steel. The "feedstock" (coating precursor) is heated by electrical (plasma or arc)
or chemical means (combustion flame)

TSA is a preservation layer (aluminium) to protect the steel substrate against

corrosion
PURPOSE OF TSA

It is therefore not used for aesthetic purposes or fire-proof measures!

It is a layer of solidified aluminium particles in the form of slats and is thereby porous
(contains 5-10%) and in layers that are thinner than 200 m it gives pores to the substrate
TSA LAYER

In all circumstances, the minimum thickness must be 200 m so that corrosion can not occur

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Application of Thermal Sprayed Aluminium

TSA is an application that involves many factors

The first point of order would be to determine to the extent to which investment costs can be
returned on a case by case basis

TSA coatings are used primarily for corrosion protection

TSA can last as long as the service life of the object its is sprayed on, anywhere from 30 to 40
years or longer
GENERAL
APPLICATION Depending on the coating thickness and the nature of the structure, the direct costs are
higher than those of a normal coating system

Investing in TSA is generally more attractive if the total costs over the service life of the
structure are lower than conventional paint systems

If necessary, a finish coat of paint can also be applied, although this will be done solely for the
purpose of improving the appearance of the object

A coating of TSA can also be applied directly under the insulation to significantly reduce the
risk of CUI (Corrosion Under Insulation)

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General background information - Thermal Sprayed Aluminium (I)

Dry film thickness (dft) of TSA is absolutely critical:

Too little and there is potential for corrosion to cause break down
Too much and the adhesive strength becomes greatly reduced and eventually when
thicknesses over about 400 microns are reached the coating will peel off the substrate

TECHNICAL
BACKGROUND Sealer coats are not applied particularly for cosmetic purposes:
INFORMATION They seal the porosity in the aluminium thus greatly enhancing the performance by
stopping bimetallic corrosion cells forming within the coating
Sealers are best applied to a still warm substrate to achieve maximum penetration

High build (epoxy) coatings should not be applied to TSA:

High build (epoxy) coatings should not be applied to TSA as they put undue stress on the
system which can lead to rapid and premature failure

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General background information - Thermal Sprayed Aluminium (II)

Very high standards of surface preparation and cleanliness are required:

This need be strictly adhered to and monitored

A rigorous inspection regime required to be in place and enforced
Typically Sa2,5 with a profile of 75-100 microns, below 20mg/m soluble ion contamination
are specified

TECHNICAL Bilfinger Brabant Mobiel has done a lot of TSA work in Holland and therefore they wrote
BACKGROUND their own (high) standards which are used by applying TSA
INFORMATION
1. Minimal TSA layer of 250 mu
2. Minimal cleanliness is SA 2,5

Thermal sprayed zinc is a far superior system for corrosion protection and porosity:

The major draw backs for the application of Zinc is Zinc Flu, due to inhalation of the
fumes extremely unpleasant

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TSA in Action

FIELD WORK TSA WITH GAS WORKING IN THE SHOP TSA WITH ELECTRIC

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Saftey@Work

WE WORK TO THE HIGHEST SAFTEY STANDARDS

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Protection mechanism and application procedure

There are basically two protective mechanisms within a metallization layer:

PROTECTION MECHANISM Cathodic protection: base aluminium offers itself in favour of the underlying steel

Closure of the surrounding environment due to this aluminium corrosion process

The molten aluminium comes in the form of droplets from the spray
gun on the steel surface

Droplets hitting the surface, hitting flat and attach to the rough
DISPLAY OF A TSA LAYER surface (or each other) by shrinking

The drops cool and solidify

The drops build a layer with a laminar structure

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Competences in Benelux - Case Study Shell
Case Study:
Thermal Sprayed Aluminium - a daring undertaking in a
petrochemical plant ?

Client: Shell

Location: Moerdijk (Netherlands)

Period: Mid of 2011

CASE STUDY - SHELL Case: Shell indicated that it intends to apply TSA (Thermal Sprayed Aluminium) to
a propylene oxide vessel while it is in operation.

Challenge: Open flame will be used during the application of TSA, which will produce
locally high temperatures. Given the presence of highly flammable

substances, this will likely create significant safety risks.

Solution: Working closely with Shell Moerdijk, Bilfinger Brabant Mobiel

has made the risks manageable

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Shell was willing to work with Bilfinger on finding a safe solution that
would allow the intended application of TSA to be implemented in a live
environment

As a rule, it is prohibited to use open flames in a petrochemical plant

The very high temperatures can be hazardous to the process and leaks create a
INITIAL SITUATION
risk of explosion
Alternative, decommission of the vessel and treat it at another location with significant
production loss

Bilfinger conducted extensive research, initially studying the ignition point of the substrate in
the vessel in question.
If during the application, the wall temperature remains sufficiently below the selfignition point
of the contents of the vessel, then there is no risk of explosion
PREPARATION
We developed a test set-up where we could accurately measure the heat inside a device
AND
during application of TSA
APPROACH
The internal temperature was accurately analysed with respect to the ignition point of the
product in the relevant vessel
Bilfinger can control the TSA process such that the wall temperature remains sufficiently
below the selfignition point

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Risk Monitoring: Photo caption of test set-up

A thermal imaging camera was used to measure the amount of heat emanating from the sheet,
making it possible to determine the risks

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Together with Shell, Bilfinger Brabant Mobiel has developed a safer
spray gun with special safety stop

Own Technology

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The risk of open flames in the plant is controlled by continuously
measuring the flammable substance levels in the plant

The risk of open flames in the plant is controlled by continuously measuring the flammable
substance levels in the plant

A large number of inspections was carried out jointly by Bilfinger Brabant Mobiel and Shell
Moerdijks fire department to ensure safety during work

Moreover, continuous monitoring for gas leaks was performed throughout the work, whereby
RISK CONTROL fire-fighting equipment was kept on hand at all times

Additionally, a comprehensive task risk analysis carried out beforehand yielded a number of
additional measures

Thus the required scaffolding was completely sealed to minimise nuisance during blasting
and protect the structural conditioning of the local area

The TSA solution was applied by qualified Bilfinger Brabant Mobiel painters

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Good preparation, clear risk control measures and a close
cooperation with Shell were key for the project success

Commissioned by Shell Moerdijk as part of the multi-

service contract at this site, Bilfinger Brabant Mobiel
applied a coat of TSA onto a propylene oxide vessel
in a running plant

A unique project, as open flame and locally high

temperatures are unconditionally associated with this
type of application.

Good preparation and additional measures rendered

risks manageable

Allowing Shells production to continue without

disruption

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The Benefits for Shell: No production loss, better quality and lower
maintenance costs

BENEFITS OF THIS PROJECT THE BILFINGER APPROACH

No production loss Extensive Research:

Accurate identification and management of safety Extensive research into circumstances under which
risks throughout the application the ignition point of the substrates present is
triggered
TSA can also be used at higher temperatures
Monitoring:
No drying or curing time required
Test set-up for monitoring tank wall temperature
Better quality, longer service life (equipment wall)
Thanks its good protective properties, TSA has a Safety:
higher quality than paint:
Sealing of scaffolding to reduce nuisance and
It can last as long as the service life of the object it protect conditioning
is sprayed on (30 to 40 years or longer).
Safety inspections in close collaboration with Shell
Lower maintenance costs Moerdijks fire department
TSA is a proven, sustainable technology with lower Real-time monitoring for gas leaks
maintenance costs.

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Pros and Cons of TSA
Benefits of Thermal Sprayed Aluminium

Pros Cons

Term of protection of about 40 years; Cost per m are significantly higher than a paint
system
The product is heat resistant so ideally suited for
industrial environments; Factor 3 to 4 times concerning shopwork

Aluminium and its oxides are not harmful to the Factor 6-10 times for field work
environment;

TSA is ideal for corrosion under insulation;

Integral costs of maintenance be reduced by a

longer maintenance cycle; Empfehlung

TSA offers lasting protection specifically in a

maritime and industrial environment

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Bilfinger Experts in TSA
Competences all over Central and Northern Europe

Region: Netherland, Belgium, International Support

BENELUX Industrial Services Erik den Adel; erik.den.adel@bis-is.com

Guy Coertjens; guy.coertjens@bils-is.com

Arnold Schep; arnold.schep@bis-is.com

Region: Germany
Bilfinger arnholdt
Michael Eck; michael.eck@bilfinger.com

Region: UK
Bilfinger Salamis Group UK
Simon Hope; s.hope.contractor@bilfinger.com

Region: Norway, Scandinavia

Bilfinger Industrier Group Johnny Vallestad; jva@bis-industrier.no

Tom Jerejian; tje@bis-industrier.no

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References across Central and Northern Europe

Shell Pernis (2013 2015)

Shell Moerdijk (2013 2015)

Exxon Botlek (2014)

DOW (2013)
REFERENCES
BP Ula

Edvard Greig process module

Kvrner Verdal

Conoco Phillips

Atlantic Resources

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