IN SEARCH OF

EFFECTIVE
CORROSION
PROTECTION:
CATHODIC
PROTECTION
AND
COATING

Report by
Dr. Magdalena Kurkowska
Despite being one of the top failure mechanisms for offshore wind structures,
corrosion has not received adequate industry attention until recently, when it has
become apparent the actual corrosive conditions of offshore wind structures can be
very different from original design specifications.

Monopile foundations, presumed to be water and airtight have been often penetrated
by oxygen and seawater, which has led to changes in environment accelerating the
corrosion processes. Corrosion problems, however, are not limited to the
foundations. Driving branch, turbine house, pneumatic system, supporting structure,
control devices access technique are all affected and require protection and
monitoring.

The most effective protection can be achieved through the combined use of a high
quality coating and a cathodic protection system.

The challenges of cathodic protection

Cathodic protection (CP) has been widely used as a primary technology to protect
offshore wind structures against corrosion. Current industry standards require
external surfaces of the submerged zones to have cathodic protection, while using CP
inside the structures is optional. In the splash zone, CP is presumed to be fully
protective below Mean Water Level (MWL).

Generally, there are two categories of CP systems applied: the sacrificial anode
protection system (SACP), which uses galvanic materials (Zn or AL alloys) and is
attached directly to structure and the impressed current cathodic protection (ICCP)
system, in which anodes are made of noble materials, such as titanium, and isolated
from structures (connected through power unit). In most projects CP is performed by
galvanic anodes placed solely on the TP, but impressed current CP systems are also
applicable in a growing number of projects. Both systems have their challenges, such
as requiring regular monitoring and maintenance.

Close fitted (attached directly to structure) ICCP systems are currently used by some
operators. These systems, however, can cause overprotection close to anodes in
order to achieve protection at mudline. Over protection of the foundation plies can
lead to hydrogen embritlement (HE) and hydrogen induced cracking (HIC), which can
result in catastrophic failure.

Semi-remote SACP solutions provide improved current distribution and can be

suspended from TP. They are often used in retrofits schemes. These systems have
been commonly used in oil & gas sector and represent a proven technology.

www.corrosion-offshore.com
Remote ICCP/SACP systems are installed on seabed, typically 10-15m from the
foundation base. Depending on the application, anode systems can be sub-bottom,
on-bottom, or bottom tethered. Sub-bottom ICCP could be used in shallow water,
while bottom tethered ICCP systems are applicable for deeper jacket type structures.

Anti-corrosion retrofit market poised for growth

At present, a number of monopile foundation structures completely lack of cathodic

protection or coating. In early projects no corrosion protection, except corrosion
allowance, was applied since the structures were presumed completely water and
air-tight. Such approach has turned out insufficient in many cases and developers
have to re-examine these structures. Until now, however, there are no precise
guidelines for internal corrosion protection.

© Deepwater
Inspections conducted over past years have exposed a considerable number of
structures that have to be retrofitted with cathodic protection.

In many cases, the retrofit can only be achieved by application of remote anode sleds,
or subsea installation of extra anode cages. These activities are very expensive and
require the use of Remotely Operated Vehicles (ROV) accompanied by supply vessels.
Moreover, the inspection and retrofit activities are restricted by weather conditions
making the process even more challenging.

www.corrosion offshore.com
-
Specialist coating systems in demand

Anti-corrosion coatings can effectively protect wind turbines against rust. Good
surface preparation, right choice of coating system, correct application and regular
inspections can assure high durability of the coating system and efficient protection
against corrosion.

The use of coatings is mandatory on steel structures in the atmospheric zone and on
primary steel structures in the splash zone; while optional in the submerged zone and
on all internal steel surfaces. The general specifications for coating systems to be used
offshore are given in international standards: NORSOK M501, ISO 12944 and ISO
20340.

A recent study on the effectiveness of the offshore protective coatings conducted by

the Fraunhofer Institute for Manufacturing and Advanced Materials Research (IFAM)
and Muehlhan, concluded maximum corrosion protection can be achieved by Zn/Al
metallization, followed by two intermediate layers of particle reinforced EP-based
paints, and a polyurethane top coat. The research has also confirmed that as long as
any mechanical damage occurs, the coating systems performed equally well across all
water zones, even in the most corrosion-prone splash zone.

Here, the flange connection is a critical structural part in terms of corrosion and a
suitable sealant between abutting faces should be considered to ensure extra
protection. In the underwater zone, the coating remained unaffected by fouling, and
provided efficient corrosion protection.

Subjected to mechanical damage, the coating starts to delaminate, allowing corrosion

to start and expand. The costs of repairing of damaged spot are very high. Therefore,
an effective coating should be very resistant to impact - particle reinforcement, or able
to compensate for corrosion of the steel by metallization.

At present, the industry suffers from lack of standards for offshore coating repairs.
The RepaKorr project, cooperation between industry and research institutes, was
created to address this issue. Since offshore coating repairs are very expensive,
optimisation of coating repair procedures may lead to substantial project cost
reductions.

As anti-corrosion coating systems have proved their effectives in offshore

applications, the demand for specialist products is growing. In fact, the market for
anti-corrosion coatings is expected to reach US$26.3 million in 2019, with offshore
wind industry likely to take a large piece of it. Hempel, BASF, AkzoNobel, International
Paint, Zinga Norway AS, Plastocor International, Mäder and Sika Group are among a
growing number of companies offering a specialist line of coating products aimed at
the offshore wind industry.

www.corrosion-offshore.com
Hempel is regarded as the leader of innovation, with its HEMPADUR AvantGuard®
product range, awarded Materials Performance Corrosion Innovation of the Year at
the NACE Corrosion 2015 Conference and Exhibition. Hempel’s researchers
discovered that only about one-third of the zinc in a standard zinc epoxy coating
features an anti-corrosive effect. Their research focused on finding a better solution.
The result is a new patented AvantGuard® technology, which uses a combination of
zinc dust, hollow glass spheres and a company’s proprietary activator to activate
more of the zinc in the coating. Hempel’s coatings provide substantially better
galvanic protection than standard zinc epoxies. They are also very resistant to rust
creep, significantly reducing the need for costly repairs. These superior qualities have
been confirmed by a range of tests, including salt spray tests (ISO 12944 part 6), cyclic
corrosion tests (ISO 20340 - NORSOK M-501 revision 6) and thermal cycling
resistance tests (NACE cracking test and Hempel’s welding test).

AkzoNobel’s suit of protective coatings for offshore wind power includes Interzone
954, designed for strong performance in environments that combine a high potential
for mechanical damage, atmospheric corrosion and immersion, Interzone 1000, a
glass-reinforced epoxy coating, containing 30%+ chemically resistant glass flake in the
dry film and Interzone 485, an ultra-high built, high volume solids, two components
catalyzed epoxy.

BASF has joined the market with RELEST®, a specialist coating system for rotor
blades.

Plastocor International has also developed a dedicated suit of coating products for the
offshore wind industry: WE-6221 and WE-6222 paints for offshore wind towers and
nacelles, WE-9300 Fast for the leading edge of wind turbine blades and WE-9400 for
wind turbines blades.

An interesting market entrant is Tesla NanoCoatings. The company’s product, Teslan,

is a Zinc primer formulated with carbon nanotubes that assemble into ropelike
structures that make them tough and flexible. Teslan-coated surfaces can be formed
after coating and still remain intact because the carbon nanotubes can be stretched
without breaking. The solution can replace conventional three-coat systems
traditionally used to protect steel surfaces of offshore wind turbines, the company
claims.

Industry hungry for effective corrosion monitoring solutions

Cathodic protection of offshore turbines by galvanic anodes is well-established.

However, the interaction between the structure and environmental factors such as
depth, current and seawater are far from being fully understood. Therefore efficient
monitoring of CP performance and detection of protection failure is crucial for
ensuring integrity of assets.

www.corrosion-offshore.com
Corrosion monitoring is particularly challenging within the foundation structures. One
method is measuring of the wall thickness by ultrasonic systems; it can be applied
either internally, or externally.

FPermaZEN offshore corrosion monitor scheme:

An example of innovative solution is

PermaZEN, the offshore corrosion monitor
developed by ZENSOR. The PermaZEN
sensor is mounted in the turbine base.

Firstly, a connection is made between a

device and the metal of the foundation
(earthing connection). Next, 4 inert auxiliary
electrodes are lowered at multiple levels in
the water within the foundation.

All are connected with a conducting

electrode cable to the sensor device. In
order to detect corrosion reactions, the
sensor applies a low-amplitude AC signal
containing multiple frequencies between
one of the auxiliary electrodes and the
foundation.

After recording the system’s response to

this excitation, the sensor algorithm is
launched. As such, for each of the
electrodes, corrosion rates are calculated
and recorded.

© Zensor

The corrosion rate data can be checked from an on-shore location. At present, a
number of research & development projects aimed at developing effective corrosion
monitoring systems for offshore wind turbines is undertaken worldwide. Force
Technology, for example, investigates corrosion monitoring inside monopile
foundations using coupons and probes installation. TNO is developing coating health
monitor and MIC sensor, both based on the electrical impedance (EIS) technology.

www.corrosion-offshore.com
Summary

Corrosion has become one of the major challenges the offshore wind industry has to
face. The scale of the problem and associated cost are yet to be fully assessed. The
current protection methods: cathodic protection and coating have proven to be
effective, but both require robust monitoring. How to effectively monitor corrosion
and avoid costly repairs is where the research and development activities are focused.
Current industry codes and standards require review and expansion. At present, they
do not fully address critical areas regarding anode distribution, internal corrosion and
monitoring.

Sources:

Image01: Credit - Deepwater. Image 02: Credit - Zensor. Cover foto: Fotolia
Hempel’s HEMPADUR AvantGuard® wins NACE’s MP Corrosion Innovation of the Year,
http://www.hempel.com/en/about-hempel/news/2015/hempels-hempadur-avantguard-wins-naces-
mp-corrosion-innovation-of-the-year
Lu A., Anti-Corrosion Coatings To Reach $34M In 2019, International Business Times,
http://www.ibtimes.com.au/anti-corrosion-coatings-reach-34m-2019-1451242
Tesla Nanocatings, http://www.teslanano.com/product-category/corrosion-resistant-primers/
Combatting the scourge, Offshore Wind Industry, 3/2015, http://www.muehlhan.com/images
/news/OWI_03_2015_24-27_schutzbeschichtungen.pdf
Black A.R. Hilbert L.R., Mathiesen T., Corrosion protection of offshore wind foundations, Force
Technology, pdf
Britton J. Offshore Wind Turbine Foundation Cathodic Protection Design Option and Relevance of
Existing Standards, Deepwater EU Ltd., http://www.subseauk.com/editorialimages/jim-britton.pdf
Zensor, PermaZEN: Continuous monitoring of offshore foundations, http://www.zensor.be/node/18
Momber A., Maintenance Concepts for Corrosion Protection Systems of Wind Tower Structures,
Muelhlan AG, pdf
Morales F.L., Remote Sensoring for an Offshore Windfarm Maintenance System, TNO, pdf
Weston D., Experts call for more action to protect turbines, Windpower,
http://www.windpoweroffshore.com/article/1297319/experts-call-action-protect-turbines
Black A.R., Corrosion monitoring within offshore wind foundation structures, Force Technology, pdf
AkzoNobel, Protective coatings for wind power assets, http://www.international-pc.com/resource-centre
/documents/coatings-for-wind-power-uk.p
BASF, Relest Wind, Coating Systems for Wind Energy, http://www.basf-coatings.com/
Plastocor International, Sustainable Corossion Protection & Coating Solutions for On/-offshore Wind
Towers, http://www.plastocor-international.com/en/wind-energy/wind-products
 4th International Conference

CORROSION
Protect1on F 10R OFFSHORE W ND

EARL V CONFIRMED SPEAKERS FROM:

EDF, VATTENFALL, CARBON TRUST, SIEMENS, INNOGY

Corrosion Protection for Offshore Wind is the premier technical event

for leaders in the wind industry. lt is a meeting place for experts to
engage with the concepts for lang lasting protection systems and
strategies.

Case studies, new research and technical advances will be

interrogated in order to increase cost-efficiency and advance offshore
wind as a world leader in commercially competitive renewable energy.

download agenda