Industrial Coatings – Example of Failures

welcome to SVC car this is another video with our industrial inspector Erik Montague in this video he talks about the damage that he’s seen in the field real-world examples what caused them and what’s repairs work he also ends up with a great salvage story on the Great Salt Lake see you like this tank was built in April yeah I inspected it in January so depending on how many days they actually used it it’s somewhere between 280 and 400 mils per year of corrosion that’s that’s almost a through-hole and that that is a hole they like and sometimes I call that meet sea corrosion the outside and the inside they got to get it I did some meet see what happened that that happened so near as I can tell that’s about this high earlier as I can tell that it’s an arc strike from a MIG gun that didn’t get strike coded well enough to be encapsulate that’s that’s the edges of my Kiehl’s so this is obviously a weld yeah and that is you can even see the strike code see the strike coat yeah sure okay so you can see the stripe coat below there’s no other roller you know to me it looks like a brush does it okay so to me it looks like a three or four inch wide brush and then they sprayed the the coating on top of it and that is impact damage to the weld who knows from what so a tool or something it was chipped yeah chip and because of that it’s corroded preferentially right at the weld and it’s over an eighth of an inch deep in four and a half months but you’re saying they’re storing saltwater and yeah so it’s it’s it’s what we call production water so it’s salt water and a mixture of oil and then they’re adding chemicals to help encourage the oil and water separation so they can separate the oil and dispose or reuse the saltwater right a newly coated tank that has failed along the weld seams weld seam weld seam nozzle a nozzle nozzle nozzle what does this tell me this tells me that if that either it started at the weld or it collected near the weld I think this was painted in in the where the tank was in the four Zonta position mm-hmm and I think that there was lots of dust and other debris maybe even moving are they sitting on the weld and that as it got painted it encapsulated that once the tank flexed enough if I saw this before they started sandblasting the day before and this was some of this was loose and when they did a sweep of blast it literally knocked it off or got underneath it and popped it off you can see some of the areas are tightly adhered on the weld zone itself but for the most part it failed on and near the weld zones if it hadn’t flexed it might be alright for a long time if it’s just the type coatings so here’s the sides of the tank they didn’t flex and as a result the coating is fine except for around a couple of isolated areas and a nozzle and the nozzle most likely flexed also so this is a good example impact damage where you’ve got a coating that’s that’s a wonderful coating that is protecting the steel substrate but because of impact damage is now created if they get the impact damage along the corner there okay now that’s a separate discontinuity let’s talk about what ru swears the impact damage these is that these two these two here in the fourth okay one of them is actually the chip of the coating that has failed let me zoom in so impact damage I’m covering one here’s one and you see here you can actually see the circle yeah that’s actually the piece of coating that popped off they dropped a what looks like a plumb bob it’s actually a gauge tape right and this striker pad is actually designed for this this takes the impact instead of this tank floor unfortunately this is directly welded over the floor which means when this corrodes all the way through it will also keep corroding through the tank floor problem this was measured in this gauge here we call it a pin gauge a 4-page Oh see reading you just laid it over on its side but you’re measuring how deep this crater is there yeah I measured that hole at 280 mils deep that’s me so it’s over a quarter-inch through the material but what was interesting is there’s actually corrosion underneath it’s spread it’s spreading behind the coating yeah coating coating yeah when this stuff costs its coating I actually was able to pop off even more in this area get over

double the diameter it’s it’s very large now this is a separate room this is actually the floor of the tank to the shell of the tank and what you have is this well what happened is this is undercut on one edge of the well so this is undercut on the shell side of the floor – shell fill it welt so you’re saying when they welded this horizontally along here it melted some of the steel well away above the weld yes so this weld is welded by hand right and right along here this stretch the guy must have changed angle yeah just another 200 that he undercut the top of the well why did occur there I mean they coded it it’s a sharp edge it’s a sharp axe my hole around there they are yeah so you’ve got that the edge of the metal comes to such a sharp point that even striped coating it you can’t get the paint it doesn’t adequately encapsulate that sharp edge and as a result everywhere this had undercuts along the tank it’s just you know or something I just you know I’ve damaged stuff out here and I have that same issue but it’s not that it’s progressed it I’ll that’s the thing is I’ve been out here for a year or so after the paint well I mean this this is this is an unusual example but this is you know you’ve got salt water and they’re adding chemicals to our salt water and as a result as hot salt water – it’s in a tanks and it’s gonna warm up for the summer right and you’re adding chemicals where it’s it’s it’s it’s accelerating or in increasing the oxygen content so now you’ve got a corrosive material and lots of oxygen and temperature exposed against carbon steel horn is don’t let it don’t wait on it get it what certain young here’s some good examples of what happens when when steel starts crude underneath a coating so you’ve got a holiday you know a little pinprick in the coating or a bubble in the coating and then this the steel starts to corrode and actually the mm scale bubble make a bubble behind the pen find it and then what it’s doing is its stretching that coating until the coating so this area here is lifted no ready or it’s no one little area out well so a pimple it doesn’t that is what a lot of time I mean that is essentially what it is it’s a pimple so you’ve got a little tiny hole and then it’s stretching the coating as the the area of corrosion we think sticks yeah it and as it expands it’s expanding linearly and circumferentially so it’s stretching the coating and as that happens it exposes more and more steel so instead of just having corrosion happening under the coating you’re actually getting more and more exposed area as the as the coating gets lifted and as a result that is actually a 3d area that that is very similar to a pendulum and in fact if you scrape that with a scraper it’ll pop the whole area I rented our areas that have not started to corrode enough to lift the coating with the holiday really what it does correct here’s an area where they welded directly to the tank on the outside on the outside in their own I’ve seen that here this is adjacent area is actually where they touched up the coating and it still felt because they probably didn’t do enough prep to protect bleed in between the coating and the repair this one is completely collapse elated so it’s not corroding and this one if they didn’t touch it up it just fell off completely or that one’s obvious that’s a bubble that is a boom so you’ve got a weld area that was repaired its noticed that you you’ve got a different coating you know of it right but because they didn’t feather that edge back it caught an air bubble nothing the original coating comes down to here yeah this line see this line right here oh it’s right here yeah I see that easy there anyone and then what they did is they patched it they just patched that whole area well they did make it wasn’t there was not enough attention to detail to catch that with a constant solvent or just an air bubble form there yeah and and maybe the guy did it wet and never came back when it was dry I mean what would he do when he comes back when it’s dry you just didn’t inspect his work just take yeah you mean yeah yeah right instead the guy did it wet walked away from and that was the last time it was touched here’s one that really gets me it’s tiny there’s no way to find this

unless he’s less than a sixth and fourth of an inch that is half of a 64 dimension that’s less yes that holiday Testament yeah we found that because of holiday testing all right probably the only way you would really find that or expect to find that is with Allah but you’re heading on in a tank with corrosive product you hit it off the problem four months down the road yes the fact that tank could be leaking in four months good microscopic and they’re probably this big because we set on it long enough with a holiday tester to literally burn the hole right because I mean it will start to open the hole yeah but at that point it’s already a pair yeah sorry no matter you’re gonna have with a sander anyway this was a piece of grit sand grit sand grit or dirt or something and it didn’t get completely encapsulate like having a little speck of sharp edge mm-hmm all that surface earth here’s here’s a piece of weld splatter it might have been an accidental strike like an arc strike with a MIG gun or it might have been splatter from an adjacent area I’m not sure but the more important part is it didn’t get encapsulated right and because it didn’t get encapsulated it Holliday test I’ll go back to that one so I said what they did is they didn’t feather the edge great it was damaged maybe there was bug in there or all right at that you know every one of them at the edge that’s a whole my god is huge it started at the will yeah well it started read all of it I see the ends of your pen in this photo so it’s not that huge but it is also through so that’s the weld is that matter interests you that is courage Dale so we’re looking to is the into the part below the tank yeah the the the space is space below the floor so what happened is they took and they they laid some they laid some I beam radially right in the middle of the tank and that floor is set at a slope all right so it’s looks like all the sonic conventionally goes to that center hole that’s in a hole so they’ve got an interstitial face and that is a hole where the coating cracked maybe there was some undercut right next to the weld all right so it was already thinner there and that’s where it preferentially failed hmm you know how long is this a same same a farm adult four month so six of those tin tanks are and that shouldn’t happen so what happened to the process when they do Roxy generated salt water with a chemical okay so they’re expecting this in four months no so know what’s wrong with the paint job there that is a good question the two thin digit digit you Ranier to thickness on it to we did thickness tests the thickness tests were thinner than what we would have expected I would have expected 35 to 50 mils some of this stuff was as thin as bait and I found it areas thinner than that I found an area that had probably 20 or 30 square feet of 5 mils in a single application single single layer single application the whole tank was single application one coat yes and I believe all of them were like that not done in accordance with the manufacturers recommendation so was the first Clues when the tank is bleeding oil down the side so what happened is this tank leaked right here yeah and then they said hey we need to get inspect right here to look at it and see why it failed in the time it took for them to schedule me on this job get the things in motion to get them on the schedule get me there you know because I I’m not usually available right now another tank developed a leak and that’s when they said hey we’ve got to do this yeah for right we’re losing tanks quickly so they they shut down that part of the tank yeah so we’re talking about a patch with a plate to repair that or just well build up I mean what’s the what’s the process for repairing a hole through all the way through the steel or even a halfway through this deal and what’s that might remind it let me do my ruler my my standard recommendation is if there’s any welding it needs to be either an insert plate or a patch so I don’t like well unless it’s not all the way through if you’ve got hole all the way through you’re gonna take a piece of copper well in season if it’s not all the way through well buildup could quickly make it all the way through well in that case what I would actually like to see is weld villain floss a patch at the very least right and I would prefer an insert plate than a patch what do you mean in certainly so any insert plate is literally where you cut a hole and insert I like that that’s that’s brute Pegman yeah they cut holes they cut a piece of steel they weld it in you watch

repair hey I have watched a few of his videos with my daughter and that is a better method it’s harder and it doesn’t give you any what some people see is extra thickness yeah a flush patch but what I see about a patch that goes on the surface is you’ve got all this area between the two we’ve got no coating where you have it’s like artists like presenting some rough so if you just have some oxygen and get in there it’s gonna continue to if you don’t seal it completely up why you do have so you’ll have interstitial space corrosion yeah and that crevice corrosion is gonna pull on the welds yeah that are attaching the plate which can get more air in accelerated it’s now a covered area in it’s a restricted area so it can’t be inspected as easy and it’s not an integral part of the of the object of the tank of it of the of the of the boat of anything how big of patches have you seen I’ve seen some that when we got done cutting them you wondered why we saved it I’ve seen some that were cut ten feet tall and 40 feet long well you were your wholesale replacing entire pieces of place disguise there so the damage is so close together that you might need to take the whole chunk you know a lot of these are also where the object is currently there you couldn’t get a permit to build a new one but you can repair the existing one it sounds like regulations getting away of good good judgement you have an object you need to use that you may not be allowed to replace but you’re allowed to repair so we repair the floor this time and then we wait and then we repair the shell and then we wait and then we replace the roof and what do you know Doug yeah we’ve got a got a new tank we’ve got an almost new object that’s not a new tank but you’ve repaired over yeah Tallyho it’s not a bad it’s not a plant bad installment plane and that’s how you’ve got a approach it’s an installment plan right it’s more expensive than just building a new one but if you tear the that one all the way down you know you’re not repairing an existing one right you’re building a new one yeah and there’s a lots of dynamics that sometimes keep that from happening you know I’ve seen patches as small as half a square foot you know is that an effective use of effort well I mean if that’s the only affected area but what happens if you’re talking about a tank that’s 150 foot diameter and 48 feet tall and you do 200 of them all right well that’s still more effective than cutting out 10 foot swath 10 by 40 in three different places I definitely think you know you look at the damage and I would think okay we’re gonna make a jigs we just magnetically put it on there around the plasma torch around it and we already have a whole bunch of water jet cut place to just drop in there and we’ll start welding in you can make it an efficient way of doing it I’ve never seen it that efficient but I have seen karbala cardboard templates put the cardboard on paint around the edge ha oh yeah cut the edge insert a plate carpet over cardboard over to make your play yeah yeah and the whole thing boatbuilding to me some of its tank building tanks tanks are designed to keep the liquid in instead of liquid out tanks and boats are very similar very similar very simple yeah so do they ever San Blas to do these repairs over the holidays yeah sometimes they do bar would you take on see a holiday and they decide to cut it back to raw material if you’re trying to get a Ruby job there’s a there’s a fine balance of coz love times what ends up happening is the guy making the decision isn’t in the field right so he’s trying to hear or read what gets reported and then make an executive decision based on that and then it’s like okay well what’s the safe call because no one ever wants to get bit by this project twice work okay you took it out of service you cleaned it then you made a repair and it didn’t work for four months there we got it again right and that’s where so many of these you know the industry has progressed so much but we’re still using the same types of things and there’s a lot of times where instead of using it and this puts me out of business so it’s kind of a touchy subject you know you’ve got a steel tank with a coating on it and because of the dynamics of trying to build and co2 tank and then get it out

to where they’re gonna use it without damaging the coating and get it into service and make sure it was inspected at all those intervals before you use it or yeah bite the bullet and you pay for an even more expensive fiberglass tank that maybe is or isn’t : and you completely skip all these steps the problem with a fiberglass tank is some people don’t see them as robust if they can’t handle the near temperature extremes and of course in a fire scenario they will not survive yeah so I mean there are some reasons to still use a steel tank it’s just when you have exotic chemicals with a corrosive product you know what you what you’re adding maybe super oxygenating your product so that if you have any holiday now you’ve got mass really massively accelerated corrosion and then when you do have a problem well do you step back and say okay we can spend the money and make an attempt at a repair maybe it works maybe it doesn’t and you still got a you know you’ve got a tightly inspect the entire process of repair for any hope of an adequate repair where you do you bite the big bullet and just get rid of all of it and then use something other than steel right and they don’t have any a lot it does not I don’t my question has to help you usually do this report that says you’ve got this many holidays in this tank you got this type of impact damage you’ve got some arc strikes in here and here do you give a recommendation as to the decision that they make these say I would scrap this tank of repairing it needs some it’s hatches it’s highly variable so much of it depends on the client and then what we’ve been hired to do right sometimes I’m hired to just come in and find it and provide that information and as a result I’ll spend a fair amount of energy to document right and then let them make the decision right other times I’ve been hired to come in and be the resident expert okay not only identify what’s wrong and where it’s wrong but also to to recommend to them what they should do and that’s a fine balance because I’m making a decision without having to pay for yeah and and and you know some people make that very flippantly I do not because I realized this represents real money a lot of and maybe somebody’s career not necessarily mine all the time made mine too of course you know there’s still plenty of my career left I worry about it in making that decision and and and that that’s what that’s what makes all of this hard you know do you do you take the safe bed or do you take do you take the angle that if it’s done correctly will work but only if they’re willing to pay the money to inspect it to make sure it’s the correct you know I’ve always said all along these products are designed well the the disconnect is when you use an awesomely designed product either not in accordance with the manufacturers recommendations in either surface prep the environmental conditions of applying it or it was applied flippantly where you know there was a lot of quality controlling the guy applying it and then there was no quality control in checking the guy that put it on you know so many of these products are used where they send a group of people to go forth and use right and there’s no inspection behind to see how well they did and that’s the disciplinarian owner doing something the risk our own knowledge of how to apply it and somebody is newly hired in a shipyard doing it without anybody at watch Hill well in strangers on both sides and so much of this in the in any industry it’s still seen as paint and that’s why I’m trying so hard to call them coatings because these are these require a lot of attention to detail in in in every city in every step and if that attention to detail in every one of those steps isn’t met and then it’s inspected to make sure it did get done correctly you’re just sending a guy out to go put a coating on what you’d send a guy out to paint a fence with consequences much more dire and when they go wrong that’s still the same guy that’s gonna go out and repair it so he didn’t do a good job when the conditions were brand-new and good and now we’re gonna send that same guy out or that same type

of guy out to make the repair now it’s dirty now it’s ain’t repair now there’s a critical schedule involved because now instead of it being brand new and we’re just waiting to sell it or deliver it now we’re under the gun to get this repair done so we put it back in service well that’s a whole lot more stress and an extra dynamic they didn’t have in the beginning and that was that was when we had a good chance to do it right and now we’ve got all the what you told me on the boat is like you got one chance to do it right the first time well that’s it’s not that you have one chance it’s that was your best chance yeah well the first time it’s my one chance well on your boat you know you know there are hundreds if not thousands of square feet on that boat did we find every holiday oh no no so as a result we’re not going to look either well and that’s the things we’d let’s meet a little water my where I’m most interested so we checked below the water line in places that were hard to paint or are prone to failure or prone to damage and if we focus on all those areas then when corrosion does happen and invariably on something this large is something that’s going to be moving through the water going in out of harbors holy blogs and hitting’s and other stuff hopefully we never have to hit a floating container but that is happens to me there are there are only two really really bad scenarios on the open ocean getting run down by a freighter by a navy ship or a freighter in the middle of the night yeah take it easy on them they are the Navy they’ve been having aerial I wasn’t saying necessarily there are more navies than just ours ours is just the most important mode down three lately and then the other one is my greatest fear especially out in the Pacific is running into a semi submerged oh yeah because that thing fully loaded will weigh almost what your boat go away yeah well there are also a lot of coral heads out there you’re trying to get into an island or something it’s like you better have the right weight marks on your charts and good weather and all type of things going to favor your father would I have a I have a lukewarm acquaintance who’s from Kiribati yeah and I have looked at that the truck for that and that is a city everyone yeah scary entrance there’s a lot about there Lana and I’ve compared what your draft is to that depth yeah they come real close to meeting we the tie is important and the swells I’m important yeah I there are a lot of places I would like to visit and a lot of them are shallow boy that’s why they have cats yeah I’ve never told you the story about my brother’s trimer and yeah and it’s flipping upside down with little bindi really a bigger truck 40 feet 85 mile an hour winds oh my goodness I have what were you doing out names my line I have the distinct and almost completely unknown mark that I have douve a salvage expedition in the Great Salt Lake you had a try on the Great Salt Lake and know we had a sunk try in the Great Salt Lake and I doe this is a horrible idea Leslie you need then take yourself down in the Great Salt Lake I was literally wearing a rectangle plate of lead that I cast for the event I used every piece of extra let I had I had every lead weight in my BC and I had 16 pounds of ankle weight per leg the other way to be splitting the size I didn’t have hardly any air in my beast I was using ordinary scuba dive equipment to do a salvage job with lots of stainless steel wire upside down happy for you it was in the marina and the Great Salt Lake is not known for death yeah but it is known for lack of visibility so after I touched the you know tank we call that trub the basic sediment yeah on the bottom there was zero visibility yeah so I did the entire job with no communication and all by field all by myself use lift bags are we hooking up for a crank call I was using a pair of bolt cutters pretty kind of everything the

one that’s cutting the rigging away so we could try to roll the boat over we gotta get this bunk bed we’re gonna have so much fun you know the neat thing about that is that that salvage job was successful and then we move that boat from the Great Salt Lake to Jacksonville North Carolina so it is now on the Atlantic and it still scares me because it’s sitting on the water not in the water but it drafts about eight inches yeah yeah it’s all about can you maintain your sense of composure that’s what saved me if you that’s why it’s like it you know are you gonna use emotion or judgment to make new decisions it’s emotion you’re dead call people the people that yeah I reached behind me and untangled all those lines I balled them up underneath my arm and I used a pair of bolt cutters to cut that entire bundle one line at a time all by field all right and then I kept moving back and every time I’d run into a line I had run it up to my tank and reach behind me and get it into my hand get it underneath my arm so I could feel it get it into the jaws that bolt cutter and cut it and I cut every line every guy wire to all that no longer standing rigging right so that we could try to drag the mast off the boat so that we could try to roll is you actually roll the boat in the water or if you they just hold it out with crane no we roll it no what we did it on no cars no I love Oh cranes no cranes it involved it involved a a built jib on land right with a cable running up and over it down into the boat well the nice thing is and that water is like even it completely flooded it doesn’t weigh as much as it does out of the water about the problem is is it it was wider than the water was deep so you couldn’t roll it you couldn’t roll it over it out of the water when I’m pulling a lot of that okay and and I end this get left then when we picked it up and threw it the Great Salt Lake is known for being and probably the most geographic unusable area you’re close enough to the mountains that when they get the wind just right it hits the mountains it actually accelerates it cuz it’s funneling it so you get 85 200 I think they’ve measured over a hundred miles an hour at the marina on the Great Salt Lake anyway you get four anchors and tie down your boat I mean it’s like there were four hangers died to that boat and it’s still what most likely happened is it got the boat too pitchy before brave yeah we became an airforce and as soon as it got enough up angle to get enough air under the boat they just flipped it all the way over on top of the mast and the Crump of the mass was available crumpled wreck that yeah me and my brother take weld it back together get us it’s on the sides die grinded the groove so that the the help the sail track would still go up and down that that’s a that was a test in in Fortitude yeah listen I can’t thank you enough for coming back out again enlightening us well I keep telling you Midland of Tulsa is a short drive yeah yeah well you come midnight else anytime you want I told you I was in the neighborhood yeah