Thermal Sprayed Aluminum (TSA) has been widely used by the oil industry for corrosion protection of steel components in submerged, splash zone, and marine atmosphere service on offshore facilities. Excellent performance of TSA coatings on hot risers has been well documented for the Hutton TLP (installed 1984), Jolliet TLWP (1989), and in accelerated laboratory testing. Recently, rapid deterioration of TSA coatings occurred on hot marine export risers in a 2-meter segment exposed to the wave zone that induced high frequency thermal cycling. Laboratory tests have shown that this failure mechanism is enhanced by excess coating thickness and retarded by higher quality sealer.

Subject
Risers, Coating performance, Piping, Aluminum spraying, Splash zone, Coating damage, Porosity, Coating thickness, Mechanical failure, Sealers, Blistering, Deterioration, Submerged zone
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2004
Association for Materials Protection and Performance (AMPP)
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