Jack-up rig at a shipyard of a leading International Exploration Company in Singapore The Challenge: A jack up rig is a mobile self-elevating drilling platform equipped with legs that can be lowered to the ocean floor until a foundation is established to support the drilling platform. The walls and floors of the mud pits are heavily corroded and it needs a good protective coating for long-term protection. However, the client would not allow abrasive air blasting, instead they want an alternative method of preparation. Due to the urgency of the repair job, they also want a coating that can be applied even when there’s welding in progress on adjoining areas. The Solution: The oil rig platform undergoes extensive repairs at Jurong Shipyard in Singapore and mud pit areas were prepared by cleaning with seawater. Afterwards, all corroded and pitted areas were marked for power tool cleaning using needle guns, power wire brush and grinders to remove rust scales and other contaminants. Hi-pressure freshwater washing at a maximum of 4000 psi was done to remove adhering dried slime, algae, loose paint, rust scales and other foreign matters. In order that the surface should have minimum soluble salt contamination such as chlorides, Chlor*Rid solution was used to assure the client that chloride contamination was brought down to the acceptable limits of less than five (5) ppm. Corro-Dur 561 White and Corro-Dur 258 White and Haze Gray were chosen as the ideal coating for this application due to several reasons: · Able to build up metal loss on crevices, depressions and deep pits · It has 100% Volume Solids which eliminates stress related problems in areas such as edges, corners because there are no solvents that will evaporate. · Solvent free and essentially odorless formulation provides worker safety and the ability to seal cracks (because wet film thickness equal dry film thickness). · A true surface tolerant coating since it can be applied on wet or damp surface with minimal surface preparation such as power tool cleaning instead of the usual abrasive air blasting. · There is no humidity limits, which means that application can be done any time of day. · Compatible with all residues of all existing coating types. · The micro fibers in our KevlarÔ reinforced epoxies provide outstanding coating strength and cohesiveness. It also exhibits good abrasion and chemical resistance. · In addition to being compliant to existing environmental regulations, it is also field friendly since the mixing ratio can be off by 10% or more without problem of curing and also the exothermic (heat releasing) reaction is much less than other epoxies. Corro-Dur 258 was applied on the wall at a total dry film thickness of 600 microns applied in multiple passes while the floor was prime coated with Corro-Dur 561 at 600 microns and top coated with Corro-Dur 258 at 300 microns. Application was done using brush, roller and spreaders by sub-contractors of the rig under supervision from Corroserv’s technical representatives. The Result: A total of five (5) mud pits and a slug pit were coated with Corro-Dur Coatings which exhibit hard and shiny surface due to Kevlar reinforcements that contributes to a very tough coating well suited to resist mechanical abrasions during agitating process.