Waste / Water Recovery and Recycling

Presenter: Scotia Boelee

Business Development Manager, Contract Resources

Transfield Worley Services 2007

UHP Surface Preparation

Water / Waste Recirculation & Recycling System

Transfield Worley Services 2007

Introduction Contract Resources Introduction HP Hydrojetting vs. Abrasive Blasting Water / Waste Recycling System BP Largs North: Tank Terminal Benefits

Transfield Worley Services 2007

Contract Resources
Since 1989 Contract Resources has provided a wide range of specialised industrial services to major clients in the oil & gas, chemical, cement, mining, utilities and dairy industries Technical alliances with a number international corporations have ensured best practice transfer, plus access to innovative equipment and processes Contract Resources extensive Engineering Design and Construction team is focused on continuous improvement, consolidating Best Practice and cutting edge technology. Delivery of optimized equipment via 3D parametric modeling and FEA technology As a service provider, prompt mobilisation and response times are achieved due to our base locations throughout Australia, New Zealand and the Americas Contract Resources has built a strong reputation based on exceptional service, technical innovation and the experience of its staff and directors

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Base Locations

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UHP or Abrasive Preparation? Surface preparation method specification

Owner Contractor Coatings Manufacturer Performance Environmental Regulations Health and Safety Economics
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Influencing factors

More Than One Type of Rust?

Flash rusting is characterised by chemical make-up, tight adhesion to the surface, colour and degree of coverage.

Yellow-brown in colour at light-medium levels Tightly and consistently adhered to the surface Oxide films well bonded to the metal which serves as reactive sites

Attract polar & chemically active groups on paint polymer binder Flash rust formed post UHP HJ with potable water consists of pure iron oxide
A constituent of some coating systems

Other types of rusting have detrimental impact on adhesion & coating longevity

Post abrasive blasting rust, heavy flash rust, mill scale, aged loose contaminated rust

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Surface Impacts of Preparation

Solid particulate blasting is effective at removing brittle rust products lying on top of the metal surface Not microscopic rust embedded in the folds UHP HJ removes rust preferentially from crevices and deep pockets Leaves tightly adherent rust products on the tips Decreases number of active corrosion sites HJ increases surface area, due to the micro profile, of a previous AB surface
Abrasive Blast: Top View

Abrasive Blast: Day 1 Black Spots

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Cavitation

Illustrates the initial point of impact by the water droplet Combination of the energy dissipation at the initial point of impact combined with the sideways action that makes water so effective in cleaning surfaces The initial impact is small compared to the water droplet.

100 micron droplet easily enter a 10 micron pit in the substrate Thus fluid water can get into crevices, pits, holes, and breaks in the coatings

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Side Shear Forces

Two actions in hydrojet cleaning

Direct impact Sideways flow

To abrade coating or rust, sufficient impact induced erosion is required

Breaks cohesion with substrate

Shear stress develops against vertical pit walls producing hydraulic lifting.

Shear stresses adhesion forces

Adhesion begins at the bottom of the pits

HJ cleans the pits

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Coating Adhesion
Metal with flash rust at light to medium levels is a suitable substrate for a majority of coating systems

Supported a number of coating manufacturers Lowest soluble salt readings of all preparation methods (lowest [Cl] ions) Test results (6 years) show at least equivalent and often preferential adhesion performance for UHP HJ surfaces

Pull-off strengths superior for UHP HJ surfaces coated with Epoxy's and equivalent results for Urethane coatings Layer of water & corrosion formed at the metal/coating interface on the AB surface was not present at UHP HJ interface For bare panels, UHP HJ surface maintained flash rust while AB surface was heavily corroded

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Adherence and Wettability

Coating performance requires intimate contact with the substrate to allow adhesive bonds to be formed

HJ increases the surface energy of the substrate, therefore wettability Coatings must wet out for optimal adherence and performance

McGaulley et al SSPC 2001 Conference Comparison of Secondary Surface Preparation over Water Jetted Surface and Effect on Coatings Performance,

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Relevant HSE Policy

General, Dust & Particulates

Workplace Health and Safety Act 1995 & Regulation 1997 Safety Act Workplace Health and Safety Queensland National Occupational Health and Safety Commission (NOHSC) Australian and New Zealand Standard AS/NZS (Respiratory Devices, Hazardous Particulates, Lead Handling, Explosive Atmospheres etc) Noise Code of Practice 2004 The Environmental Protection Act 1994 The Environmental Protection Regulation 1998 & 1996 Australian Code for Transportation of Dangerous Goods by Road and Rail Radiation Safety Act 1999 Radiation Safety Regulation 1999 Health (Radioactive Substances) Regulation 1994 Australian & New Zealand Standard Standards (Elevating work platforms, PPE)
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Waste management

Abrasive materials

Working at heights

Average Lead In Air (ug/m3)

Encapsulation recycled metallic media UHP Waterjetting Low Vol. Slurry Open Air Abrasive Small Area Touch up- hand/power tools 3015 9 4 13,439 680

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Environmental Pollution

Preventatives

Containment Processing Recycling Location: Mobilisation Containment Waste Disposal

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Drivers

Industrial Application
Latest technology UHP pumps and Spider-Jet allows large vertical and horizontal surfaces to be completely stripped Operators work from the ground

Remotely controlled pumps and accessories Fatigue and jet spray exposure are eliminated Vast majority of work can be completed without scaffolding No exposure to lead and other toxic materials

Water and debris are vacuum removed and collected and water can be recycled removing need for encapsulation Once dewatered all waste is bagged and ready for disposal

No manual labour or exposure to hazard.

Handheld AquaJet is used to work around fitting and tight crevices Any gun work required is carried with the latest microchip shutoff technology to ensure complete operator safety
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Spider-Jet
Recognised throughout Europe as the healthy, environmentally friendly, dust free method UHP water blasting systems operate at pressures up to 3000 bar without abrasive additives Substrates meet quality requirements

International paint manufacturers Standards authorities for application new coatings

Remaining chloride levels are at least 5 times lower than in a grit blasted surface Substrate profile remains intact ensuring good adhesion & reduced risk of future paint film defects The amount of waste produced is far less than that produced by dry blasting Traditionally spent water, old paint and rust are the only waste products

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Water / Waste Recycling System

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Video of Spider-Jet in Action

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HSE Impact Comparison

Average Tank
Diameter = 24M Grit / Water Usage Encapsulation / Time / Personnel Disposal Costs Abrasive Blast Traditional UHP UHP Waste/Water Recycling System 7MT Water (Recyclable) Not Required 50m2 / hour 1 Operator $90-1000/MT

30MT (Grit) (non-recyclable) Yes (~$150K+) 8-12m2 / hour 1+ Operators $901000 / MT

242MT Water (non-recyclable) Yes (~$150K+) 8-10m2 / hour 1+ Operators $90-1000/MT

Grit + Old Coating Wet Old Coating Conc. Old Coating

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BP Largs North Terminal

Painted / rusted metal surfaces were totally stripped of paint / rust Ultra High Pressure Water (up to 40,000psi) with Spider-Jet Vacuum recovery system coupled with water recycling system Tank LN 4 1,600m2 cone roof tank with over-lapping plates Older tank previously coated with several coatings including

Tar-Epoxy, Zinc, Mastic and Poly Urethane.

Total paint / rust removal plus new three coat system Aqua-Jet with a full recovery system utilised for small appendences Remaining areas were cleaned with a gun and lance
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BP Largs North Terminal

Painting crew was able to safely follow within a few meters of the Spider-Jet applying the primer coat Spider-Jet leaves the surface hot and dry Flash rusting will not occur for several hours post cleaning 100% of coating debris dislodged by the UHP is contained Vacuumed away from the surface to a cyclone Separated from the water

Water filtered to 1micron for re-use by UHP pump Water consumption is limited to about 3.5-7M3

Tank LN 18 1,372m2 cone roof tank Hazardous paint was removed with three coat system applied

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BP Largs Benefits
Zero Harm to Health, Safety, Community and Environment

Operator safety

Utilised remote control No dust contamination No noise issues

Zero ground or air contamination to immediate or wider environment Innovative response to water shortage and contamination issues
R&D work to produce the waste/water recycling system Encapsulation not required Limited waste for off-site disposal

Significant Project Time/Cost Savings

200% faster surface stripping (1 operator UHP HJ vs. 2 operators/AB systems) No requirement for scaffold / encapsulation No decontamination required for UHP

Average saving of 3 weeks for encapsulation erection, clean-up and dismantling

Superior Surface Coating Adhesion

Transfield Worley Services 2007

 Transfield Worley Services 2007