Industrial Profile of Chemichal Industry - PowerPoint by srm71221


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									Alternative Coatings For
Missile Launch & ICBM

            Mr. Dave Ellicks - AFCPCO
            Mr. John Bloyer – SAIC
            Mr. Michael Surratt - SAIC
       Past Related SAIC Alternative
 1995 Kadena AFB                  1998 Guam
  Automated Metal Wire Arc          Alternative Coatings on Vehicles:
  Spray (MWAS) refurbishment        MWAS, Zinc Rich Epoxy,
  line on MK 82, MK 84 GP           Inorganic Zinc, Ceramic loaded
  Bombs                             Epoxy, Rust Converters,
 1996, 1997, & 2002 Kelly AFB,     Corrosion preventatives
  CCAD, & Robins AFB               1999 Patrick AFB
  Powder Coating Evaluation and     MWAS on Non-powered SE
  Systems Integration              2001 JG-PP Project
 1997 Robins AFB                   Alternative Coatings On DOD
  Wing Maintenance Stands:          and NASA SE
  Alternative Coatings - MWAS
         Project Team Members
AFCPCO: Dave Ellicks                HQ AFSPC: Rich Bliss
SAIC                                   • Northrop Grumman: Bruce
   • John Bloyer -                     Fong
     Materials/Corrosion Engineer
                                       • 90 MMXS / MMXFC
   • Joe Yochum – Mechanical
     Engineer                          • 341st Space Wing
   • Michael Surratt –Senior           • 91st Space Wing
     Corrosion Analyst
                                       • 576th Space Wing
   • James Dean - Senior
     Corrosion Analyst                 • 41st Space Wing
   • John Lindsey - Senior             • 2nd SLS
     Corrosion Analyst
                                       • EG&G Technical Services,
   • Karl Plaume – Corrosion           Jacobs Sverdrup, Phoenix
                                       Management Inc
 Sprayed Metal Is
 Uses The
  “Throwing Power”
  Of Zinc On Steel
  Surfaces To Bridge
  Minor Damage
 25+ Year
  “Lifetime” Coating
  with Extensive
  Commercial Field
 Mature
  Technology 50+
  Years Of Test Data
Metal Wire Arc Spray (MWAS)
 Zero VOC Application        Proven Most Durable
 50+ Year History of          Field Applied Coating
  Exposures                   Available Wires for
 Not Degraded by UV           Cathodic protection of
 High Deposition Rate
  With Twin Wire Electrode       Aluminum
  Process                        Zinc
 Able to Spray Any Metal        85-15 Zinc/Aluminum
  in Wire Form                Barrier Protection
 Resist High Temperatures    Non-Slip Coatings
 Sensitive To Mis-Prep
   Task Description: Phase 1
 Develop Acceptable, Effective Metallizing
  Preparation/Application Process Optimization On Rocket
  Launch Towers
    Metallizing Being Accomplished Now
    Metallizing Requires Specific Preparation Or The
     Corrosion Inhibiting Value Is Diminished
    Proper Surface Prep The Major Lim/Fac In Tower
     Metallizing Application
 Validate If (Alternative coating processes / Metallizing are
  effective for application environments) Metallizing Is
  Cost/Env Effective On Rocket Launch Equipment
 Field Operational Test, Dem/Val Of Now-Term Coating
  Removal On Rocket Launch Equipment (Facilities)
Task Description – Phase II
   Field Operations Testing/Dem-Val

 Procure Equipment And Apply – Remove Materials
  From Select Sections Of Launcher/Launcher Support
  Equipment, ICBM Equipment
 Conduct Modified Coating Surface Preparation,
  Material Application Familiarization and Equipment
 Evaluate Dem/Val Results
 Track Test Sections Through 2-5 Launches SLC And
  Through Contract Period Of Performance For ICBM
           Baseline Survey
 Service Environment Exposure Profile/Mapping
 Identify Most Corrosion/Erosion Prone Locations
 Existing Depainting, Preparation, Recoating
 Coating Removal & Replacement Environmental
  Constraints, Concerns
 ICBM Site - User Needs And Constraints
 Identify Types Of On-Site Contractor/Gov
  Support And Support Equipment Available
 Available Life Cycle Cost Data On Refurbishing
  Service Environment Challenges
    SLS – Space Launch                      ICBM
          Structures            Both Coastal and NW Arid
 Coastal Environment
                                Vandenberg Test Missiles
 Combustion By-products
                                  •Combustion By-products
 Launch Temperatures
                                  •Launch Temperatures
 Coating Erosion
                                Application Temperatures
 Application Temperatures -
  Humidity                      Physical Damage
 Environmental Regulation      Water Intrusion
 Fuel/Coating Compatibility    Environmental Regulation
                                EMP Hardening
              Service Environment Exposure Mapping
                           Table 1: SLC and ICBM Environmental Zones
Environment                                             Description
  Zone A      Surfaces located in a marine environment that receive rocket engine exhaust impingement.
              Surfaces located in a marine environment that receive elevated temperatures above 65 degrees
  Zone B          Celsius (above 150 degrees Fahrenheit) and acid deposition from solid rocket booster
                  exhaust with no exhaust impingement.
              Surfaces, other than those located in Zones A or B, that receive acid deposition from solid rocket
  Zone C
                  booster exhaust products.
              Surfaces not located in the launch environment but located in a neutral pH corrosive marine
  Zone D
                  environment within 1 mile of ocean and less than 120m Elevation.
              Surfaces that tend to accumulate other types of chemical contamination (e.g., cooling towers,
  Zone E
                  diesel exhaust stacks, diesel spills, brine chiller leaks, etc.).
  Zone F      Surfaces located under insulation.
  Zone G      Surfaces located indoors that are not in an air conditioned environment.
              Exterior Surfaces located in Arid Northwest Climate that receive cold winter temperatures below
  Zone H
                  -20˚ C.
              Surfaces located in a continuous indoor air-conditioned environment below ground level and
  Zone I
                  possibly below the water table.
  Zone J      Surfaces located in a continuous indoor air-conditioned environment.
                       Service Environment Exposure Mapping
                               Table 2: Environmental Zones by Installation
                                        Zone Zone Zone Zone Zone Zone Zone Zone Zone Zone
                                         A    B    C    D    E    F    G    H     I    J

                       FE Warren                                X    X        X   X   X   X

                       Malmstrom                                X    X        X   X   X   X

                       Minot                                    X    X        X   X   X   X
   Industrial Launch

    Seacoast Heavy

                                         X     X    X     X     X    X        X       X   X
                                         X     X    X     X     X    X        X           X
                       Cape Canaveral
                                         X     X    X     X     X    X        X           X
Identify Most Corrosion/Erosion Prone
        Coating Removal & Replacement
       Environmental Constraints, Concerns
 Lead Based Paint: 29 CFR 1926.62 “Lead”.
 Abrasive Blasting: California Approved List – PM10 Concerns
 Coatings from Code of Federal Regulations: 40 CFR 59.401
         High Temp Coating                       (Max VOC = 650g/l)
         Industrial Maintenance Coatings         (Max VOC = 450g/l)
         Rust Preventative Coatings              (Max VOC = 400g/l)

 SBAPCD (Santa Barbara Air Pollution Control District) Rule 323 –
  (Local Vandenberg Restriction)
         High Temp Coating              (Max VOC = 420g/l)
         Industrial Maintenance (Currently Max VOC = 340g/l; 250g/l effective
          1/1/04; 100g/l effective in 2006)
         Rust Preventative Coatings (Max VOC = 400 g/l)
         Aerospace Coatings             (Max VOC Topcoat = 420 g/l)
                   Rule 337              (Max VOC Wing = 750 g/l)
                                         (Max VOC Primer = 350 g/l)
                                         (Max VOC Stripper = 400g/l)
    Depainting, Preparation, Recoating Processes
                          Typical Inherent Capabilities of Field Units
                                       ICBM                                  SLC
                                   Shop Corrosion Prevention Tools
Abrasive Blast Booth   Plastic Media Blast                   Outdoor area
Paint Booth            Minimum 10’ x 15, Heated              None
                                                             HVLP: Paint
Spray Guns             HVLP: Paint
                                                             Conventional: Inorganic Zinc
                                Portable Corrosion Prevention Tools

Abrasive Blaster       Small Portable Unit: 1 Bag            Large Units: 6 Bag – 8 Ton Capacity

                       Needle guns, Grinders, Descalers,     Needle guns, Grinders, Descalers,
Power Tools
                       Sanders                               Sanders
HEPA Vacuum            3 or More                             3 or More for Hand Tools
Pressure Washer        None                                  2500 - 4000 PSI, Some Boss Units
Metal Wire Arc
                       50% of Field Units                    Several Per Field Unit
                              Paints and Corrosion Preventatives Used
                                                             Approved Material List and Local
Paint Acquisition      Military Spec and Local Purchase
               Baseline Coating Systems Maintenance

                Prep            Primer            Intermediate   Topcoat

                                Commercial     Commercial        Commercial
   Vandenberg    SP 3 - SP 11
                                Aluminum Epoxy Epoxy Mastic      Polyurethane

a Vandenberg SP 3 - SP 11       Inorganic Zn
                                                  None           None
     SLC 3                      WB
t            SP6 Commercial
             Brush Blast or
e Canaveral Power tool           Zn Rich Epoxy    None           None
n Complexes SP 3 - SP 11        (Solvent Based)
n    ICBM
c            SP 3 - SP 11       MIL PRF 53022     None           TT-E-489
     ICBM                                                        TT-E-489 or
                 SP 3 - SP 11   MIL PRF 53022     None
    Exterior                                                     MIL PRF 85285
         Baseline Coating Systems Refurbishment

                Prep             Primer         Intermediate   Topcoat

                                                Commercial     Commercial
                SP 3 - SP 11     Aluminum
R                                               Epoxy Mastic   Polyurethane
f            Power Wash with
u                                None           None           None
             baking soda
             Power Wash with
I                                None           None           None
  Vandenberg baking soda
    SLC 3
h                                Inorganic Zn
             SP 3 - SP 11                       None           None
m                                WB
n    Cape
             Abrasive Blast to   Inorganic Zn
t  Canaveral SP 10                               None          None
                                 (Solvent Based)
  Surface Preparation Alternatives
Baseline                                Less than Baseline
 Power Tool Cleaning To Bare            Hand Tool Cleaning
   Metal With Vacuum Attachment          Power Tool Cleaning
                                         Power Tool Cleaning With
Alternatives                               Vacuum Attachment
 Open Abrasive Blast Cleaning           Power Tool Cleaning To Bare
   with Expendable or Recyclable           Metal
   Abrasives                            Other Methods Considered
 Sponge Jetting                         Wet Abrasive Blast Cleaning
 Vacuum Abrasive Blast Cleaning         Ultra High Pressure Water Jetting
 Chemical Stripping                     Ultra High Pressure Water Jetting
 Combinations:                            With Abrasive Injection
    •   Chemical Removal Followed by     Sodium Bicarbonate Blast Cleaning
        Abrasive Blast
                                         Carbon Dioxide Blast Cleaning
    •   Vacuum Power Tool Followed by
        Abrasive Blast                   Combinations of Removal Methods
 High Pressure Water Jetting            Laser Removal with Vacuum
 High Pressure Water Jetting with         Attachment
  Abrasive Injection
Surface Preparation Potential Alternative
Surface Preparation Testing
  • Coating Strip Rate & Costs
  • Surface Cleaning Level
  • Waste Generation
  • Airborne Particulate Generation
  • Damage to Substrate
  • Tensile Pull ASTM D4541
  • Mandrel Bend
  • Gravelometer
  • Surface Profile
  • Investment & Maintenance Cost
  • Ergonomics
  Steel Surface Preparation Alternatives
   Paint Removers & Lead Stabilizers
Paint Removers                  Lead Stabilizers
 B&B 5095                      Blastox Abrasive Additive for
 El Dorado PR 5044             Lead Stabilization
 Napier Remove All 210, 1010   Leadx Abrasive Additive for
                                Lead Stabilization
 Napier SV 35A
 Dumond Peel Away 1            Steel Grit
 ABR Grip N Strip 800
 ABR Citrus Paint remover      •Not All removers tested for Aerospace
   paste                        Applications of TO 1-1-8, Weapons system
                                specific application
 Pretox 7000                   •Additional alternatives are being
 Cee Bee E-2002
       Paint Remover Test
• Coating Dwell Time       • Hypergolic
• Surface Cleaning Level
                           • Recoat ability
• Waste Generation
                              • Cross Hatch Adhesion
• pH                            ASTM D 3359
• Damage to Substrate         • Wet Tape Adhesion
                              • FED-STD-141C
• MIL PRF 25134                 M6301.2
   • Immersion Corrosion      • Tensile Pull ASTM
   • Sandwich Corrosion         D4541
   • Hydrogen              • Ergonomics
Potential Alternatives (Coatings)
       • High Solids Penetrating Epoxy Coatings Process Description
       • High Solids Epoxy Mastic Coatings Process Description
       • Aromatic 100% Solids Polyurea
       • Aliphatic 100% Solids Polyurea
Computer Based Training
          Points of Contact
 Air Force Corrosion Prevention And Control
 Office – Mr. David Ellicks, (478) 926-3284, DSN
 Prefix 468
 Science Applications International Corp – Mr.
  John Bloyer (478) 918-2946
 Mr. Michael Surratt (478) 918-2902

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