4-11 PLURAL COMPONENT PAINTING OF SUBMARINE MAIN BALLAST TANKS

PLURAL COMPONENT PAINTING OF SUBMARINE MAIN BALLAST TANKS

Revision Date:	8/03
Process Code:	Navy and Marine Corps: IND-005-99; Air Force: PA01; Army: PNT
Usage List:	Navy: High; Marine Corps: Low; Air Force: Low; Army: None
Alternative For:	The use of single component units to paint main ballast tanks of submarines.
Compliance Impact:	High
Applicable EPCRA Targeted Constituents and CAS Numbers: None identified

Overview:

Plural component painting systems were evaluated during the 1990's and have been listed in the Navy P2 Equipment Book since May 1997. The original assessments identified the environmental and economic benefits associated with using these systems, as well as the compatibility of the equipment with ship and shore operations. P2 Opportunity Handbook Datasheet: Plural Component Proportioning System for Epoxy Paints, offers an in-depth discussion of this technology. However, special considerations with respect to submarine material and maintenance procedures were not evaluated in the initial assessments. Special aspects that must be considered when new equipment is being evaluated for this kind of specialized work include: atmospheric controls, confined and limited space, unique hull shape, submerged submarine hull integrity safety (SUBSAFE) requirements, and safety factors. Because these special considerations were not evaluated in the initial studies the Submarine Maintenance, Engineering, Planning and Procurement Activity (SUBMEPP) entered into a Memorandum of Agreement (MOA) with Portsmouth Naval Shipyard (PNS) and Naval Sea Systems Command (NAVSEA) Code 92T to evaluate P2 plural component painting systems. The objectives of the study were to: 1) evaluate the environmental and economic benefits of using plural component painting units for submarine material and maintenance work; 2) compare them to the single component units in use at the time of the study; and 3) determine if submarine shore facilities could integrate plural component painting units into their operations. The results of this study, P2 Equipment Evaluation of Plural Component Painting, completed in March 2002, are summarized in this Datasheet.

The following recommendations were made as a result of this study:

Establish plural component paint spraying of Main Ballast Tanks (MBTs) as a Best Management Practice (BMP) for Submarines for depot-level maintenance.
Update UIPI 6311-460 ("Seawater Tanks, Preservation of") to reflect the use of plural component painting equipment.
Consider centrally procuring six plural component paint units for each shipyard that services submarines.
Study the potential use of plural component painting at Ships Intermediate Maintenance Activities (SIMA) and other intermediate maintenance activities.

Compliance Benefit:

None are indicated in the SUBMEPP Report. For additional information, see the Compliance Benefit section of the P2 Opportunity Handbook Datasheet: Plural Component Proportioning System for Epoxy Paints.

The compliance benefits listed here are only meant to be used as general guidelines and are not meant to be strictly interpreted. Actual compliance benefits will vary depending on the factors involved, e.g., the amount of workload involved.

Materials Compatibility:

None are indicated in the SUBMEPP Report. For additional information, see the Material Compatibility section of the P2 Opportunity Handbook Datasheet: Plural Component Proportioning System for Epoxy Paints.

Safety and Health:

Health concerns depend on the variety of paint that is used. The use of polyurethane paints requires implementation of precautions associated with isocyanates. Inhalation of lead- and zinc chromate-based paints can lead to irritation of the respiratory system. Some lead compounds are carcinogenic. Solvent-based paints can irritate the lungs and mucous membranes. Prolonged exposure can affect respiration and the central nervous system. Proper personal protective (PPE) equipment should be used. These safety and health issues are also applicable when using conventional methods.

Consult your local industrial health specialist, your local health and safety personnel, and the appropriate MSDS prior to implementing this technology.

Benefits:

The amount of labor required to paint the MBTs decreased approximately 40 percent because paint-mixing personnel were not needed when plural component units were used.
The amount of paint waste decreased by 87 percent because the need for premixing the paint was eliminated. This decrease was realized even though the amount of paint needed for both kinds of painting units was basically the same.
Plural component proportioning systems are effective for many two-component paint systems besides epoxy paints, such as polyurethane paints.
The total amount of hazardous waste decreased by 12 percent.
The paint quality and thickness were not adversely affected by using the plural component spray unit.
The ability to position the equipment under the hull after the submarine is placed into the drydock is a key factor. This allows the workers who operate the pumps to closely communication with the painters. Plural component painting units equipped with wheels are important for painting submarines in graving drydocks.

Disadvantages:

The amount of solvent used increased by 368 percent.
The amount of solvent waste increased by 86 percent.
The paint-out time for the entire job increased by approximately 3 percent.

Note: The SUBMEPP Report evaluators thought that solvent use was high and that the paint-out time was extended because only two plural component painting units were used during the study. The use of two units meant that equipment cleanup and restart was required each time the paint color was changed. Since six paint changes are required during each MBT job, these paint color changes account for a significant amount of solvent use and paint-out time. The PNS evaluators suggested that a total of six plural component painting units be used for each MBT job. Three plural component painting units would be used in the bow area to service the forward tanks, and three plural component painting units would be used in the stern area to service the aft tanks. In each area one unit would be used for each of the three required paint colors: primer, stripe and topcoat. The use of six painting units would allow for a continuous paint supply during each MBT job without the need for cleanup and restart for each paint color change.

Some types of spray guns require more maintenance and frequent change-out of seals, which results in downtime during the painting operation. It is important to use the most appropriate spray gun for the type of paint applied.
Attachments for pumping paint from 55-gallon drums are superfluous for submarine work. The additional $20,000 cost negates the need for them on MBT work on submarines.
Equipment provided by foreign companies may have electrical requirements different from those in the United States. These differences could require modifying the units in order to meet local utility needs.

Economic Analysis:

Initial investment costs:

Purchase of 2 Plural Component Painting units @ $65,000 each = $130,000.
Initial Training: 15 hours for 10 people @ $75 per hour = $11,250.

Assumptions:

The cost of personal protective equipment is the same for both single and plural component spraying.
The cost of air and electricity is the same for both single and plural component spraying.
The estimated annual workload for a Naval Shipyard is two paintings of a 688-Class submarine MBT system (10 tanks each).
Inflation is 3 percent per year.
Useful equipment life is 10 years.
Only two plural component painting units are purchased.

Note: An Economic Analysis for the purchase of six plural component painting units is also available.

Annual Operating Cost Comparison for Plural Component Painting versus Single Component Painting for Submarine Main Ballast Tank Maintenance

Plural Component Painting

Single Component Painting

Annual Operating Costs:

Paint

$98,402

$94,662

Solvent

$1,556

-

Spray Lines

$6,000

-

Spray Gun Tips

$1,200

-

Maintenance Parts

$3,000

$400

Hazardous Waste Disposal

$2,110

$1,854

Operating Labor

$135,000

$81,000

Cleanup Labor

$1,800

$1,800

HW Management

$16

$50

Equipment Maintenance

$1,500

$150

Economic Analysis Summary

Net Present Value :$175,695 for 10 years
Internal Rate of Return: 35.9% for 10 years
Discounted Payback: 3.58 years

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NSN/MSDS:

None identified

Approving Authority:

Appropriate authority for making process changes should always be sought and obtained prior to procuring or implementing any of the technology identified herein.

Points of Contact:

For more information

Vendors:

This is not meant to be a complete list, as there may be other manufacturers of this type of equipment.

WIWA GmbH & Co KG
POB 29
D-35631 Lahnau
Germany
Phone: +49 64 41 6 09 0
Fax: +49 64 41 6 09 50/58
Email: info@wiwa.de
URL: http://www.wiwa.de/

Graco
P.O. Box 1441
Minneapolis, MN 55140
Phone: 877-844-7226

Do You Use Two Part Epoxy Paint? - Navy Environmental Quality Initiative (EQI)

Plural Component Paint System - P2 Equipment Book

Plural Component High and Ultra High Solids Paint Systems - P2 Equipment Book

Sources:

P2 Equipment Evaluation of Plural Component Painting, Submarine Maintenance, Engineering, Planning and Procurement Activity in cooperation with Portsmouth Naval Shipyard

Supplemental:

Plural Component Painting of a Ship

Current Plural Component Spray Painting Process