Study on alternative approaches to corrosion protection of ballast tanks using an economic model

One of the most relevant problems in ship construction and maintenance nowadays is corrosion in ballast tanks of modern merchant vessels. On the one hand, there is a general consensus that the economic lifespan of such a vessel depends, to a large degree, upon the corrosion state of its ballast tanks, while on the other hand these ballast tanks, located between the outer hull and the cargo tanks, makes routine inspection and maintenance a difficult task.Today, ship's ballast tanks are usually constructed in steel and protected with an epoxy coating backed up by sacrificial zinc anodes. Such a construction has been applied without significant alterations for many years. The objective of this economic study is to compare this construction method with some potential alternatives. The considered alternatives are: (1) an increase in structural scantlings, eliminating the necessity to replace corroded at a cost of real cargo carrying capacity of the ship, (2) application of the novel and more durable TSCF₂₅ coating (3), the use of corrosion resistant steel in ship construction and (4) a standard PSPC₁₅ coating combined with lifetime lasting aluminum sacrificial anodes. A cost model was used to evaluate these alternative options together with sensitivity analysis. It is concluded that the durable coating and the use of lifetime lasting aluminum anodes are bound to improve the actual basic tank concept. Corrosion resistant steel becomes attractive when the steel price becomes competitive.     

A field study of the effectiveness of sacrificial anodes in ballast tanks of merchant ships

Sacrificial anodes have become a standard practice for the protection of ballast tanks of merchant vessels against corrosive damage. A well protected tank should extend the life span of a ship and consequently enhances its economic value. An in situ survey comprising more than 100 merchant vessels provided the opportunity to measure the impact of these anodes on the life expectancy of these vessels. Contrary to the general belief of these anodes’ beneficial effect, no significant difference was found in our observations in terms of corrosion occurrence between ship populations with and without sacrificial anodes, across all ship ages. This may be explained by the highly variable conditions and the complex geometry in a ballast tank severely impede optimal and straightforward installation of these anodes in these tanks. Also, poorly placed anodes in it may harm the integrity of the coating of the tank. We therefore plead for uniform and clear rules on anode installation and inspection.     

铝合金船体阴极保护系统的数值模拟仿真

采用以边界元法为基础的数值模拟仿真技术,在停航、各种航行航速状态和防腐蚀涂层几种典型损伤状态下,仿真计算铝合金船体表面保护电位分布、保护电流密度分布以及牺牲阳极消耗速度,确定牺牲阳极的有效极限体积,达到在停航及各种航行航速状态下,使船体全部表面上保护电位值处于有效范围内,从而确立船体的最优牺牲阳极保护方案.两年实际使用情况表明,边界元数值模拟仿真技术用于船舶阴极保护系统优化是一种有效的、先进的方法.     

牺牲阳极和包覆材料联合保护在友谊港的防腐应用

根据不同海洋腐蚀区域的特点,采取涂层保护、冷包缠防腐保护和牺牲阳极阴极保护组合保护的形式,对毛里塔尼亚友谊港钢管桩进行防腐修复。施工过程中严格质量控制,达到了预期的实施效果,顺利通过了友谊港业主的验收。     

Analytical modelling of ship collision based on full-scale experiments

This paper presents a theoretical model allowing us to predict the consequences of ship–ship collision where large forces arise due to the sloshing in ship ballast tanks. The model considers the inertia forces of the moving bodies, the effects of the surrounding water, the elastic bending of the hull girder of the struck ship, the elasticity of the deformed ship structures and the sloshing effects in partially filled ballast tanks. The study focuses on external dynamics. Internal mechanics, presenting the collision force as a function of penetration, was obtained from experiments. The model was validated with two full-scale collision experiments, one with a significant sloshing effect and the other without it. The comparison of the calculations and the measurements revealed that the model predictions were in good agreement, as the errors at the maximum value of penetration were less than 10%.     

CSR对超大型油船装载及压载舱分舱的影响

国际、国内的油运市场对超大型油船(VLCC)的需求非常迫切。油船结构共同规范(CSR)不仅对VLCC结构设计的影响是全面和系统的,还对VLCC的装载工况和压载舱分舱方案有很大的影响,而这些因素直接决定了船体的最大中拱静水弯矩。该文针对30.8万吨VLCC,对CSR进行了研究,通过装载计算,初步阐明了CSR对VLCC装载工况和压载舱分舱设计的影响。     

船体在疲劳和腐蚀损伤下的可靠性

在疲劳和腐蚀作用下，船体梁舯剖面模数折减，导致极限承载能力下降，在此基础上进行可靠性分析。文中腐蚀率是一个有常数平均值的随机变量，疲劳裂纹根据Paris公式计算，当静水弯矩和波浪弯矩的组合值超过船体梁极限承载能力时，发生船体梁失效。以一艘散货船为例，计算其可靠性随时间的变化。计算结果可为船东和船级社评估船舶营运期间疲劳和腐蚀对船舶可靠性的影响提供参考。     

超大型油船新型防泥沙设计

压载舱中的泥沙不仅会对船舶双层底产生额外载荷,还会加速底部构件腐蚀,妨碍检查,而清除淤泥一直是令船东和船员们头痛的难题。文章主要介绍应用于超大型油船VLCC的4种新型防泥沙设计概念,并分析这些设计对船舶设计、审核和建造的影响,重点关注了防泥沙设计中涉及的船体梁设计载荷和局部强度。     

Optimal ballast water exchange sequence design using symmetrical multitank strategy

The quality of the ballast water exchange scheme affects many aspects of a ship, including intact stability, structural strength, building and operational expenses, etc. This paper focuses on developing an optimization methodology for large-scale sequential ballast water exchange. The method of transversely symmetrical ballast water tanks being exchanged simultaneously is adopted, and the potentials of multiple tanks being exchanged at a time are explored. The mathematical model for the symmetrical ballast water exchange problem is built by minimizing the occurred maximum trims, maximum hull girder bending moments, and shearing forces as objectives, and the related safety assessment criteria as constraints. A multiobjective genetic algorithm with some operators specially designed for the problem is presented to obtain a set of approximate Pareto-optimal solutions for engineers to choose from. Finally, a real case study on the symmetrical ballast water exchange of a 176,000 DWT bulk carrier is conducted to illustrate the effectiveness of the proposed approach.     

Markov决策过程在船舶结构维修中的应用

船舶腐蚀和疲劳是导致船体老化,进而使其逐渐丧失结构承载能力的重要原因.本文采用具有无后效性的Markov链来模拟船体结构老化过程,其状态空间由完好(不需要维修)、可见裂纹维修、油漆和阴极防护维修、腐蚀修理、疲劳裂纹修理、腐蚀疲劳组合修理和完全失效共计七种状态组成.每一状态均可采取无修理、修理和更新三者之一的维修方案.通过迭代来获得最佳维修方案以实现单位时间成本最低的维修优化目标.算例表明,Markov链可以合理地模拟船舶结构的老化过程,并可方便快捷地运用于船舶维修经济论证.     

铝基牺牲阳极阴极保护在海船压载水舱中的应用研究

海船压载舱使用海水压载，引起船体板的腐蚀，焊缝处会产生蚀孔漏水。采用铝基牺牲阳极阴极保护系统可大为降低腐蚀速率，使压载水舱的保护度在７８％～９５％，保护与未作保护的试片腐蚀率相差８倍，效果明显。     

船体腐蚀对船舶强度的影响

基于营运船的船体腐蚀状况,运用船体剖面模数概念,分析了船体腐蚀对船舶强度的影响,提出了一些保证船舶强度的措施,为船舶的保养工作提供参考,以减少船舶安全事故的发生.     

VLCC改装为VLOC时燃油舱保护的设计特点

主要介绍在超大型油船（VLCC）改装为矿砂船（VLOC）设计中,燃油舱保护要求对改装设计的影响,以及燃油舱的改装方案。影响主要体现在：燃油舱容的减少量,可能会占用压载舱或其他部位增加新的燃油舱舱容;增加新的内壳引起钢料的增加;新增舱室要增加管系、人孔盖及梯子等。燃油舱的改装方案关键在内壳线型。内壳线型首先要满足MEPC．141（54）的要求,其次要考虑内部通道及梯子的布置,还要兼顾改装的特点、船厂施工的要求,可能会不同于新建船舶的设计。     

Sacrificial anode stability and polarization potential variation in a ternary Al-xZn-xMg alloy in a seawater-marine environment

In this paper, the effects of zinc (Zn) and magnesium (Mg) addition on the performance of an aluminum-based sacrificial anode in seawater were investigated using a potential measurement method. Anodic efficiency, protection efficiency, and polarized potential were the parameters used. The percentages of Zn and Mg in the anodes were varied from 2% to 8% Zn and 1% to 4% Mg. The alloys produced were tested as sacrificial anodes for the protection of mild steel in seawater at room temperature. Current efficiency as high as 88.36% was obtained in alloys containing 6% Zn and 1% Mg. The polarized potentials obtained for the coupled (steel/Al-based alloys) are as given in the Pourbaix diagrams, with steel lying within the immunity region/cathodic region and the sacrificial anodes within the anodic region. The protection offered by the sacrificial anodes to the steel after the 7th and 8th week was measured and protection efficiency values as high as 99.66% and 99.47% were achieved for the Al-6%Zn-1%Mg cast anode. The microstructures of the cast anodes comprise of intermetallic structures of hexagonal Mg₃Zn2 and body-centered cubic Al₂Mg₃Zn₃. These are probably responsible for the breakdown of the passive alumina film, thus enhancing the anode efficiency.     

考虑腐蚀与疲劳损伤的船体总纵极限强度与可靠性分析

本文定量考虑了腐蚀与疲劳两类损伤对船体结构随时间变化的情况,并建立了船体总纵极限强度与时变可靠性的计算方法。对一条实船的分析说明,腐蚀和疲劳损伤虽然短时间内的破坏并不显著,但积累到一定程度,对船体结构的影响相当大。采用可靠性评估的方法,对船体总纵强度的安全水平可作出合理的评价。     

Time-variant bulk carrier reliability analysis in pure bending intact and damage conditions

Time-variant reliability analysis of a corroded bulk carrier in intact and damage conditions is performed by First-Order (FORM), Second-Order (SORM) Reliability Methods and Importance Sampling simulation. Annual failure probabilities are determined up to 25-year ship lifetime, accounting for time-variant corrosion wastage of structural members contributing to hull girder strength. Statistical properties of hull girder capacity are determined by Monte Carlo simulation, applying three correlation models among corrosion wastages of structural members contributing to hull girder strength, namely no correlation, full correlation and full correlation among wastages of structural members belonging to the same category of compartments. A modified incremental-iterative method is applied, to account for instantaneous neutral axis rotation, in case of asymmetrical damage conditions, as for collision and grounding events. Incidence of intact/damage condition, as well as correlation among corrosion wastages, on annual sagging/hogging time-variant failure probability is investigated and discussed. Time-variant sensitivity analyses for intact and damage conditions are also performed, to investigate the incidence of random variables' uncertainties on the attained failure probability. Finally, the bulk carrier section scheme, benchmarked in the last ISSC Report, is applied as test case.     

Reliability assessment of maintained ship hulls with correlated corroded elements

This paper reviews the factors that affect the corrosion rate of the ship hull girder. It is shown that corrosion rates vary as a function of the location of the element in the structure, of the ocean area and type of ballast tank and steel. However, the corrosion rate in elements that are subjected to similar conditions is highly correlated.

A time-variant formulation is proposed including the correlation between the corrosion rates in neighbouring elements in modelling the degrading effect that corrosion has on the reliability of ship hulls. The effect of corrosion is represented as a time-dependent decrease of plate thickness that affects the midship section modulus. One repair policy was considered and the example results show the effect of plate replacement when its thickness reaches 75% of the original value. The results also illustrate how the limit value of the thickness in the repair criteria influences the reliability and the decision about repair actions. This is also shown for the effect of different corrosion rates, inspection intervals, and allowable stresses.     

獭山港码头钢管桩牺牲阳极阴极保护效果的评定

獭山港某码头钢管桩采取防腐涂层和牺牲阳极阴极保护措施已10余a。通过对该码头钢管桩阴极保护系统防腐效果的检测，计算牺牲阳极的剩余使用寿命，测量保护电位和检查钢管桩腐蚀状况，并对牺牲阳极保护效果进行评价和分析。     

腐蚀对双壳超大型原油运输船船体的影响研究（英文）

This study aims to examine and analyze the effect of corrosion wastage on the ship hull of a double hull very large crude oil carrier. To calculate the ultimate bending moment capacity, along with the neutral axis position at the limit state, section modulus, and moment of inertia, the incremental-iterative method is employed. This paper also considered the residual strength checking criteria of ship hull and the ultimate stress behaviors of the representative structural elements. Then, Paik's probabilistic corrosion, which employs two levels of corrosion rate and three different assumptions of coating life time, is applied to assess the corrosion effects. The calculation results obtained through relevant analyses are also presented.     

铝合金船腐蚀与防护策略

本文在铝合金腐蚀特性分析的基础上,对近年来大批量的铝合金船腐蚀问题一手材料进行搜集和综合分析研究,介绍了铝合金船的防腐体系,提出了全寿命期防腐链的理念。