8. Coating Application & Inspection Procedure-Rev 0

SOUTHERN PETROLEUM CONTRUCTION JOINT STOCK COMPANY ALPHA ECC

CLIENT

PETROVIETNAM LOW PRESSURE GAS DISTRIBUTION JOINT STOCK COMPANY – PVGAS D

PROJECT

LOW PRESSURE GAS DISTRIBUTION SYSTEM FOR POMINA PROJECT

DOC. TYPE: PROCEDURE

DOC. NO: POMINA-AP0015-QCD-08

COATING APPLICATION AND INSPECTION PROCEDURE

0

10-2-12

Rev

Date

Issued for Review & Approval

T.D.D

Description

Prepared

T.V.N

N.V.P

Checked

Approved

ALPHA ECC

Reviewed

Approved

CLIENT / CA


Doc. No: POMINA-AP0015-QCD-08 POMINA-AP0015-QCD-08

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Page: 2/11


Doc. No: POMINA-AP0015-QCD-08 POMINA-AP0015-QCD-08

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CONTENTS

SECTION

DESCRIPTION

PAGE

1.0

SCOPE

3

EXECUTION OF WORK

3

2.0

CODES AND STANDARDS

3

3.0

SURFACE PREPARATION

4

3.1

BLASTING

4

3.2

POWER TOOL CLEANING

5

3.3

SOLVENT CLEANING

5

COATING PROCEDURE

5

4.1

MATERIAL COATING SYSTEM

5

4.2

GENERAL APPLICATION

6

4.3

SPRAY APPLICATION

8

4.4

BRUSH AND ROLLER APPLICATION

9

4.5

REPAIR OF PAINTING DAMAGE

9

4.6

POST WELD PAINTING

10

INSPECTION/QUALITY INSPECTION/QUALITY CONTROL

10

5.1

INSPECTION

10

5.2

VISUAL INSPECTION

10

5.3

FILM THICKNESS

10

5.4

TEMPERATURE AND RELATIVE HUMIDITY

11

5.5

SURFACE PREPARATION

11

5.6

ABRASIVE

11

6.0

SAFETY

11

7.0

APPENDICS

12

1.1

4.0

5.0

•

PAINTING SYSTEM MATRIX

•

DATA SHEET OF PAINT MANUFACTURER MANUFACTURER

•

COATING INSPECTION REPORT

2


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Doc. No: POMINA-AP0015-QCD-08 1.0

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SCOPE

This procedure covers the requirements for surface preparation and coating application and inspection for structural steel work and above ground piping for Low Pressure Gas Distribution system for POMINA Project. 1. 1

EXECUTION OF WORK

Extent of the work shall be defined as follows: 1.1.1

Surfaces and Material that Require Coating: •

•

•

•

•

1.1.2

Surfaces and Materials that shall not require coating: •

•

•

•

•

•

2.0

Carbon steel. Low-alloy steel. Other surfaces of materials subject to corrosion. Carbon steel piping and supports All other surfaces nominated for coating on the Project AFC Drawings.

Austenitic stainless steel (except for those operating above 65deg C) Instrument tubing, which is supplied polymer sheathed. Galvanized grating (unless note otherwise on drawing) Tap holes and threaded components Plastic/Rubber or plastic-coated materials. Other surfaces of materials which are corrosion resisting.

CODES AND STANDARDS

The following CODES and STANDARDS are part of this procedure: NACE: NACE RP0176

: National Association of Corrosion Engineers. : Corrosion Control on Steel Fixed Offshore Platform Associated with Petroleum Production. : Steel Structure Painting Council. : Solvent Cleaning. : Power Tool Cleaning : Brush off Blasting Cleaning. : Near White Blasting Cleaning. : Surface preparation before application of paints : Near White Blasting Cleaning.

SSPC SP-1 SP-3 SP-7 SP-10 ISO 8501-1-1998 Sa 2.5 St-3

: Power Tool Cleaning

111339-03-SPE-003 3.0

: Painting Specification

SURFACE PREPARATION

The surface preparation for each system shall comply with the requirements detailed in coating system.

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Doc. No: POMINA-AP0015-QCD-08 3.1

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BLASTING

Blasting abrasive shall be dry, clean. The size and type of abrasive grits shall give the angular profile and standard cleanliness specified in the applicable specification. Copper slag, steel shots / steel grits mix shall be used for blasting of carbon steel surfaces only (Copper slag may be acceptable provided it does not leave copper slag particles imbedded in the blast surface) Abrasive shall contain not more than 50 ppm total soluble salts by weight, the type and graded size adequate to give uniform, angular surface profile (anchor pattern) of 35-75 microns average, with blast rough peak not exceeding 100 micron unless otherwise noted in coating systems. Galvanized surface when required coating surface shall be detergent washed and then etched with wash primer or equivalent specialist product as supplied by the paint manufacturer. Power wire brushing may be used on old surfaces to remove zinc salt, provide it does not result to a “ burnished” surface The surface preparation of stainless steel shall be carried out by sweep blasting using a fine abrasive not containing iron (e.g. garnet, aluminum oxide...), glass pearls or stainless steel grits. Recycling of spent abrasives such as copper slag, garnet and other non-metallic abrasive blasting grits are not permitted. Steel shots/steel grits mix can be recycled when utilized as blasting media is a closed blasting chamber equipped with facibilities for humidity control, grits recycling and dust extraction. Silicate sand or other mineral with free silica shall not be permitted for blast cleaning Prior to abrasive blasting, all parts of control valves, flanges, tag names, machinery, electrical fixtures etc. that may be exposed to either the blast or the abrasive material, shall be properly protected from the blasting medium. Blast cleaning shall not be conducted when the relative humidity is greater than 85% or as per manufacturer's recommendation. Prior to blast-cleaning, any oil and grease contamination shall be removed by solvent cleaning. All sharp edges, corners, and rat holes shall be rounded by grinding to 2mm radius. Rough weld profiles shall be ground smooth to blend with adjoining welds. Hard layers resulting from flame cutting shall be removed by grinding prior to blast-cleaning. In the event rusting occurs after completion of surface preparation, the surface shall be re-blasted and cleaned. After blasting, all blasting residues and spent grits shall be blown down with compressed air for visual inspection. Any unsatisfactory areas shall be re-blasted. 3.2

POWER TOOL CLEANING

The surfaces for which blast cleaning is specified but cannot be so treated because of their location shall be power tool cleaned only after obtaining Company approval. Surface preparation shall be in accordance with SSPC SP-3 or ISO St-3. 4



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Power disc sanders and abrasive flap wheels shall be used in preference to wire brushes, dependant on surface configuration. Power tool cleaning shall overlap a minimum of 25mm onto adjacent coated surfaces. No acid washes shall be used on metal surfaces after they are blasted. This includes inhibitive washes intended to prevent rusting. Welded areas shall be ground and/or blast cleaned to remove rust, residual flux and weld spatters. 3.3

SOLVENT CLEANING

Where solvent cleaning is carried out prior to blast cleaning or power tool cleaning to remove oil, grease or other contaminants, it shall be performed in accordance with SSPC SP-1.

4.0

COATING PROCEDURE

4.1

MATERIAL COATING SYSTEMS

4.1.1

Material Supplier The paint materials for project will only be supplied by SIGMA PAINT.

4.1.2

Coating Systems The coating systems and the required surface preparation standard and anchor profile shall be in accordance with the Company Specification, or Technical Data Sheet or AFC Drawing. The vendor coated items shall be assessed of its suitability for exposure against offshore or marine environment. Where Vendor applied coating needs upgrading, the Company shall be notified for disposition of the suitable coating products/coating system to be applied on vendor applied coatings. Damages to vendor coated items shall be repaired in consultation with the Company Representative.

4.1.3

Packing and Storage All paint and coating materials shall be furnished in the manufacturer's unopened containers, which shall be identifiable and protected. Batch number and date of manufacture shall be clearly marked on the containers. The recommended shelf life and the "use by date" shall be clearly identified All materials shall be stored out of direct sunlight in well ventilated areas and away from heat sources, In addition manufacturer’s recommendation guideline in storage of coating materials shall be attached to.

4.1.4

Visual Checking 5



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Prior to paint work, the paint shall be visually checked confirming that the paint is in suitable condition for application. 4.1.5

Mixing All components shall be thoroughly mixed by mechanical means. This mixing shall be done in clean containers, free from traces of grease, other paint or contaminants. Multi-component coatings, such as inorganic zinc, epoxy and polyurethane shall have the components accurately measured under the manufacturer direction.

4.1.6

Thinning Thinning ratio of the materials will conform to the limits recommended by the manufacturer. Only manufacturer's specified thinner shall be used.

4.1.7

Pot Life The coating manufacturer's recommended pot life shall not be exceeded. When this limit is reached, the spray pot shall be emptied and cleaned, and new material shall be mixed.

4.2

GENERAL APPLICATION

4.2.1

Application Painting shall be carried out by airless spray and/or conventional air spray according to the manufacturer recommendation.

4.2.2

Environmental Conditions Coatings shall not be applied when any of the following conditions exist: Wet surfaces Relative humidity exceeds the manufacturer's recommendations or 85% Steel surface temperature is less than 3°C above the dew point •

•

•

•

4.2.3

Ambient or surface temperature is above or below the manufacturer's recommended temperature for application or is greater than 40 deg.C.

Dust Every possible precaution shall be taken to eliminate dust before and during painting process. Cleaning down prior to painting is recommended by manufacturer following long periods between coats and following inclement weather. Cleaning down may be done by chloride free fresh water spraying, sanding paper or by other approved methods.

4.2.4

Primer coating Blast cleaned surfaces shall be coated with one complete application of primer as soon as is practically possible, but in no case later than 4 hours after blasting provide the surface condition is SSPC-SP10/Sa2.5 at the time of coating application.

4.2.5

Dryness 6



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In a proper state of cure, prior to the application of succeeding coats, Materials shall be considered dry for re-coating when manufacturer's technical representative has accepted the coat and the additional coat can be applied without the development of any detrimental film irregularities, such as lifting or loss of adhesion of the undercoat. The drying times as specified in the manufacturer's data sheets, will be observed at all times. 4.2.6

Re-coating The maximum and minimum re-coating interval specified in the manufacturer's data sheets, will be observed before successive coats are applied. The only exception to this may be after the application of a mist coat where the recommended re-coat interval may be reduced in accordance with the coating manufacturer's recommendations. Any thin spots or area missed in the application shall be recoated and permitted to dry before the next coat is applied. All areas such as external corners and edges, welds, bolts, nut and interstices (excluding galvanized surface) shall receive a stripe coal prior to application of the specified coat (excluding the inorganic zinc silicate primer) to ensure these areas have at lease the minimum specified film thickness as to ensure continuity of the coating. The stripe coat shall be allowed to become touch dry prior to coating with the specified coat. When successive coats of the same product, the alternate color shall be applied to ensure contrast for complete coating coverage and control of thickness during application, Tinting may be permitted when allowed by the Paint Manufacturer provided the tinting materials are not detrimental to the service performance of the coating. Insitu tinting of the final coat is not permitted.

4.2.7

Masking All nameplates, manufacturer's identification tags, machined surface, finish flange faces, control valves, electric fixtures etc, shall be masked to prevent coating contamination. All field weld margins shall be masks after blasting to leave 50mm un-primed margin. Each layer of coating shall require a further 50mm masked margin prior to over coating to facilitate final touch up of field welds.

4.2.8

Stripe coating of edges, corners, welds, interstices etc. All difficult to reach areas edges, corners, welding seam, interstices areas, etc.(excluding galvanized surface) shall be stripe coated prior to spray coating application of the specified coat (excluding the inorganic zinc silicate primer) to ensure these are have at least the minimum specified thickness as to ensure continuity of the coating. The stripe coat shall be allowed to become touch dry prior to coating with specified coat.

4.3

SPRAY APPLICATION

4.3.1

Operators Operators shall be skilled in the proper application technique for each coating. 7



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Doc. No: POMINA-AP0015-QCD-08 4.3.2

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Application Paint shall be applied in a uniform layer, with the gun held perpendicular to the surface being painted and with 50% overlap on the previous pass.

4.3.3

Equipment Cleaning Spray guns including spray tips, air caps, fluid tips, hoses and pressure pots shall be cleaned with suitable equipment cleaner recommended by the Paint Manufacturer before adding in new coating material.

4.3.4

Compressed Air Operation pressure shall comply with the recommendation of the coating manufacturer. Separate regulators shall be used to adjust the pressure and each regulator shall be provided with a pressure gauge operating properly at all times. Adequate moisture traps shall be placed on the air supply line of the compressor and other location as deemed necessary.

4.4

BRUSH AND ROLLER APPLICATION

Coating may be applied with a brush or roller for items, which cannot be sprayed, coated properly, only after obtaining company approval. Brushes, maximum 150mm wide, shall be of the type, style and quality that will enable proper application of coating materials. Paint shall be worked into all crevices and corners, and runs or sags shall be brushed out in order to eliminate air pockets, solvent bubbles or voids.

4.5

REPAIR OF PAINT DAMAGE

Coatings damaged by fit up, cutting, heating, welding and mechanical works shall be cleaned and prepared by spot abrasive blasting to the specified SSPC-SP10/Sa2.5 near white metal blast cleaning and required anchor profile. Power tool cleaning to St3 to repair other forms of coating damages shall only be carried out with prior company approval. All damaged areas, before and after erection, shall be repaired using the original full paint system. Where paint has been damaged or is loosely adhering, the paint shall be re-blasted and applied the original full paint system. The surface to be repaired shall be feathered back progressively by fine sand paper, revealing each coat applied and will show sufficient of each coat to permitting satisfactory keying in of each repair coating applied. If repair to the coating of vendor supplied equipment is necessary it shall be carried out in accordance with the vendor's recommendations and after Company approval.

8



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All galvanizing damaged in fabrication, erection, assembly, handling welding and by other or other operations shall be repaired by spot blast cleaning and apply Company approved zinc primer. Where the repaired damaged galvanizing is part of full-coated galvanized item, the repaired area shall receive full coats of the same coating system applied to that galvanized item.

4.6

POST WELD PAINTING

Where coated surfaces were damaged during fabrication and welding, the damaged areas shall be spot blast cleaned to SSPS-SP10/Sa2.5 and anchor profile of 35-65 micron unless noted otherwise in the specific system and apply the specified full coats. The finish coat shall be applied extending beyond the repair areas until it blends well with the existing finish coat.

5.0

INSPECTION/ QUALITY CONTROL

5.1

INSPECTION

To ensure the quality control and painting inspection requirements are maintained during painting operations, inspection will be carried out by the paint manufacturer's representative in accordance with the requirements of this procedure.

5.2

VISUAL INSPECTION

Individual coats and completed coating shall be visually inspected for appearance. Coating shall be free from excessive sagging, dry spray, pinholes, blisters and other types of coating application defects and shall be free of any coating damages.

5.3

FILM THICKNESS

5.3.1

Measurement During coating application, the wet film thickness shall be spot- checked using a clean wet film gauge. The dry film thickness of each coat shall be measured using a coating thickness gauge such as Elcometer E-345 or E-456. Incase of MIO/Non metallic substrate paint system, WFT shall be controlled during application time.

5.3.2

Dry Film Thickness (DFT) Value. Five separate spot measurements, average of three readings, spaced evenly over each 10 square meter area to be measured for each coat. The average of five spot measurements for each such 10 square meters area shall not be less than the specified thickness. 9



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The minimum acceptable thickness at any single reading shall be not being less than specified minimum thickness. The Maximum acceptable thickness is 120% of the specified DFT. Thickness measurement of coatings on curved surfaces such as pipes, valve bodies shall be done using curve probe to the DFT Gauge and calibrated using certified foils/shims on the same curve surface to be checked. Pipe supports with usual geometry shall be inspected for the coating integrity and coating thickness measured with extended length and/or angle probe.

5.4

TEMPERATURE AND RELATIVE HUMIDITY

Temperature and relative humidity shall be measured by means of a temperature gauge and a hygrometer using a humidity gauge such as Elcometer E-319, 116, 114 Readings shall be taken prior to the commencement of blasting and/or painting and at regular intervals, if changes in climatic conditions occur. All gauges and recorders shall be calibrated and certified prior to testing. Gauges, which are of doubtful accuracy, shall not be used.

5.5

SURFACE PREPARATION

The blast cleaned surfaces shall be visually inspected to ensure that the areas are clean, dust-free, and complies with the minimum specified surface Preparation Sa2.5 near metal blast with anchor profile of 35-75 microns unless noted otherwise in the specific coating system .

5.6

ABRASIVE

Steel shot, Steel grit, copper slag shall be visually checked with samples placed in sieve and shaken over white paper to ensure that they are free from dust, oil and other forms of contaminant. All blasted surface profile shall be measured by Elcometer 124 dial gauge and testex replica film and documented in the blasting and painting report.

6.0

SAFETY

Blasting operator shall be equipped with suitable long-sleeved protective clothing preferably coverall, safety boots, air-fed full face blasting helmet/hood, dust respirator, leather gloves and safety goggles. Blast nozzle shall be fitted with “ DEAD MAN CONTROL” and checked it is functioning prior to blast leaning. Applicators shall be equipped with suitable long sleeved clothing, preferably coverall, painter’s respirator, face shield, safety goggles, gloves, safety boots, and safety helmet. 10



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MSDS of coating materials shall be posted in blast cleaning and coating area.

7.0

APPENDICES

•

COATING INSPECTION REPORT (shall be applied when as built)

•

PAINTING SYSTEM MATRIX

•

DATA SHEET OF PAINT MANUFACTURER (shall be applied when as built)

11

COATING INSPECTION REPORT

COATING INSPECTION REPORT CLIENT :

REPORT No.

:

CONTRACTOR :

LOCATION

:

PROJECT:

Date

:

ITEM :

Page

:

A. SURFACE PREPARATION (ISO 8501-1,Sa2.5, St3/SSPC: SP1, SP3, SP5, SP7, SP10)

- Surface Finish Specification Standard: - Surface Profile Average (mic.) : - Substrate :

- Cleaning method: - Type of Abrasive used: - Final cleaning:

B. PAINT PREPARATION

- Paint Manufacturer: - Method of Application: ( Airless Spray/ Spray/ Roller/Brush ) Coat ST

1

2

Colour

Thinner

Req'd DFT (μm)

Type paint & code No. Batch & Curing agent No.

ND

3

Description type of paint

Type paint & code No. Batch & Curing agent No.

RD

4

Type paint & code No. Batch & Curing agent No. .

TH

Batch & Curing agent No.

C. PAINT APPLICATION

1

ST

Coat

ND

2

RD

Coat

3

Coat

TH

4

Coat

1. Date Application 2.Time Taken Dry Bulb. (Deg. C) Wet Bulb. (Deg. C) Surface Temp. (Deg. C) Relative Humidity (%) Dew Point (Deg. C) 3. Weather 4. Actual (WFT & DFT)

Average

Average

Average

Average

Wet Film Thickness WFT(mic.) Dry Film Thickness DFT (mic.) D. DESCRIPSION OF DRAWING No/LINE No:

E. COMMENTS/REMARK

Project

:

Paint Supplier Name:

Alpha - ECC

PVGAS D

Name:

Name:

Name:

Signature:

Signature:

Signature:

Signature:

Date:

Date:

Date:

Date:


Document Title:

Date: 10 Feb 2012

Project


Job title

GAS METERING SKID

Document Title:

Date: 10 Feb. 2012 Page: 01 to 01

COATING SYSTEM Rev. 0

Job No.

AP0016

Contractor

SOUTHERN PETROLEUM CONSTRUCTION J.S COMPANY (ALPHA-ECC) Activity:

Document No.

POMINA-AP0015-QCD-08

Item No

1

Description (Surface / Item)

FABRICATION

Location:

Surface preparation and Standard

Blasting to Sa 2.5 Painting for external of above ground (ISO 8501-1: 2007) steel piping & structures Surface profile 35-65µm

CS No

Coat No

AL-01

Generic name

Sigma paint (Product name)

Workshop Alpha-ECC

Color Code

Thinner

DFT ( m)

Greenish Grey

Thinner 90-53

50

1

Inorganic zinc silicate

Sigmazinc 158

2

Epoxy base high solid

Sigma cover 410

Red

Thinner 91-92

120

3

Epoxy base high solid

Sigma cover 410

Grey

Thinner 91-92

120

4

Acrylic topcoat

Sigma Dur 188

Yellow

Thinner 21-06

50

TOTAL

4 Coats

REMARK

340

NOTES:

PREPARED BY ALPHA-ECC NAME:

VU VAN LONG

NAME:

APPROVED BY PVGAS D PHAN VAN QUANG

APPROVED BY CLIENT

NAME:

NAME:

SIGNATURE:

SIGNATURE:

SIGNATURE:

SIGNATURE:

DATE:

DATE:

DATE:

DATE:

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8. Coating Application & Inspection Procedure-Rev 0

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