method statement for Painting

Pls. refer comments on page 4 to 9

By Ramamoorthy Kasiraj at 5:53 pm, Oct 03, 2016

UPPER ZAKUM 750 ISLANDS SURFACE FACILITIES PROJECT – EPC2 PROJECT No. P7512 METHOD STATEMENT FOR PAINTING OF STRUCTURAL STEEL SUPPORTS (SHOP WORK AND SITE INSTALLATION) Doc. No. P7512-27-002-GN-MTS-0103

Rev. A

TABULATION OF REVISED SECTIONS / PAGES Revision

Page / Section

A

12 pages

TABULATION OF HOLDS Page / Section

Description

Description Issued for Review

Page:2 of 12


Rev. A

Page:3 of 12

TABLE OF CONTENT 1. PURPOSE

.

4

2. SCOPE

4

3. REFERENCES

4

4. TERMS & DEFINATION

4

5. ROLES AND RESPONSIBILITIES

5

6. EQUIPMENT

5

7. PROCEDURE

5

7.1

PAINT STORAGE

7.2

PRE-BLAST CHECK

7.3

MARKING

7.4

WHEATHER CONDITIONS

7.5

PRE-COATING CLEANING

7.6

SURFACE PREPARATION

7.7

PAINT MIXING

7.8

PAINT APPLICATION

7.9

TOUCH UP AND REPAIR

8.

QAQC REQUIREMENTS

12

9.

HEALTH AND SAFETY

12


1.0

Rev. A

Page:4 of 12

PURPOSE: This method statement Is to describe the procedure and responsibilities of Blasting and Painting of structural steel supports for HVAC and EIT works of Upper Zakum 750 Islands Surface Facilities EPC-2 Project.

2.0

SCOPE: This Procedure is applicable in Blasting and Painting application in NBHH Paint Shop and Site Installation works.

3.0

REFERENCE DOCUMENTS AND STANDARDS: All work shall conform to the latest issue of Engineering Specification and in conjunction with the International Standards and Codes listed in the Specification for Welding Works. •

P7512-27-002-GN-MTS-0088

Method Statement for Steel Erection

•

P7512-TS-2000-S-0001

Specification For structural steel(onshore)

•

P7512-27-002-QC-ITP-0033

Inspection and Test Plan for Fabrication and installation of structural steel

•

P7512-27-002-QC-ITP-00XX

Inspection and Test Plan for Painting

Shopwork Painting ITP number to be specified (Shop Work) •

P7512-27-002-GT-REQ-0179

MAR For Duct Wall Penetration Sleeve

•

P7512-BD-2000-W-0002

Corrosion Control Procedure

•

P7512-TS-2000-Y-0003

Coating and Lining Specification

4.0 TERMS AND DEFINATIONS: COMPANY

: Zakum Development Company of Abu Dhabi ,UAE

CONTRACTOR

: Petrofac Emirates LLC and Daewoo Shipbuilding & Marine Engineering Co.Ltd

SUBCONTRACTOR

: Nael & Bin Harmal Hydroexport, Est. (NBHH)

ITP

: Inspection and Test Plan

RFI

: Request For Inspection

QCP

: Quality Control Procedure

HSE

: Health, Safety & Environment

QA/QC

: Quality Assurance / Quality Control

QC Inspector

: Contractor/Subcontractor personnel as applicable

MS

: Method Statement

DFT

:Dry Film Thickness (Thickness of the coating system remaining on the surface after hardening

MSDS

:Material Safety Data Sheet


Rev. A

Page:5 of 12

5.0 ROLES AND RESPONSIBILITIES: • • • • • •

It is overall responsibility of PM to organize resources to perform fabrication activities as per project specification, in compliance with quality, schedule & safety sure that all the works are performed safely as per latest Approved for Construction prequirements. NBHH will enroject specifications. enroject ? The relevant Engineer and Supervisor will ensure that all the work is conducted in accordance with this method statement and project specification. The QC Inspector will ensure that all work is executed according to project specifications requirements. Safety and Construction supervision will be carried out under responsibility of Contractor and Company may provide guidance if necessary. EQUIPMENT:

6.0 • • • • • • • • • • • • • • 7.0

Compressor Sand Pots Power Disk – grinding machine Power cups brushes Hand steel wire brushes Hand chipping tools Paint brushes(assorted sizes) Hand cleaning brushes Paint rollers and with/Handles Mechanical paint mixer Abrasive paper disc Emery paper / Sandpaper DFT gauge Surface Thermometer PROCEDURE:

7.1 Paint Storage •

• •

•

The date of manufacturer , date of expiry and batch number shall be clearly marked on each paint container and paints that have exceeded their shell life shall be discarded. The same shall be monitored on regular basis as per manufacturer instruction. Paints and thinner shall be stored in the areas that are well ventilated, and as specified by approved paint manufacturer. Painting material shall be adequately stored in the area designated, away from the sparks and flames and protected against freezing and or deterioration. Painting drums must be kept closed except during used. Epoxy paint cans, paint skimming and cleaning solvents shall be collected and disposed in accordance with local disposal law and regulation, Dumping these material on ground, in ditches or in sewer is prohibited.


• •

• • •

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Discarded paint, Empty paint buckets,thinners,or any rags, cloths etc., shall be discarded into containers and hauled off to an approved dumping site. MSDS of all paints and related stuffs shall be field at Shop.

7.2 Pre-Blast Check •

Rev. A

filed

The Painting supervisor shall check and ensure that all the pre painting activities like Welding, NDT is completed and released for Painting . He shall be carrying on checks if cleaning is required before blasting either by the chemicals or solvents, utilizing the approved scaffolding built or certified man lift with skilled operator. The painting supervisor to be taken clearance from concerned QC inspector to make sure that the equipment released for blasting and painting from any activities. Prior to blasting, welds and cut-offs shall be 2mm ground to a smooth edge and weld spatters shall be removed, if any. All compressed air for abrasive blasting and /or painting supply shall be dry and free from oil.

7.3 Masking •

•

The painting supervisor shall ensure that all tag plates and any identification No is covered properly by masking tape or any other proper method prior to blasting and painting activities. After completion of painting, The supervisor shall ensure that all masking, overspray etc. are removed.

7.4 Weather Conditions •

•

•

Calibrated and valid hygrometer, disk type calculator or equivalent should be used to determine the relative humidity and dew point. Surface preparation shall be conducted in the following condition. a. When steel temperature is less than 3°c above dew point. b. When the air temperature is below 5°c . c. When the relative humidity is very high as per coating and lining specification or by painting manufacturer data sheet. Weather condition requirement as per clause 9 off coating and lining specification and as per manufacturer recommendation. Painting/Coating shall not be conducted in the same weather condition or abrasive blast cleaning and also under the following conditions as per coating and lining specification. Under extreme weather conditions like rain, fog, sand storm, high velocity wind, high wave tide or such conditions are likely before the painting/coating has become dry.

7.5 Pre-Coating Cleaning •

Under not any circumstances the surfaces that have been contaminated should be coated before the surface has been adequately cleaned by proper means, prior to surface preparation, surfaces shall be tested according to coating and lining


Rev. A

Page:7 of 12

specification P7512-TS-2000-Y-003 revB7 appendix E for soluble salts if the environmental conditions indicate contamination could occur. 7.6 Surface Preparation •

•

• •

•

• •

Surface preparation shall be carried out as per coating and lining specification P7512-TS-2000-Y-003 revB7 appendix E visible oil, grease and soil shall be removed, as well as welds and sharp edges and all visible burrs, silvers, scabs and weld spatters, if any. The surface shall be prepared prior to application of primer or paint as per the applicable project painting/coating specification. Ensure the removal of all existing paint from the entire area, if exists, including skirts incase the scope is for re-blasting and re-painting. Verify the cleanliness and dryness of abrasive. After Cleaning, the surfaces shall be kept free from oil, grease, dirt etc. until the coating has been applied. Surfaces left over night or areas not meeting the blasting profile shall be re blasted prior to coating Abrasive material shall be approved as per P7512-TS-2000-Y-003 revB7 specification used abrasive shall be removed from external surfaces by blowing down with clean dry compressed air or by any other proper means. Instruments, gauges, cables etc, shall be protected by plastics sheets and covered properly during paint application at site or removed ,if possible. Surface cleanliness profile requirement shall be as P7512-TS-2000-Y-003 revB7 specification and in accordance with manufacturer recommendation.

Abrasive blasting air supply shall be comply with clause 8.3.3 of P7512-TS-2000-Y-003 Abrasive blasting restriction shall be comply with 8.3.4 of P7512-TS-2000-Y-003 7.7 Paint Mixing • • •

Paint shall be properly mixed with power mixtures, strained and kept at a uniform consistency, mixing shall be as per MSDS. Multi component material shall be mixed in the provided by the coating manufacturers as kits. Thinner ratio shall be as per manufacturer recommendation MSDS or TDS.

7.8 Paint Application • • • •

• • •

Paint shall only be applied if the following conditions are met (and as specified by paint manufacturer). All HSE requirement to be full filled in comply with project specification. Safe access should be provided for personnel and hooking points available. The surface shall be free of oil, grease, dirt, loose paint, rust and other surface contaminants. Before primer application surface profile shall be meet the requirements as per P7512-TS-2000-Y-003 revB7 specification and paint manufacturer instructions. The surface temperature shall be at least 3°c above the dew point. Or as per painting manufacture. Each coat shall be checked by QCI as per ISO 19840 for DFT. Primers , Intermediate coats and top coats shall be contrasting colors. If more than one application is required to achieve the film thickness, then the same color can be used. The coats applied shall be within coating intervals specified in the product data

Primer and intermediate coat color shall be as per approved procedure and specification Paint application requirement shall be comply with clause 9.4 of P7512-TS-2000-Y-003


•

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Rev. A

Page:8 of 12

sheet. Finished coatings shall be free of runs ,drips,dry spray etc. areas that are cracked damaged or below minimum dry thickness shall be repaired in accordance with approved paint system. Time interval for curing of minimum and maximum inter coat intervals shall be as per paint manufacturer’s recommendation/MSDS. Paint application shall be by spray, however corners, angles, and interface of two non-planners surfaces shall be painted by brush before spray painting.

7.8.1. Priming • Primers shall be applied before flash rusting or other contamination occurs. • If the intermediate coat(s) are not applied immediately after the zinc rich primer has cured, or if the primer is exposed to humid or outdoor conditions prior to application of the intermediate coat(s), a tie-coat to 25 micron thickness shall be applied on top of the primer immediately after the primer has cured. • Apply the Protective Coating system within four (4) hours of blast cleaning or in any case before visual tarnishing of the steel occurs. Surfaces left longer than four (4) hours shall be re-blast cleaned before coating. Surfaces that develop visual tarnishing (red rust or black spots) at any time before coating shall be re-washed down with fresh water dosed with an approved chloride neutralizing solution and re-blast cleaned prior to coating. • Previously coated surfaces shall be protected d) from contamination and overspray. • Primer shall have a uniform thickness over welds, edges, and corners and shall be free of mud cracking. • Primer shall not be applied within 100 mm of un-blasted surfaces or 150 mm from the edges to be field welded. 7.8.2. Priming Intermediate coat • Each coat of paint shall be if possible of a contrasting color to indicate extent of coverage. • Each coat of multiple coat systems shall be allowed to cure sufficiently in accordance with the coating manufacturer’s recommendations prior to top coating. The minimum drying time between coats shall be in compliance with the manufacturer’s recommendations. When the maximum recoat time has been exceeded, previously applied coatings shall be roughened prior to top coating or treated in accordance with the manufacturer’s recommendations. 7.8.3. Film Thickness • Wet film thickness shall be checked during the application of each coat to assure the specified dry film thickness (DFT) will be met. Wet film thickness measurements are not suitable for some materials such as inorganic zinc primers. • The DFT of each coat shall be checked in accordance with the procedures defined in ISO 19840. • All gauges shall be adjusted to compensate for the substrate effect as described in ISO19840 prior to application of any coating.


Page:9 of 12

Rev. A

7.8.4. Defects • Each coat of paint shall be of a uniform film and of a uniform thickness and appearance, free of defects (i.e., pinholes, voids, bubbles, skips, runs, sags, blisters, wrinkles, and mud cracking). • Care shall be taken to prevent overspray, spillage, or application of coatings to surfaces for which they are not intended. Dry spray and overspray shall be removed. Detailed procedures to prevent the above shall be described in the CPS. • Touch-up shall consist of application of repair coatings listed c) in section 19. The finish color and gloss shall match, as close as practical, the adjacent surfaces.

Paint system and color shall be comply with approved procedure and specification Paint Systems as below: 1- Structural steel supports for firefighting works ( Shop work) Paint system NC02 (External) Painting Product coat

HVAC,EIT

and

Color

Volume solids %

Thinner No

DFT(µm)

1

Primer

Resist 86

75

Grey

61

17

2

Intermediate

Jotabuild HB MIO 80ᶺ23 X 2/ Penguard Midcoat MIO-80 X2

125 X 2

Buff

82

17

3

Finish

Jotathaneᶺ24/Hardtop XP

50

BS00A05

63

10

Volume solids %

Thinner No

2- Structural steel supports for HVA,EIT and firefighting works ( Repair- site work ) Paint system NC02 (External) Painting Product DFT coat

Color

1

Primer

Barrier 80

75

Grey

61

17

2

Intermediate

Jotabuild HB MIO 80ᶺ23 X 2/ Penguard Midcoat MIO-80 X2

125 X 2

Buff

82

17

3

Finish

Jotathaneᶺ24/Hardtop XP

50

BS00A05

63

10


Rev. A

Page:10 of 12

7.9 REPAIR TO DAMAGED COATINGS 7.9.1 General • The provisions of Sections as above shall apply. • Areas subjected to severe damage or field weld shall be prepared and painted in accordance with original specification used for surroundings paint works. • To achieve a sound firmly adherent applied paint system for the repaired areas, all repair work and field weld painting, surface preparation and painting shall extend a minimum of 25 mm onto surrounding paintwork. All such work shall achieve a high standard of decorative finish blending in with the surrounding area. • The coating shall be holiday tested when fully cured. Any defects shall be repaired. The final test report shall be submitted to the CONTRACTOR. • Any necessary repair or remedial work required and caused by handling or negligence of the VENDOR/SUB-CONTRACTOR shall be repaired at the VENDOR/SUBCONTRACTOR's expense and strictly in accordance with Paint Specification and practices above.

7.9.2 Touch-Up • •

•

Prior to application of any subsequent coat, all defects and damage to the previous coat(s) shall be repaired. Damage to finished work shall be thoroughly cleaned and recoated. Damaged areas shall be spot blast cleaned or power tool cleaned as necessary to restore any exposed steel to its original degree of cleanliness. All loose, cracked, and damaged coating shall be removed and the adjacent sound coating feathered back approximately 2 inches (50 mm) to form a uniform and smooth surface. Feathering shall be done by hand or power sanding with a grit wheel or sandpaper. The prepared surface shall be free of loose, burnt, or blistered coating. Unless specified otherwise, the coating used for repair shall be the same as the original and shall have the same DFT

7.9.3 Repair • • • •

Surface to be repaired must be blasted to near white metal SA 2.5 surface profile range shall be 50 microns to 70 microns. Will adhered coating/painting adjusting to the area of repair shall be roughened and feathered. The feathered edge shall be approximately 1” width. Damage coatings for bare metal shall be repaired according to P-7512-TS-2000-Y0003 RevB7 Clause 9.5. After repair the painted surface shall be re-inspected by PED and Company.


Rev. A

Page:11 of 12

FLOW CHART

Structure Fabrication Release for Sand Blasting Inspection after blasting Painting Inspection after Painting Repair and Touchup Final Inspection


Rev. A

Page:12 of 12

8.0 QA/QC REQUIREMENTS • • •

All operators such as blasters and painters shall be qualified. The subcontractor will provide documented training & experience of all blasters and painters before the qualification test. Painting inspector shall be approved by contractor prior to carry out the painting activities.

8.0 HEALTH AND SAFETY • • • • • • •

All necessary PPE shall be provide and worn at all the times(such as: Safety helmets , Safety glasses , Safety shoes , hand gloves , Mask, Earplugs, etc. The worksite shall be kept in a clean and tidy condition. Work permits shall be obtained prior to any work carried out and wok shall commence in accordance with specific measure systemized on the permit. Job hazard Analysis shall be strictly enforced during the activities. Safety notice board will be installed. Waste/Scraps shall be segregated and disposed regularly to the designated locations. Area to be barricaded if applicable.

method statement for Painting

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