Painting Specification for Equipments, Piping & Structures.pdf

INTEGRITY & QUALITY DIVISION CORROSION & INSPECTION DEPARTMENT

SOP.022 Issue 1 Rev 12 th

Date: 20 April 2013

Revisions and Approvals Rev.

0-9

10-11

Prepared By: Alan Tatters Julious Agastian Julious Agastian / B.N. Rao Manoj M. Nair / Lakshmi Kottapally

12

Reviewed Reviewe d By HC&I

Approved by I&QM

Mahdi Al Marzouqi Romer Gil / Dr. Emad ElRoubi

Dr. Ahmed Abbas

Romer Gil / Houssam Sabry

Julious Agastian / B.N. Rao Ravikant K. / Salaheldin Ahmed Manoj Nair / Lakshmi N Kotapally Romer Gil / Houssam Sabry

SOP 022 Issue-1 Revision-12 Revision-12

Jassim Josham Al Ali

Page 0

This is a controlled document and issue only to the document holders.

CONTROLLED COPY HOLDERS


COPY

HOLDER

1

HC&I

2

SPIE

3

SC&ME

4

IPC

Page 1

CONTENTS SECTION

TITLE

No of Pages

1

INTRODUCTION – SCOPE

3-4

2

DEFINITIONS

5-8

REFERENCED CODES AND

3

STANDARDS

09-10

4

CONTRACTORS RESPONSIBILITY AND STATEMENT OF COMMITMENT (QUALITY CONTROL)

11-14

5

COATING MATERIALS

15-18

6

SURFACE PREPARATION

19-23

7

APPLICATION

24-29

8

STORAGE OF MATERIALS

30-31

9

EQUIPMENT USED FOR SURFACE PREPARATION AND COATING COATING APPLICATION APPLICATION

32-33

10

INSPECTION AND TESTING Inclusive of Attachment-1 – N.C.R.

34-39

11

FINISH COLOUR AND IDENTIFICATION

40-41

APPENDIX A

COATING SCHEDULES - A, B, C & D

42-68

APPENDIX B

SCHEDULE OF COLOURS FOR IDENTIFICATION OF PIPELINES AND SERVICES (including BS 1710)

69-86

APPENDIX C

ADGAS APPROVED COATING SUPPLIERS

87-92

APPENDIX D


APPROVAL FOR SITE BLASTING

93-99

Page 2

SECTION 1

INTRODUCTION - SCOPE

SOP 022 Issue-1 Revision-12

Page 3

INTRODUCTION 1.0

SCOPE 1.1

This specification covers ADGAS’s requirements for the preparation and painting of metallic and concrete surfaces, which are either located, or are to be installed on Das Island or neighbouring offshore structures.

1.2

This specification covers methods of surface preparation and coating application for both new construction and maintenance painting, and includes the requirements for tank and vessels internals, concrete surfaces and for buried pipe work and equipment.

1.3

This specification covers ADGAS inspection related to coating requirements in regard of its corrosion protection to all areas mentioned above and in all subsequent schedules.

1.4

This specification also includes generalized coating compositions appropriate to the generic coating descriptions used in the coating systems.

1.5

The coating systems to be used are given in the Schedules A, B, C & D.

N o t e : Revision-12 ,


changes indicated in blue colour .

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SECTION 2

DEFINITIONS


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2.

DEFINITIONS 2.1

The terms in this specification are defined as follows:CONTRACTOR:

The Company who is contracted to supply materials and carry out work in accordance with the painting specification.

Manufacturer/Supplier: -

The manufacturer/supplier of the paint / coating & composite wrapping and wrapping tape material.

Company: -

Designated ADGAS.

representative

of

In this specification the words “will”, “may”, “should” and “shall” and the term “approve” have specific meanings as follows. “Will” is used normally in connection by the Company rather than by a Contractor or Supplier. “May” is used where alternatives are equally acceptable. “Should” is used where is a provision is preferred. “Shall” is used where a provision is mandatory. “Must” is used only where a provision is in accordance with local Legislative rules. The term “approve” as applied in this specification is used in this specification where the COMPANY does not wish to proceed unless certain features have been agreed in writing with the CONTRACTOR. Generally, all units to be used are those of the SI system (International System of units). Maintenance: Repair and refurbishment work to rectify damage to a coating caused by corrosion, ageing. New Fabrication: Coatings applied on the new structures, piping and equipment on DAS. Appendix-A, Schedule A: Metal Surfaces- Coatings for New Construction (Vendors & Off Das). Appendix-A, Schedule B: Metal Surfaces- Coatings for Maintenance or New Fabrication on Das. 2.2

Specific Definitions Coatings (paints): The words “paint” and “coating” have little distinction between them as detailed below. In fact, they are often used interchangeably i.e., all paints are coatings and all coatings are paints. Coatings (paints) are polymeric materials that applied in fluid stage, cure to a continuous film.


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Paint is any liquid material containing drying oils alone or in combination with natural resins and pigments which, when applied to a suitable substrate, will combine with oxygen from the air to form a solid, continuous film over the substrate, thus providing weather resistant decorative surface. Thus, they provide less permanent protection against corrosion than the more sophisticated protective coatings. Paint may also be defined as any liquid material containing aqueous dispersions of latex, polyvinyl acetate, or acrylic or modifications thereof, in combination with pigments, plasticizers, and additives, which when applied to a suitable substrate, will coalesce into a solid continuous film over the substrate, thus providing a weather resistant decorative substrate. These paints are semi permeable thus allowing moisture vapour to penetrate and release from the dried film. Protective Coatings: A protective coating is chemically a substantially different material. It outperforms paint in adhesion, toughness, and resistance to chemicals, weather, humidity and water. A protective coating is any material composed essentially of synthetic resins or inorganic silicate polymers which, when applied to a suitable substrate, will provide a continuous coating that will resist industrial or marine environments. Lining: Coatings applied to the internal surface of process piping & equipment, exchangers and tanks & vessels that will resistant to the immersion conditions of the intend services. Composite Wrapping: Reinforced fibre / polymer composites (RPCs), which when applied to the suitable substrates likely to the piping & pipe fittings and support members, will provide a continuous spiral form wrapping system, that will in turn, provide corrosion and wear resistance that it outperforms paint and coatings. Wrapping: High build epoxy (cumerone Indene Based Resin) coatings applied to the underground piping (buried pipe works, valves & fittings) and additionally protected with cold applied tape wrap system in continuous spiral form with an overlap of 50%. Chalking: The appearance of a loosely adherent fine powder on the surface of a paint coating, arising from the degradation of one or more of its constituents


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Cracking:

The splitting of a coating, usually as the result of ageing

DFT: Dry film thickness; the thickness of a dried or cured paint or coating Flaking: The detachment of pieces of the paint film itself either from its substrate or from paint previously applied. Flaking is usually preceded by cracking or blistering. TDFT: Total dry film thickness; the thickness of the total number of coatings specified. WFT:


Wet film thickness; the thickness of an uncured or wet paint or coating film.

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SECTION 3

REFERENCED CODES AND STANDARDS


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3.

REFERENCED CODES & STANDARDS The latest versions of the following standards and codes of practice shall apply where relevant to applications of this specification. In cases of conflict between this specification, coating manufacturers data sheets and application notes, codes, and standards, the most stringent and significant requirements shall apply. ISO 8501-1, 1988/BS 7079, Part A1 -Preparation of steel substrates before the application of paints and related products. The Society of Protective Coatings (S.S.P.C - Pittsburgh P.A.) Manual. Volumes 1 - Good Painting Practice 2 - Systems and Specifications BS 5493: 1977:-

Code of Practice for Protective Coating of Iron and Steel against Corrosion. (BS-EN-ISO-12944 / 14713 - 1999)

BS 1710: 1984:-

Identification of Pipelines and Services

BS 4800: 1989:-

Schedule of Colours for Building Purposes

ISO-4628, Evaluation of Degradation of Painting Coatings, Parts 1 to 10. BP RECOMMENDED PRACTICE – GS 106-2: 1992 “Painting of Metal Surfaces” ADGAS Health, Safety, Environmental Managements Systems


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SECTION 4

CONTRACTORS CONTRACTORS RESPONSIBILITY AND STATEMENT STATEMENT OF COMMITMENT COMM ITMENT (QUALITY CONTROL)


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4.

CONTRACTORS CONTRACTORS RESPONSIBILITIES 4.1

Standards of Work and Safety The contractor shall perform all work in a safe manner and comply in all aspects with the Safety regulations as applied by “Company” and ADMA OPCO particularly in regard to certification (Green Square) and Safety inspection of all Plant and Equipment (Mobile (Mobile Compressors, etc.) The contractor shall ensure that his workforce is conversant with, contributes to, and understands the basis and content of the above mentioned safety regulations with regard to operating and permit to work procedures that are in place.

4.2

Personnel/Items to be provided by Contractor The contractor shall supply all necessary personnel, equipment, materials and inspection instruments, including (unless specified otherwise) the following:(a) (b) (c) (d) (e) (f)

Evaluation of all hazards and provision of any proposals to meet any local legislative requirements. Skilled, experienced and competent personnel. Product data and material safety data sheets. Provision and maintenance of plant, equipment and tools to undertake the work (including personal protection equipment). Inspection personnel instruments. Documentation of work

4.3

Protection of Surroundings The contractor shall ensure protection of the surroundings with particular reference to the damaging effect of over blast and over spray and shall ensure subsequent subsequent safe disposal disposal of material and equipment used. used. He shall be responsible and in the case of any failure in this respect leading to damage which shall be repaired and cleaned as appropriate.

4.4

QUALITY CONTROL: STATEMENT OF COMMITMENT It shall be the CONTRACTORS responsibility and requirement to establish a quality control commitment and maintain the correct levels of quality of work on the job site, for all activities associated with the product and application of product and services to be carried out. This commitment to quality control by the CONTRACTOR shall be in strict accordance with the COMPANY approved specification and in agreement with the tender document requirements and shall in no way incur any additional costs directly or indirectly to COMPANY.


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CONTRACTOR shall also liaise with MANUFACTURER to acquire and record all relevant documentation to establish and confirm the lot to lot material samples in regard to coating coating formulation formulation certification; this in turn shall be confirmed by an independent test authority as approved by COMPANY. This shall be undertaken as directed by COMPANY at least 4 times in any 12 month period or at any time when there is sufficient doubt established in regard to a particular coating or coating system. 4.5

PROCEDURAL METHOD STATEMENT AND INSPECTION TEST PLAN The CONTRACTOR shall submit the above documents along with the quality control commitment document to COMPANY for approval. This shall be in general guidance with ISO-9001-2000/QMS Quality Management Systems all relevant parts (latest editions). The Method Statement/Inspection Test Plan shall include, but not be limited to:Reference Panels Test

-

Surface Preparation Coating Application Coating Application Visual Finish Site/Field Locations

4.6

The CONTRACTOR shall establish a quality assurance program which complies with the requirements of ISO 9001-2000 at the earliest practical time consistent with the schedule for implementing the activities with the project.

4.7

The CONTRACTORS inspection and test plan (I.T.P.) which which will be subject to approval by “COMPANY” and in addition may be audited by “COMPANY” following an agreed period of notice.

4.8

Unless specified by “COMPANY”, a copy of the th e I.T.P. signed by both CONTRACTOR and “COMPANY”, shall be submitted to “COMPANY”, witness and hold points of completion will be either specified or approved by “COMPANY”.

4.9

The CONTRACTOR shall ensure that technical and Q.A. requirements specified in the enquiry and purchase documentation are applied to all materials and services provided by sub-contractors and to any free-issue materials.

4.10

The artisans employed by the CONTRACTOR CONTRACTOR may be subject subject to a trade test when used on the “COMPANY” site, or verification as to their ability may be requested when work is carried out at the Contractors works.


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4.11

Reports and Records The Inspection and Test Plan and Daily Inspection Reports shall be prepared by the Contractor and kept up to date. They shall be in a form approved by, and be available when required by “COMPANY”.

4.12

Inspection records shall show the condition of surface before preparation. They shall also state when surfaces were prepared and coatings were applied to the various sections of the coating works. In addition to showing the total amount of work completed, the reports shall include the date on which surfaces were examined before preparation and also when the approval or otherwise was given to prepared surfaces, priming, intermediate and final coats of the coating systems. Information on conditions which were responsible for suspending coating work on any sections shall be included in the works Contractor’s record sheet. The Daily Inspection Reports shall show the daily weather conditions including temperature and humidity and also fluctuations in those conditions which affect the coating work. A quality control document shall be provided by the Contractor for each day’s work. Areas of completed work must be clearly defined by reference to record drawings.

4.13

4.14

4.15

4.16 4.17

Daily Inspection Reports shall be cross-referenced to confirm progress. A Non Conformance Report - N.C.R. will be issued by COMPANY to cover any works that are not to the satisfaction of the COMPANY approved representative, stating details of non-conformance to the specification, and required action to be taken and shall be agreed by both parties. 4.18 Only on completion to COMPANY satisfaction will the N.C.R. be released by the originator. 4.19 Only on completion of the work to the satisfaction of ADGAS, shall it be provisionally accepted. At this time a date shall be set for the final acceptance inspection, this date shall be in accordance with the specified warranty period following completion of the work scope. On successful completion of the final inspection, the final acceptance certificate shall be issued by ADGAS and the Contractor released from the performance bond (where applicable). 4.20 Site Clearance On completion of the site works, the Contractor shall remove all surplus materials, scaffolding, plant and equipment and leave all areas in a clean and tidy condition. 4.21 ADGAS General Terms and Conditions of Contract Any conflict between the definition of requirements in this section and company contractual terms and conditions, the more stringent requirement shall apply. 4.22 All correspondence, technical documents, etc., to be in the English Language.


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SECTION 5

COATING MATERIALS


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5.

COATING MATERIALS 5.1

General All coatings shall be purchased from a supplier approved by “COMPANY” as given in Appendix C (approved coating suppliers). Vendor supplied equipment purchased in the United Arab Emirates or elsewhere requiring coating at vendors shop, shall only be coated with materials procured from an approved supplier. To ensure compatibility of all layers of coating in a specified system, the paint, thinners/solvents, cleaners shall be purchased from one supplier only. An exemption may be granted when a shop priming coat is being applied only, at the equipment manufacturers. Full details are to be forwarded to Company.

5.2

Coating The coatings to be used are specified in Appendix A (schedule of treatment). Thinners required to thin the paint for spraying shall be supplied by the same coating manufacturer to ensure compatibility. The colour schedule for the coating system is given in Appendix B (schedule of colours for identification). In order to obtain the colour marking other than grey the final coat shall be omitted and two coats of finishing colour applied, the media being either alkyd resin, polyurethane or 2-pack epoxy in accordance with the preceding coats.

5.3

Composition All coatings used shall conform to BS 5493 (1977), Section 2, Tables 4a to 4m, Page 24. Figures quoted shall be for main pigment in total pigment (weight % minimum). The contractor shall supply for the approval of ADGAS at the tender stage such details of compositions from the Manufacturers pre-qualification list to establish the suitability of the product. (a) Zinc phosphate two pack epoxy primer shall be based on a polyamide cured two pack epoxy media and shall contain a minimum of 40% Zinc Phosphate by weight of the total pigment content. (b)

Micaceous iron oxide coating shall be based on a polyamide cured epoxy media and shall contain a minimum of 80% micaeceous iron oxide by weight of the total pigment content. Contrasting colours may be obtained by incorporating leafing aluminium pigment.

(c)

Where colour finishes other than micaceous iron oxide are required they shall be based on titanium dioxide and/or light fast coloured pigments dispersed in a polyurethane media. A full gloss finish is required. Such coatings should be used in conjunction with their appropriate undercoats.


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(d)

Two pack epoxy finish shall be based upon a polyamide, or amine adducts cured epoxy resin formulation. Two pack polyurethane finishes shall be based upon acrylic modified polyurethane formulations. All finish coatings shall be pigmented with titanium dioxide and/or light fast coloured pigments to provide the necessary opacity, film build and weather resistance. With polyurethane finishes a full gloss finish is required.

(e)

Zinc Silicate primer shall be based on inorganic or ethyl silicate media and shall contain not less than 85% metallic zinc by weight of the total pigment content.

(f)

Zinc Rich Epoxy Primer - shall be based upon a polyamide cured two-pack epoxy media with a minimum of 90% of metallic zinc by weight of the total pigment content.

(g)

Aluminium Pigmented Epoxy Primer - shall be based upon a flexibilized, surface tolerant epoxy media containing leafing aluminium pigmentation and specifically formulated for application to mechanically prepared surfaces.

(h)

Mordant Solution (T-Wash) for preparation of Galvanized surfaces - shall comprise of phosphoric acid and copper salts in a solvent/water solution.

(i)

Zinc Phosphate Epoxy – shall be based upon a two pack formulation incorporating:Pack-1 – epoxy resin and zinc phosphate pigment. Pack-2 – polyamide curing agent. The zinc phosphate shall comprise of 40% main pigment in total pigment weight in the mixed epoxy resin blend. For contrasting of intermediate coats, aluminium, MIO or red oxide pigmentations may be allowed by the colour of the final coat shall be in accordance with the ADGAS Plant Colour Scheme as given in Appendix-B.

(j)

Aluminium Silicone - shall be based upon a single-pack formulation comprising of a leafing aluminium pigment dispersed in modified silicone media (e.g.: acrylic silicone) and capable of withstanding o continues atmospheric exposure at temperatures between 80 C > o 600 C. N.B: Aluminium metallic pigmented coatings and aluminium metal spray shall not be used on any surface operating above o 150 C in zone 1 areas. Such areas will be specified by ADGAS.


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(k)

Glass Flake Lining - shall be based upon a bisphenol-A polyester or vinyl-ester resin containing not less than 20% by weight of glass flakes. The specific resin used in the formulation shall have an established track record of chemical resistance to the service duty at the maximum operating temperature.

(l)

Cold Applied Tape - shall consist of a polyvinyl chloride or polyethylene carrier tape 0.75mm thick bonded to a self adhesive bituminous rubber compound 0.8-0.9mm thick, specifically formulated to withstand operating temperatures up o to 75 C. Cold applied tape primer - shall comprise of a quick drying bituminous primer specifically formulated for use with the cold applied tape. All completed cold applied tape shall be subjected to 100% D.C. Holiday Detection, with a voltage rate of 5 volts per micron.


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SECTION 6

SURFACE PREPARATION


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6.

SURFACE PREPARATION 6.1

General The surface preparation required on all materials is as specified in Appendix A - (schedule of treatments), and is the minimum expected before the application of the coating system. All surface preparation shall be carried out after complete fabrication of any item unless approved by ADGAS.

6.2

Steel surfaces to receive coating 6.2.1 Shop Preparation Shop preparation shall consist of one, or a combination of the following methods in order to achieve the required surface, but the initial method is preferred:(a)

Blast clean to ISO-8501 (05 5900/BS7079) to one of the grades specified. The types and grades of abrasives used for blast cleaning shall conform strictly to the requirements of BS 7079. The use of abrasives containing silica is not permitted. After blast cleaning and before application of the priming coat the surface shall be vacuum cleaned to remove dust and abrasives. Due care shall be exercised to prevent the abrasive grit entering inside equipment and pipework. On completion of blasting operations the inside of equipment and piping shall be inspected and cleaned out if the presence of abrasive grit is detected. Only Aluminium Oxide/ Natural Garnet/Stainless steel abrasives shall be used on stainless steel equipment/pipe work.

(b)

Pickling by either Sulphuric Acid or Phosphoric Acid strictly in accordance with a recognized procedure such as SSPC-SP8 (Steel Structure Painting Council).

(c)

Power Tool cleaning, rotary wire brushing etc.

(d) Hand cleaning by scraping or wire brushing to localized areas of mechanical damage, can only be accepted when coating is not damage fully back to bare steel. 6.2.2 Shop Priming Coats The use of temporary or holding shop primers shall not be employed, all coatings applications applied at shop shall be in strict accordance with the requirements of the Coating Schedules A, B, C. Should vendor’s items be required to employ a temporary/holding shop primer for transit requirements, all works shall involve the complete removal of the shop primer and coated to the required ADGAS Protective Coating Specification prior to installation at site.


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N.B: It should be noted that the responsibility of quality assurance and control rests first and for most with the vendor. The absence of an ADGAS approved inspector does not in any way relieve the vendor of any QA/QC obligation. 6.2.3 Site Preparation Site preparation shall consist of one or a combination of the following:(a) Surface cleaning shall remove all surface contamination including dirt or grease in accordance with SSPC-SP1 (solvent cleaning and high pressure sweet water washing with emulsified cleaning agents). Potable water used for cleaning shall have a chloride content of less than 30ppm. Prior to blast cleaning, steelwork shall be dressed, so all weld splatter and laminations etc. should be removed by grinding. (b-1) Blast cleaning to ISO 8501-1-1988 (05 5900/BS 7079). Due care shall be exercised to prevent other areas and wet coated surfaces from contamination. Contractors shall erect necessary screens around the work area to prevent contamination. Abrasive shall not be allowed to enter the inside of equipment and piping. Natural Garnet is the only acceptable substance to be used with a particle size of between 0.85 and 0.5mm. This can be used for both carbon and stainless steel equipment and pipe work. Before any blasting occurs in a site location the enclosed form Appendix D must be filled in and signed by the appropriate personnel responsible. This is in line with ADGAS Standing Instruction No. H-10-1. (b-2) Where blast cleaning to Sa 2,5 (near white metal cleaning) is not advisable due to substrate excessive corrosion, portable spot blast cleaning equipment with straight bore nozzle operating at lower pressure (less than 50 psi) can be used. Spot blast equipment with straight bore nozzle to be kept far away from the substrate (more than two foot distance.) while Carrying out SWEEP blast cleaning. (c) Power tool cleaning using impact tools, rotary wire brushes and flap discs. (d) Hand cleaning by scraping or wire brushing. (e) It should be noted, that mechanical or hand cleaning must be considered marginal as this method of surface preparation will not remove mill scale, rust or provide a surface profile/anchor pattern.


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(f)

Ultra High Pressure Water Jetting (with or without abrasive) at pressure up to 25,000 to 30,000 psi shall only be considered for use on site pending full ADGAS approval.

6.2.4 Nuts and Bolts Surface preparation shall be directed to achieve the same standard as the adjacent surfaces. 6.2.5 Aluminium Surfaces No preparation or coating is required. 6.2.6 Galvanized Surfaces to receive Coating Surface preparation shall consist of thoroughly degreasing and treating with a mordant solution (comprising of a phosphoric acid solution incorporating copper salts in a solvent/water solution-“T” wash or similar). After the reaction period the surfaces shall be cleaned with potable water. Note: Weathered galvanized surfaces should be wire brushed or blast cleaned if required, first to remove all corrosion products. 6.2.7 Weld areas and difficult corners All weld seams, sharp edges and surface irregularities shall be contoured and surface irregularities ground smooth as required. Stripe coating shall be required to all subsequent coats including the primer, and shall be applied by brush to physically wet in the substrate, particularly the weld seam. 6.2.8 Site Preparation of Shop Primed Surfaces Site preparation shall first consist of thoroughly degreasing followed by the cleaning method as described in section 6.2.2 to remove all loosely adhere shop primers and to prepare the surface to the condition specified. Temporary/holding primers shall be completely removed and re-worked in accordance with the coating schedules prior to installation on site. 6.2.9 Agreed Standard of Surface Preparation For blast cleaned surfaces the contractor shall use the colour photographic standards as ISO-8501-1, 05 5900/BS 7079 (1988). For power tool and hand tool cleaning the contractor shall use the colour photographic standards for hand cleaning ISO 8501-1: 1988 05 5900/BS 7079 (1988) Part-1. 6.2.10 Surface Profile The surface profile after blast cleaning shall have a min/max height of 50/75 microns for carbon steel and a min/max height of 30/50 microns for stainless steel (as measured by surface replica technique - TESTEX). 6.2.11 Rogue Peaks SOP 022 Issue-1 Revision-12

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These may be defined as peaks of exceptional height in the blastcleaned surface, which may not be indicated by the normal methods of surface profile measurement. The presence of rogue peaks may be demonstrated by: Viewing the surface through an illuminated magnifier. Rubbing lightly over the surface with a clean cotton glove. Care must be taken to ensure that no cotton fibers remain on the steel. The presence of ‘rash rusting’ on the primed surface, due to the peaks not being coated with primer. If rogue peaks are found, they may be removed by lightly scuffing the surface with emery paper, a metal bar or, preferably, by hand. It is essential to check that all dust and other contamination is completely removed after the sanding operation, also that the operation has been successful in the removal of the rogue peaks. 6.2.12 Soluble Iron Corrosion Products (Soluble Salts) When rusted steel has been blast-cleaned and is acceptable to a Sa3 or equivalent visual standard, it is still probable that the surface is contaminated with ‘soluble iron corrosion products’ (“Soluble Salts”). Care shall be taken to determine the presence of “Soluble Salts” and their adequate removal shall be in accordance with tests described in BS 5493: 1977: Appendix G Test for detecting soluble rust producing salts remaining on blast cleaned steel. Refer to Painting Inspection Procedure, item 3.4.1 (Sheet 2 of 5). 6.2.13 Treatment of Mechanical Damage to Coated Items Where the substrate has been exposed, by mechanical damage, the area shall be re-prepared to the original standard and coated with the specified system to restore the full film thickness. The surrounding 50mm (2 in) of sound paintwork shall be lightly blasted or abraded to provide a firm key. Where very small areas of such damage occur in otherwise sound coatings, hand or power driven tools may be used to prepare the exposed substrate. Recoating shall completely cover the prepared surface and the surrounding 50mm of intact coating. Areas which have been damaged without exposing the substrate shall be washed with proprietary detergent solution and rinsed with fresh water. This shall be followed by abrading the area of damage including the first 50 (2 in) mm of surrounding intact coating. The relevant intermediate and finish coats as shown in the coating schedules shall then be applied in accordance with this specification.


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SECTION 7

APPLICATION


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7.0

Coating Application 7.1

General All surfaces to receive coating shall be cleaned and free from grease, salt, and surfaces deposition and shall be thoroughly dry. Coatings shall be applied strictly in accordance with the manufacturer’s instructions as soon as the previous coating is hard enough to receive another coat. Delay may facilitate washing down between coats.

7.2

7.3

Weather Conditions Surface preparation, application of coatings, wrapping and composite wrapping shall not be undertaken under the f ollowing conditions or when such conditions are likely to prevail before the coating is hard: (a) At temperature below 5°C or when the temperature is likely to fall below this value before the surface film is dry or on surfaces registering low temperature. (b)

When the relative humidity of the atmosphere exceeds 85 %.

(c)

The steel temperature is less than 3°C above the dew point.

(d)

During foggy or misty conditions.

(e)

Before dew or moisture has evaporated.

(f)

When it is raining or rain is imminent.

(g)

Excessive elevated steel temperature shall be governed by Manufactures parameters, data sheets etc.

Preparation of coating Skins shall be completely removed from the container and the coating shall be stirred until it is of homogenous consistency. No hand stirring is allowed for quantities in excess of 5 liters. Before use, coating shall be allowed to stand for a time long enough to remove aeration caused by stirring.

7.4

Method of Application The method used to apply the coating shall be compatible with the type of coating and the surface to be covered, in order to obtain film of even thickness, free from any sag, runs or pin holes, holidays, and any other form of discontinuity. Standard method of application shall be airless spray unless specified, application by rollers, brush or conventional spray shall be by “Company” approval. Due care shall be exercised to prevent overspray and contamination of other surfaces by the use of shields, etc.


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Brush application shall be limited to stripe coating and small local areas for touch up. Under no circumstances shall zinc or aluminium in the form of pigments or metal spray be allowed to come into contact with stainless steels, nickel based alloys or copper based alloys. 7.5

Film Thickness Due care shall be paid to the solids content of the coating when deciding upon the wet film thickness to be used in order to arrive at the specified dry film thickness, in general guidance from the manufacturers data sheets and SSPC - PA2 Measurement of Dry Film Thickness (with Magnetic Gauges). Steel Structures Painting Council.

7.6

Priming The priming coat shall be applied as soon as possible after the surface preparation has been carried out and before any deterioration of the specified standard has occurred. Irrespective of this, the following maximum time limits are required. (a)

(b) 7.7

Blast cleaned surfaces, shop and site, within 4 hours. Power tool and hand tool cleaned surfaces, within 12 hours.

Over coating Where possible the subsequent application shall be applied over the primer coating as soon as the primer is dry and hard enough to receive the next coating and in general guidance from Manufacturers data sheets. Before application of the next coating the contractor shall ensure that the previous coating is thoroughly dry and clean from all harmful matter, such as grease, oil, dust, etc. Swab samples of the surface may be taken at the discretion of “Company”.

7.8

Contrasting Colours Where it is necessary to apply more than one coat of a particular paint to obtain a specified dry film thickness, then the first coat shall be selected sufficiently different in colour, in order to distinguish from the next and subsequent coats.

7.9

Bolted connections Shop bolted connections shall be prime coated and brought together whilst the coating is still wet. Bolted connections using high strength friction grip bolts shall not be coated and the contractor shall ensure that all surfaces for these bolts are adequately masked off before coating. The size of masking shall be a minimum of 25mm greater than the connected surface.

7.10

Stripe Coating Stripe coating shall be required to all welds, bolts, nuts, angles and sharp edges to all subsequent coats including the primer prior to spray coat application to maintain dry film build.


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7.11

Cold Applied Tape Cold Applied tape wrappings shall be applied in full accordance with the manufacturer’s recommendations. manufacturer’s recommendations. Tape wrapping shall be applied over the compatible primer coat in a continuous overlapping spiral with a minimum overlap of 50% and with sufficient tension to provide good adhesion without wrinkling or necking of the plastic carrier. carrier. The tape shall begin and terminate in a square end, such that all of the substrate is covered by a double thickness of tape. The tape shall be applied in such a manner that it does not bridge discontinuities in the surface of the substrate. Where, surface discontinuities cannot be accommodated by the tape without bridging, and then the surface shall be profiled with compatible moulding putty, before tape application. The moulding putty shall shall be specifically formulated for this purpose and obtained from the same manufacturer as the tape. Where piping emerges from the ground the tape wrapping shall extend 18” (450mm) (450mm) above ground and overlap the above ground coating coating system system by a minimum of 4” (100mm). Finish shall shall be Off -white -white or Light Grey for U.V. resistance.

7.12

Composite Wrapping. Composite wrappings shall be applied in full accordance with the manufacturer’s recommendations. recommendations.

7.13

Internal Lining of Tanks and Vessels General The selection of coating materials for the internals of tanks and vessels, including heat exchanger water boxes and channels etc., shall be in accordance with the coating systems systems shown shown in SCHEDULE ‘C’ of this specification. The methods of surface preparation and coating application shall be as described in section 6 & 7 except as amended below. All removable fittings shall be prepared and coated outside the vessel or tank and reinstalled once the internal lining has fully cured. Contractor’s personnel shall take care to avoid damage to the applied coating and all wear clean overshoes when working inside the vessel or tank.

7.14

Surface Preparation Surface preparation shall include the removal of all rough weld capping and surface laminations, and profiling of all sharp edges, corners etc. followed by dry abrasive blasting to the standard in SCHEDULE ‘C’.

Equipment, piping and Tanks shall be flushed out to remove deposits such as rust and loose scale before examination and preparation of the SOP 022 Issue-1 Revision-12 Revision-12

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surface. Crusts formed by by inhibitors used during hydrostatic testing shall be removed prior to degreasing and blast cleaning. The entire surface to be coated shall be inspected to ensure freedom from imperfections and surface flaws. All surfaces shall be degreased in accordance with SSPC SP1, steam cleaning, detergent scrubbing or low-pressure water cleaning. For equipment such as vessels or tanks blast cleaning shall start at the top and proceed downwards. All dust, spent abrasive and debris shall be removed by brushing and vacuum cleaning when surface preparation preparation is complete. The surface shall be re-inspected to ensure that cleanliness is of the specified standard and that surface-breaking flaws are absent. 7.15

Lining Application Environmental conditions for lining application shall meet the requirements of Section 7.2. Lining application shall shall begin within two hours of the start of blast cleaning and while the surface is at the specified standard of cleanliness. cleanliness. Dehumidifiers shall be used as necessary necessary to ensure compliance with this requirement. Over-coating delay times (if any) shall be strictly in accordance with the lining manufacturer’s recommendations. Application of linings shall be by airless spray. Brushes may be used for stripe coating and where access access is difficult. Rollers shall not be used. All welds, corners and edges shall receive an additional stripe coat of each layer in the coating system so as to ensure that the specified thickness is achieved. During and after lining, the coated surfaces shall be maintained at the temperature and under the humidity recommended by the coating manufacturer until curing is complete

7.16

Extent of Coating The lining shall extend over the total internal surface including the bore of nozzles and over the faces of all flanges, unless the latter are weld overlaid with corrosion resistant alloy (CRA), in which case the lining shall terminate on the CRA. To ensure correct sealing, glass flake coatings on flange faces shall be press moulded or machined that after fully f ully curing. Where sacrificial anodes are installed, care shall be taken to minimize damage to the coating at the attachment points and to ensure that the active surfaces of the anodes are not n ot coated.

7.17

Lining Inspection


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The lining shall be inspected for any irregularities such as raised areas, pinholes, soft spots, disbandment, discontinuities and and delaminations. The final inspection shall include electrical discontinuity testing over 100% of the coated surface in accordance with NACE SP-0188-2006. All indicated coating holidays shall be thoroughly investigated and all defective coating removed and replaced fully in accordance with the requirements of this specification. The electrical discontinuity test shall be repeated over over all repaired areas. 7.18

Repairs to Glass Flake Linings Any pinholes located by high voltage holiday detection, delaminations, soft spots or other coating defects shall be ground out and fresh lining material applied, with each coat of the repair material overlapping the surrounding intact material by a minimum of 25mm.

7.19

Concrete Surfaces Concrete surfaces shall be fully rehabilitated using an epoxy resin based motor following the application of a low-viscosity penetrating concrete surface primer. All surface imperfections, such as blow holes, areas of mechanical damage, cracks etc. shall be completely filled to provide a smooth profile for the finishing coats. In accordance with schedule D-2, Appendix-A. Appendix-A.


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SECTION 8

STORAGE OF MATERIALS


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8.

STORAGE OF MATERIALS 8.1

All coating materials shall be received in sealed containers clearly marked with product description, reference number, batch number and date of manufacture. Paint, thinners, solvents, etc., shall be stored in a well ventilated fire proof building, and separated from other painting consumables as per manufacturers recommendations.


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SECTION 9

EQUIPMENT USED FOR SURFACE PREPARATION AND COATING APPLICATION


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9.

EQUIPMENT USED FOR SURFACE PREPARATION AND COATING APPLICATION

9.1

Grit blasting Equipment All equipment supplied will have a current inspection certification from a third party independent source if required. The pressure and volume of the compressed air supply for blast cleaning shall meet the work requirement and shall be sufficiently free of oil and water contamination to ensure that the cleaning process is not impaired. Trays, separators and filters shall be emptied and cleaned regularly. Stage air coolers are a requirement especially during summer conditions. All equipment shall be adequately earthed.

9.2

Hand tools Chipping, scraping and steel wire brushing using manual or power driven tools shall be of a type acceptable to “COMPANY”.

9.3

Spray Equipment All equipment supplied will have a current inspection certification from a third party independent source if required. The pressure and volume of the compressed air used for spray application shall meet the work requirements and be free from oil and water contamination. Trays, separators and filters shall be emptied and cleaned regularly. All equipment shall be adequately earthed.


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SECTION 10

INSPECTION AND TESTING Inclusive of Attachment-1 N.C.R. – Non-Conformance Report


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10.0

INSPECTION AND TESTING All surface finishes of coating shall be inspected by a “COMPANY” approved coating inspector for workmanship in accordance with the approved Quality Plan and “COMPANY” Internal Paint Inspection Procedure Ref. Painting Inspection SOP.023, Issue 1 Rev 1 as issued to all contractors in the pre-tender documents. Any work rejected due to poor workmanship or incorrect application of the coating shall be corrected by remedial action as directed by “COMPANY” issued N.C.R. (Non Conference Report). All finished dry film thickness shall be tested by use of an Magnetic Dry Film Thickness Gauges (Types 1 & 2) on both ferrous and non-ferrous surfaces to determine the required total dry film thickness, and shall be in accordance with S.S.P.C. Steel Structures Painting Council PA-No.2. "Measurement of Dry Film Thickness". Calibration of the Magnetic film thickness gauges shall be carried out, in accordance with the above, on the job site and agreed between the inspector and contractor. ANY layer or total coating system which does not meet the required dry film thickness specified shall be brought to the required thickness using the material of the last coat applied. All the previous clauses of the specification will be applied at all times during the coating preparation and application. It is the Contractors responsibility first and foremost to maintain QA/QC to ADGAS requirements as mentioned in Section 4. Furthermore, all inspection and testing requirements to be undertaken by the inspection authority of ADGAS in both qualitative and quantitative tests, including Non-destructive and destructive testing, is given in the ADGAS S.O.P.-023 "Painting Inspection Procedure", latest revision (Rev.1).


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SECTION 10 (Cont’d.) ATTACHMENT 1

ADGAS NON-CONFORMANCE REPORT (N.C.R.)


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NONCONFORMANCE REPORT CORROSION & INSPECTION DEPARTMENT Non-conformance Report # _________ Attention: _________________________

Date ________________

Company: _________________________

Fax No. ______________

Description of Nonconformance: Process: ___________________________

Work Order # _________

Disposition:

Comments: ___________________________________________________________ Signature: __________________________________

Date ________________

Disposition Implemented by: ___________________ Position: _____________ Signature: __________________________________

Verified by: _______________________________

Date ________________

Position: M/Representative

Closure Signature: ____________________________

Date ________________

Form: QS 8 Rev.0


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ADGAS – CORROSION & INSPECTION DEPARTMENT CORRECTIVE & PREVENTIVE ACTION LOG Report #

CAR

PAR

Issue Date

Complaint

Supplier Failure

Internal Failure

Date Initiated

Originator

FORMAT FOR REFERENCE


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Follow-up Date

Closure Date

ADGAS – CORROSION & INSPECTION DEPARTMENT CORRECTIVE & PREVENTIVE ACTION LOG Report #

CAR

PAR

Issue Date

Complaint

Supplier Failure

Internal Failure

Date Initiated

Originator

FORMAT FOR REFERENCE


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Follow-up Date

Closure Date

SECTION 11



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11.0


11.1

Colours Colours of all equipment, structural steel, etc. shall conform to the colours given in: Table for ADGAS Plant & Equipment Colour Scheme. All piping shall be in accordance with BS 1710, Identification of Pipelines and Services and shall also conform to the requirements of BS 4800: 1972 - as given in Appendix B - (Schedule of Colours for Identifying Pipelines and Services). All piping codes shall only be undertaken on Das under the guidance of Operations representative, and not at Vendors/Shop etc. 11.2

Identification 11.2.1 Stenciled Letters (to Plant Equipments, and piping where designated) Stenciled letters shall preferably be 50mm high, but not less than 38mm high, and shall be black gloss for both “straight on stenciling” and colour blocks, on a yellow back ground. Stenciled information shall comprise of the following:(a) Plant item number including TAG & WIN Nos. if applicable, mainly equipment. (b) Description of item if applicable, mainly equipment. (c) Name of contents, for equipment and pipe work. (d) Direction of flow to show the directional flow of the product within the pipe, by means of an arrow --> <--. 11.2.2 Blocks Blocks shall be painted in a prominent and easily readable position, as directed by “COMPANY”. The size of the blocks shall normally be 600mm long by 300mm although they may be increased if all the information cannot be incorporated. Additionally, pipe work contents shall be made known by banding codes, at intervals to be agreed between “COMPANY” and contractor to distinguish the pipe contents, (in general guidance of BS 1710).


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APPENDIX A

COATING SCHEDULES - A, B, C & D


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APPENDIX A, SCHEDULES A, B, C & D Application of Protective Coatings: Protective coating systems designed to apply during the plant is under operational running condition within the process parameter, however for easy approach, substrate surface temperature break up was given in the table below during application. For ambient application, the weather conditions mentioned in the section 7.2 to be followed, surface temperature should be a minimum of 5°F [3°C] above the dew point. Coatings to be apply in between 10°C to 45°C to achieve continuous film formation. However if the steel surface temperature falls below 10°C and above 45°C that it means, exceeding the specified limits between, shall be governed by manufacturers parameter, technical data sheets etc. Coating schedule B & C has been developed especially for maintenance works of protective coatings during ambient, shutdown or operational conditions of the plant equipment, tanks & vessels, heat exchangers, pipes, fittings whilst the plant is under operational running conditions within a temperature range of +10 °C to 45°C. When the plant is operating below 10°C and above 45°C due to its process requirement, the coating schedules B (except B-2b, B-4a & B4-b) & C, stipulated here cannot be applied unless the plant is available in shutdown condition or ambient condition. Application on Hot Surfaces: Application of protective coatings on hot surfaces under operational conditions of the plant, that it means that maintenance of coatings to be carried out without needing to shut down the plant. The following coating schedules has been developed especially for maintenance works of protective coatings during operational conditions, plant operating at its process temperature, hence the coating schedules were stipulate for coatings to apply on vessels, equipment, heat exchangers, pipes and fittings whilst the plant is under operational running conditions. Coating system B-2b application temperature up to 120°C Coating system B-4a application temperature up to 150°C. Coating system B-4b application temperature up to 316°C.   


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Substrate Temperature’s During Application Of Coatings Coating schedules A-1a & 1b, A-2a A3 A4-b A-5a, 5b, 5c, A-6a, 6b, A-7a, 7b, 7c, A-8a, 8b, 8c and A-9a & 9b. A-2b & B-2b B-4a B-4b A-9c & B-9c B-1a, 1b, B-2a, 2c, 2d, B-3, B-5a, 5b, B-6a, 6b, B-7a, 7b, 7c, B-8a, 8b, 8c B-9a, 9b B-10a, 10b & 10c C-1, C-2, C-3, C-4, C-5 & C-6 D-1, D-2 & D-3


Application conditions and curing requirements. +10°C to 45°C If exceeds this limit, consult with manufactures for specific application conditions.

+10°C to 120°C +10°C to 150°C +10°C to 316°C Factory applied coating to be comply with manufactures recommendations

+10°C to 45°C If exceeds this limit, consult with manufactures for specific application conditions.

+10 to 45°C above or below this range consult with manufactures for specific application conditions. Comply with manufactures recommendations

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Schedule A: Metal Surfaces - Coatings for New Construction (Vendors & Off Das) Spec A-1a.

Jetty Splash Zones, The area on an offshore structure that is alternatively dry and wet because of the influence of tides, wind, and waves. The Splash zone is defined from 1.5 meters below the Low Altitude Tide (LAT) level to 1.5meters above the High Altitude Tide (HAT) level. (Jetty Splash zone height is Approximately 4.68 meters). A-1b. Jetty Atmospheric Zone: The area on an offshore structure that is above the splash zone. A-2a. Onshore Structural Steel Works Etc. and Uninsulated Pipe works and o Equipment design temperature unto 80 C. A-2a. Option – 1 (Coating system based on Zinc Silicate primer). A,2a. Option – 2 (Coating system based on Zinc rich epoxy primer) A-2b. Atmospheric service between Ambient to 120°c. o A-3. Process Pipe works and Equipment design temperature up to 200 C and Thermally Insulated. A4-a deleted. A-4b Application of coating for Process Pipe work and equipment design temperature in Cyclic service -185 ⁰ c to 650 ⁰ c (Uninsulated and Insulated). o A-5a,5b Process Pipe work and Equipment design temperature from 80 C > to o 600 C non-insulated. o A-5c Process Pipe work and Equipment design temperature from 80 C > to o 600 C non-insulated or insulated. o A-6a Stainless Steel Surfaces design temperature from – 162 ⁰c to 80 C, Uninsulated o A,-6b Stainless Steel Surfaces design temperature from 80 C> 600 ⁰ c, Uninsulated. A-7a. New Galvanized items other than Galvanized Gratings. A-7b. New Galvanized Gratings. A-7c. Non – Galvanized Gratings & Weathered Galvanized Gratings (Existing) A-8a,. Passive Fire Protection with Intumescent Epoxy. A-8b. Passive Fire Protection with Intumescent Epoxy. A-8c. Passive Fire Protection with Intumescent Epoxy. A-9a. Buried Pipe work Valves and Fittings. A-9b Coating system for Tank bottom plate back side resting on the earth. A-9c External fasteners coating (bolts, studs and nuts) Deleted A-10a, 10b


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Metal Surfaces – Coatings for Maintenance Painting and New Fabrication on Das. Specification B.1a. Jetty Splash Zones, The area on an offshore structure that is alternatively dry and wet because of the influence of tides, wind, and waves. The Splash zone is defined from 1.5 meters below the Low Altitude Tide (LAT) level to 1.5meters above the High Altitude Tide (HAT) level. (Jetty Splash zone height is Approximately 4.68 meters). B.1b. Jetty Atmospheric Zone: The area on an offshore structure that is above the splash zone. B,2. Onshore Structural Steelwork Process Pipelines and Equipment design temperature up to 80 ⁰ C . a) Dry Blast cleaning. b) Atmospheric service between Ambient to 120°c. c) Hi-Pressure Water Jetting. d) Power Tool Cleaning. B,3. Process Pipe works and Equipment design temperature up to 200 o C and Thermally Insulated. B,4a. Coating application under operational conditions for the Process Equipment’s & Piping substrate temperature up to 150 ⁰ c. B,4b. Process Equipments and Piping design temperature in o DUAL/CYCLIC temperatures from -185°c to +650 C for coating application "Ambient/ Shutdown/under operational condition/Cyclic”. (Non-Insulated / Insulated) B,5a, b, Process Pipe work and Equipment design temperature from 80 °c to 600°c Non-insulated. B,5c Process Pipe work and Equipment design temperature from 80 °c to 600°c insulated or non-insulated. o B,6-a Stainless Steel Surfaces design temperature from -162 ⁰c to 80 C, Non-insulated. o B, 6-b Stainless Steel Surfaces design temperature above 80 C, Noninsulated. B, 7a. Galvanized Surfaces – Weathered other than Galvanized gratings. B,7b. Galvanized Gratings. B,7c. Non – Galvanized Gratings & Weathered Galvanized Gratings B,8a,. Passive Fire Protection with Intumescent Epoxy. B,8b. Passive Fire Protection with Intumescent Epoxy. B,8c. Passive Fire Protection with Intumescent Epoxy. B,9a. Buried Pipe work Valves and Fittings. B,9b Coating system for Tank bottom plate back side resting on the earth. B,9c External fasteners coating (bolts, studs and nuts) B,10a. Pipe support area Corrosion prevention system for not having Severe corrosion. B,10b. Corrosion prevention and wear resistance system for pipe support area with Composite wear pad. B,10c. Corrosion prevention system for Pipe support area, pipe and equipments severely corroded, having pitting and wall thickness loss . Schedule B


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Schedule C

Metal Surfaces - Tank and Vessel Linings

Specification C,1. Gas Separation Vessels and Storage Tanks in Condensate & Carbonate Service. C,2. Surface Condenser Channels, in Cooling Water Service (Sea water) C,3. Desalinated De-Ionized and Dematerialized Water Storage Tanks. C,4. Potable/Drinking Water Storage Tanks. C,5. Amine storage tanks for design temperature up to 120 °c (special system to be selected on case to case basis, so Contractor to seek Company approval). C,6. Condensate stripper water draw drum up to 180 °c (special system to be selected on case to case basis, so Contractor to seek Company approval). Schedule D

Concrete Surfaces D,1. D,2. D,3


Internal Repairs to Cement Lined Pipe works. Structural Concrete Surfaces. Structural Concrete Surfaces - Immersed

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APPENDIX A - COATING SCHEDULE-A METAL SURFACES – COATINGS FOR NEW CONSTRUCTION (At Vendors Works or Off Das) (All surfaces are carbon steel unless otherwise indicated) Coating Systems Ref.

A-1a

A-1b

Coating system

JETTY SPLASH ZONE

JETTY ATMOSPHERIC ZONE

Location/Item

Splash zone: The area on an offshore structure that is alternatively dry and wet because of the influence of tides, wind, and waves. The Splash zone is defined from 1.5 meters below the Low Altitude Tide (LAT) level to 1.5meters above the High Altitude Tide (HAT) level. (Splash zone Approximately 4.68 meter)

Jetty Atmospheric Zone: The area on an offshore structure that is above the splash zone. Glass Flake Polyester to withstand high humidity, aggressive atmospheric environment and suitable for sea water immersion service.

Remove marine fouling and deleterious material by HPWJ

Dry Abrasive blast to ISO 8501-1, Sa 2.5 (SSPC-SP10).Roughness using abrasive suitable to achieve a coarse surface of grade Medium to coarse (50-85 microns ) ISO 8503 – 2

Surface preparation

Priming Undercoats and Finish Minimum Total Dry Film Thickness (Microns) Comments

Polyurethane jacketing system shall be used in the splash zone area. PU Jacket with gel inhibition system Jacket assembly

Two coat of Glass flake Polyester at 500 to 600 m icrons per coat. Total DFT 1000 to 1200 microns

6.25mm Follow manufacturer technical data sheet for details.


Followcoating manufacturer data sheet for application temperature, mixing ratio and mixing procedure, pot life, application equipment capacity, application spray nozzle size requirement details, recoating times and other application details.

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SCHEDULE A (continued) METAL SURFACES – COATINGS FOR NEW CONSTRUCTION (At Vendors Works or Off Das) (All surfaces are carbon steel unless otherwise indicated) Coating Systems Ref.

A-2a

Coating system

Option - 1 (Coating system based on Zinc Silicate primer)

Location/Item

Onshore Structural Steel Work, Etc. Process Equipment & Piping o Design temperature up to 80 C (Non-Insulated) Dry abrasive blast to ISO 8501-1, Sa 3 (SSPC - SP5)

Onshore Structural Steel Work, Etc. Process Equipment & Piping Design o temperature up to 80 C (Non-Insulated)

1 Coat of zinc silicate primer at 75 microns. 1 Coat of two pack epoxy tie coat at 25 microns. 2 Coats of high build M.I.O. epoxy at 100 microns per coat. 1 Coat of acrylic modified polyurethane at 75 microns.

1 Coat of zinc rich primer at 50 microns.

Surface preparation Priming Undercoats and Finish

Total DFT (Microns) Comments

Option - 2 (Coating system based on Zinc rich epoxy primer)

Dry abrasive blast to ISO 8501-1, Sa 3 (SSPC SP5)

2 Coats of high build M.I.O. epoxy at 100 microns per coat. 1 Coat of acrylic modified polyurethane at 75 microns.

375 microns

325 microns

Zinc silicate primer shall be based on inorganic or ethyl silicate and shall contain not less than 85% metallic zinc by weight of the total pigment content.

Zinc rich epoxy primer shall be based upon


a polyamide cured two pack epoxy media with a minimum of 90% of metallic zinc by weight of the total pigment content.

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A-2b Atmospheric service between Ambient to 120°c. Applied to hot surfaces of onshore process equipment & piping design temperature up to 120 °c (non – insulated). For carbon steel: Dry abrasive blast clean to ISO 8501-1, Sa 2.5 SSPC – SP 10 For Stainless steel –Dry abrasive SWEEP / BRUSH OFF blast clean equivalent to ISO-8501-1 (SSPC-SP-7) 40 Microns Surface Profile. Two coat of Cold Spray Aluminium (CSA) @100 microns each coat, total of 200 microns (two coats). It is recommended that multiple thin film coats to be applied using “wet on wet” technique (similar to application of “mist coat”) until the required film build is achieved. For example at 120°c seven to ten mist coats with as little as one minute between coats maybe required to build up to the recommended 200 micron dry film thickness. This will allow the solvent incorporated within the applied film to escape. Application of a heavy coat direct to the hot steel may result in film bubbling. For selection of coating r efer ADGAS approved coating manufacturer product list for coating system “ A2b”

SCHEDULE A (continued) METAL SURFACES – COATINGS FOR NEW CONSTRUCTION (All surfaces are carbon steel unless otherwise indicated) Coating Systems Ref.

A-3

A-4b

Coating system for “Carbon steel and Stainless steel”

Phenolic Epoxy for Process equipments & piping Design temperature up to 200°c and Thermally insulated.

General

Location/Item

Surface preparation

Process Equipment Design temperature up to 200°c and Thermally insulated. For Carbon steel -Dry abrasive blast clean to ISO 8501 – 1, Sa 2.5 (SSPC – SP10) (NACE No – 2) - Near white blast cleaning. For Stainless steel –Dry abrasive SWEEP / BRUSH OFF blast clean equivalent to ISO-8501-1 (SSPC-SP-7) 40 Microns Surface Profile

Coating system for “Carbon

steel and Stainless steel” Cyclic Services/Dual Services

Cyclic/dual condition and Service Temperature minus 185 °C to 650 °C. Process Equipment & Piping in Cyclic Service( Uninsulated or Insulated. For carbon steel -Dry abrasive blast clean to: ISO-8501-1, SA-3 (SSPC-SP5). For Stainless steel –Dry abrasive SWEEP / BRUSH OFF blast clean equivalent to ISO-8501-1 (SSPC-SP-7) 40 Microns Surface Profile

Priming

Two coat of thickness.

Undercoats + Finish

N/A

N/A

250 MICRONS For selection of coating refer ADGAS approved coating manufacturer product list for coating system “A3”

250 to 300 microns The substrate temperature should be minimum 10°c and at least 3°c above the Dew point of the air. 125 to 150 Microns DFT per coat. For selection of c oating refer ADGAS approved coating manufacturer product list for coating system “A-4b”

Total Dry Film Thickness (microns) Comments:

A4-a deleted from the system.


Phenolic epoxy each 125 microns Dry film

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Two coat of Inert Polymeric Matrix @125 to 150 microns each coat, total of 250 to 300 microns (two coats).


A-5 a,b,c

Location/Item Surface preparation Priming

Process Equipment & Piping, Design temperature from 80°C Up to 600°C. Dry abrasive blast clean to ISO – 8501 – 1 SA – 3 (SSPC – SP5). a Coating system for equipment’s and piping’s non – insulated for design temperature 80 ⁰ c to 400 ⁰ c

c Coating system for equipment’s and piping’s insulated or non-insulated for design temperature 80 ⁰ c to 600 ⁰ c

Modified Silicone at 25 Microns.

b Coating system for equipment’s and piping’s non-insulated for design temperature 150 ⁰ c to 600 ⁰ c Modified Silicone in two application25 to 30 microns per coat total of 50 to 60 microns. N/A

100 microns

50 to 60 microns

150 microns + sealer coat

In – organic Zinc Silicate at 75 microns Undercoats + Finish coats Total Dry Film Thickness (microns) Comments

TSA (Thermal Spray Aluminium) at 150 microns.

Manufacturer Approved Sealer as required.

1. Modified Silicone can be Aluminium Pigmented or supplied range of colors to approval of client. 2. Zinc silicate primer shall be based on inorganic or ethyl silicate and shall contain not less than85% metallic zinc by weight of the total pigment content.


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A-6a

A-6b

Location/Item

Stainless Steel Surfaces, process Equipment & Piping Design o o temperature from -162 C up to 80 C Non-insulated Dry abrasive SWEEP / BRUSH OFF blast clean equivalent to ISO8501-1 (SSPC-SP-7) 40 Microns Surface Profile

Stainless Steel Surfaces, process Equipment & Piping o Design temperature from 80 C to 600 c Non-insulated Dry abrasive SWEEP/BRUSH OFF blast clean equivalent to ISO8501-1 (SSPC-SP-7) 40 Microns Surface Profile

Priming

Red Oxide Pigmented Epoxy to 75 Microns Primer *

Modified Silicone in two applications of 25 to 30 Microns each coat Total 50 to 60 Microns

Undercoats + Finish coats

High-Build M.I.O. Epoxy in two applications at 100 Microns per coat (200 Microns)

Finish Coat can be Aluminium pigmented or range of supplied colours.

Total Dry Film Thickness (microns)

275 microns

50 to 60 microns

Comments

* Primer shall be Chloride Ion Free

Surface preparation

S/S temperature at time of application as per manufactures product data sheet.


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A-7a Galvanized items other than Gratings.

Location/Item

Surface preparation

Priming Undercoats & Finish Coats

Total Dry Film Thickness (microns) Comments

A-7b Galvanized Gratings

A-7c Non – Galvanized Gratings

Galvanized Steel - New

All the New Galvanized Steel Gratings to be coated as per the coating system “A7b”.

Thoroughly degrease, and chemical etch with Mordant Solution, PVC Etch-Primer, or British Rail T-Wash. Should no chemical or primer pretreatment be undertaken then Light Sweep Blast clean to ISO-8501-1, SA-1 (SSPC-SP-7 Brush Off) Zinc-Rich Epoxy Primer at 50 Microns

Thoroughly degrease, and chemical etch with Mordant Solution, PVC Etch-Primer, or British Rail T-Wash. Should no chemical or primer pre-treatment be undertaken then Light Sweep Blast clean to ISO-8501-1, SA-1 (SSPC-SP-7 Brush Off)

All the New Non - Galvanized Steel Gratings to be coated as per the coating system “A7c”. Dry abrasive blast to ISO 8501-1, Sa 3 (SSPC SP5)

High Build Epoxy, MIO in two applications 100 Microns Per coat* 200 Microns Polyurethane Top Coat at 75 Microns

325 Microns. Zinc rich epoxy primer shall be based upon a polyamide cured two pack epoxy media with a minimum of 90% of metallic zinc by weight of the total pigment content.


Zinc-Rich Epoxy Primer at 50 Microns High Build Epoxy, MIO in two coat applications 100 Microns Per coat* Due to Safety Concern all the galvanized Gratings to be coated as per the “A7b” coating system i.e. only with MIO finish(non – slip finish). 250 Microns

Due to Safety concern all the Gratings to be coated with MIO finish. Zinc rich epoxy primer shall be

based upon a polyamide cured two pack epoxy media with a minimum of 90% of metallic zinc by weight of the total pigment content..

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1 Coat zinc rich primer at 50 microns. 2 coats of high build M.I.O. epoxy at 100 microns per coat. Due to Safety Concern all the Non Galvanized Gratings to be coated as per the “A7c” coating system i.e. only with MIO finish(non – slip finish).

250 Microns Zinc rich epoxy primer shall be based upon a polyamide cured two pack epoxy media with a minimum of 90% of metallic zinc by weight of the total pigment content.

SCHEDULE A (continued) METAL SURFACES – COATINGS FOR NEW CONSTRUCTION (All surfaces are carbon steel unless otherwise indicated) Systems Ref.

A8a, b and c Carbon Steel Surfaces Passive Fire Proofing Option - A-8a Intumescent Epoxy

Option - A-8b Intumescent epoxy

Option - A-8c Intumescent epoxy

Substrate must be clean, dry and free from contamination prior to abrasive blast cleaning to Sa 2.5 ISO-8501-1:1988 Blast profile range 30 – 75 microns Compatible primer, jet fire scrim cloth and polyurethane top coat to be selected Intumescent epoxy.



1. Intumescent epoxy can be applied on –line in the temperature ranges 25to45 ⁰c.2. Equipment design temperature above 45 ⁰c requires shutdown for application. 3. Compatible Intumescent epoxy material can be applied over primer for equipment up to design temperature 80 ⁰c. 4. Equipment design temperature above 80 ⁰c up to 150 ⁰ c thermal barrier compatible to be applied for the selected Intumescent epoxy 5. To meet the desired fire ratings consult manufacturer for application PFP thickness requirement. 6. If Equipments design temperature above 150 ⁰c and below 0 ⁰c requires PFP, the material selection and application of PFP to be consulted with manufacturer.7. For selection of coating refer ADGAS approved coating manufacturer product list.

1.Intumescent epoxy can be applied on –line in the temperature ranges 25 to 45 ⁰c. 2. Equipment design temperature above 45 ⁰c requires shutdown for application. 3. Compatible Intumescent epoxy material can be applied over primer for equipment up to design temperature 80 ⁰c. 4. Equipment design temperature above 80 ⁰c up to 150 ⁰ c thermal barrier compatible to be applied for the selected Intumescent epoxy 5. To meet the desired fire ratings consult manufacturer for application PFP thickness requirement. 6. If Equipments design temperature above 150 ⁰c and below 0 ⁰c requires PFP, the material selection and application of PFP to be consulted with manufa cturer.7. For selection of coating refer ADGAS approved coating manufacturer product list.

1. Intumescent epoxy can be applied on –line in the temperature ranges 25 to 45 ⁰c.2.Equipment design temperature above 45 ⁰c requires shutdown for application. 3. Compatible Intumescent epoxy material can be applied over primer for equipment up to design temperature 80 ⁰c.4. Equipment design temperature above 80 ⁰c up to 150 ⁰ c thermal barrier compatible to be applied for the selected Intumescent epoxy 5. To meet the desired fire ratings consult manufacturer for application PFP thickness requirement. 6. If Equipments design temperature above 150 ⁰c and below 0 ⁰c requires PFP, the material selection and application of PFP to be consulted with manufacturer.7.For selection of coating refer ADGAS approved coating manufacturer product list.

Approved PFP Material Blast cleaning

Priming and Intumescent epoxy Fire rating J 60 H 120 Approved by DNV & Lloyds Register for J 60 fire rating. Approved by Lloyd Register, DNV and Under Writers Laboratory to UL 1709

Comments

1. For the application of PFP over stainless steel, compatibility of above coatings to be confirmed by the Fire-proofing Manufacture for S/S. Epoxy Intumescent PFP to Full Jet Fire Ratings J-60 / H-120, Test to comply OTI-95-634, Approved by Under Writers Laboratory for UL 1709, Approved by Lloyds Register of Shipping, Approved by DNV (SINTEF).Manufacturers shall present full copies of Lloyds Design Verification Report or DNV Design Appraisal Document submitted for full technical assessment to the "CERTIFYING " body is M A N D A T O R Y . They shall also be NORSOK-501 Durability Rated.


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SCHEDULE A (continued) METAL SURFACES – COATINGS FOR NEW CONSTRUCTION (All surfaces are carbon steel unless otherwise indicated) Coating Systems Ref. Location/Item

Surface preparation

Priming and coating

A-9a Buried Pipe works, Valves &Fittings (COAT & WRAP) Dry abrasive blast to:- IS0-8501-1, SA-3 (SSPC-SP5)

Compliant High-build Epoxy (Cumerone Indene Based Resin)* Apply in 3 coats at 200 Micron per coat.

A-9b

A-9c

Coating system for Tank bottom plate back side (Resting on the earth). Dry abrasive blast to:- IS0-8501-1, SA-3 (SSPC-SP5)

External fasteners coating

Compliant High-build Epoxy (Cumerone Indene Based Resin)* Apply in 3 coats at 200 Micron per coat

TOTAL Dry film thickness (Microns)

600

600

Abrading+ Priming+ Wrapping

Use of Cold Applied Tape Wrap primer. PVC Bitumen Backed Tape of 1.5mm (Denso-Tape) (Bitumen Based) Continuous spiral wrap, with a minimum 50% overlap. Prior to application of Wrap Primer the epoxy coat shall be light abraded to provide an adequate 'key'. 100% Holiday Detection to be carried out to ensure no holiday.

NA

Comments


100% Holiday detection to be carried out to ensure no holiday.

(bolts, studs and nuts) Fluorocarbon polymer system, PTFE or equivalent to be approved by Company. Bolting shall be accomplished using the special tools and the instructions as supplied by the approved Vendor. Alternate coating will only be acceptable upon thorough investigation of such coating as to the type, application procedures and the results of necessary testing’s that prove to be equivalent. It is the Contractor’s responsibility to perform the necessary investigation and to advise the outcome to Company. General clarification as to the extent to which the requirement is applicable is as follows. Included: 1. All external flanged connections (shop and field assembled), including insulated flange bolting where the service temperature is less than 200°c. 2. Equipment bolting that requires removal for scheduled maintenance and inspection. Excluded: 1. All structural bolting. 2. Fasteners/bolts used in assembly of various components within a manufacturer’s standard equipment, miscellaneous standard valve assemblies and the instrumentation. Contractor shall review manufacture’s standard coating for its suitability in the specified jobsite conditions, on case by case basis. 3. Alloy fasteners. 4.Insulated flange bolting above 200°c

Page 55

SCHEDULE B METAL SURFACES – COATINGS FOR MAINTENANCE or NEW FABRICATION ON DAS (All surfaces are carbon steel unless otherwise indicated) Coating Systems Ref.

B-1a

B -1b

Coating system

JETTY SPLASH ZONE

JETTY ATMOSPHERIC ZONE

Location/Item

Splash zone: The area on an offshore structure that is alternatively dry and wet because of the influence of tides, wind, and waves. The Splash zone is defined from 1.5 meters below the Low Altitude Tide (LAT) level to 1.5meters above the High Altitude Tide (HAT) level. (Splash zone Approximately 4.68 meter)

Jetty Atmospheric Zone: The area on an offshore structure that is above the splash zone. Glass Flake Polyester to withstand high humidity, aggressive atmospheric environment and suitable for sea water immersion service.

Polyurethane jacketing system shall be used in the

Dry Abrasive blast to ISO 8501-1, Sa 2.5 (SSPC-SP10).Roughness using abrasive suitable to achieve a coarse surface of grade Medium to coarse (50-85 microns, ) ISO 8503 - 2

Surface preparation Priming Undercoats and Finish

splash zone area. Remove marine fouling and deleterious material by HPWJ PU Jacket with gel inhibition system Jacket assembly

Minimum Total Dry Film Thickness (Microns)

Comments

Two coats of Glass flake Polyester , each coat DFT 500 to 600 microns. 1000 to 1200 microns

6.25mm Follow manufacturer technical data sheet for details.


Followcoating manufacturer data sheet for application temperature, mixing ratio and mixing procedure, pot life, application equipment capacity, application spray nozzle size requirement details, recoating times and other application details.

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SCHEDULE B METAL SURFACES – COATINGS FOR MAINTENANCE or NEW FABRICATION ON DAS (All surfaces are carbon steel unless otherwise indicated) Coating Systems Ref.

B2

Coating system

Location/Item

Surface preparation

B-2a

B -2 c

B- 2d

Onshore Structural Steel Work, Etc. Process Equipment & Piping o Design temperature up to 80 C (Non-Insulated)

Atmospheric service between +10 to 120°c. Applied to hot surfaces of onshore process equipment & piping design temperature up to 120 °c (non – insulated).

On shore structural steel works, etc Process equipment & piping design temperature up to 80 ° c

Onshore Structural Steel Work, Etc. Process Equipment & Piping Design temperature up to o 80 C (Non-Insulated

Dry abrasive blast to ISO 8501-1, Sa 2.5 (SSPC – SP10)

For carbon steel: Dry abrasive blast clean to ISO 8501-1, Sa 2.5 SSPC – SP 10 For Stainless steel –Dry abrasive SWEEP / BRUSH OFF blast clean equivalent to ISO8501-1 (SSPC-SP-7) 40 Microns Surface Profile. Two coat of Cold Spray Aluminium (CSA) @100 microns each coat, total of 200 microns (two coats).

Ultra High pressure water jet cleaning up to 25,000 to 30,000 psi One coat of two pack epoxy wet blast surface tolerant primer at 75 microns DFT. 2 Coats of high build M.I.O. epoxy at 100 microns per coat. 1 Coat of acrylic modified polyurethane at 75 microns.

Power tool clean to ISO 8501, St 3 (SSPC – SPC3) One coat of surface tolerant epoxy aluminum primer at 125 microns. 2 Coats of high build M.I.O. epoxy at 100 microns per coat. 1 Coat of acrylic modified polyurethane at 75 microns.

Priming

1 Coat of zinc rich epoxy primer at 75 microns.

Undercoats and Finish

2 Coats of high build M.I.O. epoxy at 100 microns per coat. 1 Coat of acrylic modified polyurethane at 75 microns.

Minimum Total DFT Comments

B- 2b

350 microns The choice of surface preparation is to be entirely at Client’s discretion. Zinc rich epoxy primer shall be based upon a polyamide cured two pack epoxy media with a minimum of 90 % of metallic zinc by weight of the total pigment content.


It is recommended that multiple thin film coats to be applied using “wet on wet” technique (similar to application of “mist coat”) until the required film build is achieved. For example at 120°c seven to ten mist coats with as little as one minute between coats maybe required to build up to the recommended 200 micron dry film thickness. . For selection of coating refer ADGAS approved manufacturer product list for system “B 2b”

350 Microns The choice of surface preparation is to be entirely at Client’s discretion.

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Total DFT 400 microns The choice of surface preparation is to be entirely at Client’s discretion.

SCHEDULE B (continued) METAL SURFACES – COATINGS FOR MAINTENANCE or NEW FABRICATION ON DAS (All surfaces are carbon steel unless otherwise indicated) Coating Systems Ref.

General

Location/Ite m Surface preparation

Priming Total DFT (microns) Comments

B- 3 Carbon steel and Stainless steel (Insulated)

B- 4a Carbon steel and Stainless steel (Insulated)

B -4b Carbon steel and Stainless steel (Insulated or Non-insulated) (Cyclic services) Cyclic/Dual service and Service Temperature minus 185 °C to 650 °C. Surface application temperature for on – line under operational conditions between 10°c to 316°c

Phenolic Epoxy for Process equipments & piping Design temperature up to 200°c and Thermally insulated.

Application of phenolic epoxy under operational condition +10°C to substrate temperature 150°c under operational condition (Thermally insulated).

Process Equipment Design temperature up to 200°c and Thermally insulated. For carbon steel -Dry abrasive blast clean to: ISO-8501-1, SA-3 (SSPCSP5). For Stainless steel –Dry abrasive SWEEP / BRUSH OFF blast clean equivalent to ISO-8501-1 (SSPCSP-7) 40 Microns Surface Profile

Process Equipment design temperature up to 200°c. Application under operational condition up to substrate temperature 150°c. For carbon steel -Dry abrasive blast clean to ISO 8501 – 1, Sa 2.5 (SSPC – SP10) (NACE No – 2)Near white blast cleaning. For Stainless steel –Dry abrasive SWEEP / BRUSH OFF blast clean equivalent to ISO-8501-1 (SSPC-SP7) 40 Microns Surface Profile

Process Equipment & Piping in Cyclic Service(Noninsulated or Insulated for Coating under operational condition / AMBIENT / SHUTDOWN For carbon steel -Dry abrasive blast clean to: ISO-8501-1, SA-3 (SSPC-SP5). For Stainless steel –Dry abrasive SWEEP / BRUSH OFF blast clean equivalent to ISO-8501-1 (SSPC-SP-7) 40 Microns Surface Profile. The substrate temperature should be minimum 10°c and at least 3°c above the Dew point of the air.

Two coat of Phenolic epoxy each 125 microns DFT.

Two coat of Phenolic epoxy each 125 microns Dry film thickness.

Two coat of Inert Polymeric Matrix @125 to 150 microns each coat (total of 250 to 300 m icrons - two coats).

250 MICRONS

250 MICRONS

For selection of coating refer to ADGAS approved manufacturer product list for system “B 3”


250 to 300 microns

. For selection of coating refer to ADGAS approved manufacturer product list for system “B 4a”

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For application under operational conditions Apply between 10 °C to 316 °C, up to 125 to 150 Microns DFT per coat. Suitable Coating System for Cyclic and service temperatures range from185 °c to +650 °C. For selection of coating refer ADGAS approved manufacturer product list for system “B 4b”


B - 5a, b, c

Location/Item

Process Equipment & Piping, Design temperature from 80°C Up to 600°C. For coating in Ambient or Shutdown conditions. Dry abrasive blast clean to ISO – 8501 – 1 SA – 3 (SSPC – SP5).

Surface preparation Priming

Undercoats + Finish coats Total Dry Film Thickness (microns) Comments

a Non- insulated equipment’s and piping’s design temperature 80 ⁰ c to 400 ⁰ c In – organic Zinc Silicate at 75 microns Modified Silicone at 25 Microns.

b Non-insulated equipment’s and piping’s design temperature 150 ⁰ c to 600 ⁰ c Modified Silicone in two applications 25 to 30 microns per coat total 100microns. N/A

100

50 to 60

c Insulated or non- insulated equipment’s and piping’s design temperature 80 ⁰ c to 600 ⁰ c TSA (Thermal Spray Aluminium) at 150 microns.

Manufacturer Approved Sealer as required. 150+ sealer coat thickness

1. Modified Silicone can be Aluminium Pigmented or supplied range of colors to approval of client. 2. Zinc silicate primer shall be based on inorganic or ethyl silicate and shall contain not less than 85% m etallic zinc by weight of the total pigment content.


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SCHEDULE B (continued) METAL SURFACES – COATINGS FOR MAINTENANCE or NEW FABRICATION ON DAS (All surfaces are carbon steel unless otherwise indicated)

Coating Systems Ref. Location/Item

Surface preparation

Priming

Undercoats + Finish coats Total Dry Film Thickness (microns) Comments


B- 6a

B- 6b

Stainless Steel Surfaces, process Equipment & Piping o o Design temperature from -162 C up to 80 C Non-insulated

Stainless Steel Surfaces, process Equipment & Piping o Design temperature from 80 C to 600 c Non-insulated

Dry abrasive SWEEP / BRUSH OFF blast clean equivalent to ISO-8501-1 (SSPC-SP-7) 40 Microns Surface Profile

Dry abrasive SWEEP/BRUSH OFF blast clean equivalent to ISO-8501-1 (SSPC-SP-7) 40 Microns Surface Profile

Red Oxide Pigmented Epoxy to 75 Microns Primer *

Modified Silicone in two applications of 50 Microns Total 25 to 30 Microns

High-Build M.I.O. Epoxy in two applications at 100 Microns per coat (200 Microns)

Finish Coat can be Aluminium pigmented or range of supplied colours.

275 microns

50 to 60 microns

* Primer shall be Chloride Ion Free

S/S temperature at time of application as to manufactures product data sheet.

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B -7a

B -7b

B- 7c

Galvanized items other than Gratings.

Galvanized Gratings

Non – Galvanized Gratings & Weathered Galvanized steel Gratings(Existing)

Location/Item

Galvanized Steel - New

All the New Galvanized Steel Gratings

All the New Non - Galvanized Steel Gratings

Surface preparation

Thoroughly degrease, and chemical etch with Mordant Solution, PVC Etch-Primer, or British Rail T-Wash. Should no chemical or primer pretreatment be undertaken then Light Sweep Blast clean to ISO-8501-1, SA-1 (SSPC-SP-7 Brush Off)

Thoroughly degrease, and chemical etch with Mordant Solution, PVC Etch-Primer, or British Rail T-Wash. Should no chemical or primer pre-treatment be undertaken then Light Sweep Blast clean to ISO-8501-1, SA-1 (SSPC-SP-7 Brush Off)

Dry abrasive blast to ISO 8501-1, Sa 3 (SSPC SP5)

Priming

Zinc-Rich Epoxy Primer at 50 Microns

Zinc-Rich Epoxy Primer at 50 Microns

Undercoats & Finish Coats

Total Dry Film Thickness (microns) Comments

High Build Epoxy, MIO in two applications 100 Microns Per coat* 200 Microns Polyurethane Top Coat at 75 Microns

325 Microns. Zinc rich epoxy primer shall be based upon a polyamide cured two pack epoxy media with a minimum of 90% of metallic zinc by weight of the total pigment content.


High Build Epoxy, MIO in two coat applications 100 Microns Per coat* Due to Safety Concern all the galvanized Gratings to be coated i.e. only with M IO finish (non – slip finish). 250 Microns

Due to Safety concern all the Gratings to be coated with MIO finish. Zinc rich epoxy primer shall be

based upon a polyamide cured two pack epoxy media with a minimum of 90% of metallic zinc by weight of the total pigment content..

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1 Coat zinc rich primer at 50 microns. 2 coats of high build M.I.O. epoxy at 100 microns per coat. Due to Safety Concern all the Non – Galvanized gratings to be coated i.e. only with MIO finish (non – slip finish). 250 Microns Zinc rich epoxy primer shall be based upon a polyamide cured two pack epoxy media with a minimum of 90% of metallic zinc by weight of the total pigment content.

SCHEDULE B (Continued) METAL SURFACES – COATINGS FOR MAINTENANCE or NEW FABRICATION ON DAS (All surfaces are carbon steel unless otherwise indicated) Systems Ref. Approved PFP Material Blast cleaning

Priming and Intumescent epoxy Fire rating J 60 H 120 Approved by DNV & Lloyds for J 60 Approved by Lloyds Register, DNV and Under Writers Laboratory to UL 1709

Comments

B 8a, b and c Carbon Steel Surfaces Passive Fire Proofing Option – B- 8a Intumescent epoxy

Option - B -8b Intumescent epoxy

Option - B -8c Intumescent epoxy




.1.Intumescent epoxy can be applied on –line in the temperature ranges 25 to 45 ⁰c. 2. Equipment design temperature above 45 ⁰c requires shutdown for application. 3. Compatible Intumescent epoxy material can be applied over primer for equipment up to design temperature 80 ⁰c. 4. Equipment design temperature above 80 ⁰c up to 150 ⁰ c thermal barrier compatible to be applied for the selected Intumescent epoxy 5. To meet the desired fire ratings cons ult manufacturer for application PFP thickness requirement. 6. If Equipments design temperature above 150 ⁰c and below 0 ⁰c requires PFP, the material selection and application of PFP to be consulted with manufacturer.7. For selection of coating refer ADGAS approved coating manufacturer product list.

. .1.Intumescent epoxy can be applied on –line in the temperature ranges 25 to 45 ⁰c. 2. Equipment design temperature above 45 ⁰c requires shutdown for application. 3. Compatible Intumescent epoxy material can be applied over primer for equipment up to design temperature 80 ⁰c. 4. Equipment design temperature above 80 ⁰c up to 150 ⁰ c thermal barrier compatible to be applied for the selected Intumescent epoxy 5. To meet the desired fire ratings consult manufacturer for application PFP thickness requirement. 6. If Equipments design temperature above 150 ⁰c and below 0 ⁰c requires PFP, the material selection and application of PFP to be consulted with manufa cturer.7. For selection of coating refer ADGAS approved coating manufacturer product list.

.1.Intumescent epoxy can be applied on –line in the temperature ranges 25 to 45 ⁰c. 2. Equipment design temperature above 45 ⁰c requires shutdown for application. 3. Compatible Intumescent epoxy material can be applied over primer for equipment up to design temperature 80 ⁰c. 4. Equipment design temperature above 80 ⁰c up to 150 ⁰ c thermal barrier compatible to be applied for the selected Intumescent epoxy 5. To meet the desired fire ratings consult manufacturer for application PFP thickness requirement. 6. If Equipments design temperature above 150 ⁰c and below 0 ⁰c requires PFP, the material selection and application of PFP to be consulted with manufacturer.7. For selection of coating refer ADGAS approved coating manufacturer product list.

1. For the application of PFP over stainless steel, compatibility of above coatings to be confirmed by the Fire-proofing Manufacture for S/S. Epoxy

Intumescent PFP to Full Jet Fire Ratings J-60 / H-120, T est to comply OTI-95-634, Approved by Under Writers Laboratory for UL 1709, Approved by Lloyds Register of Shipping, Approved by DNV (SINTEF).Manufacturers shall present full copies of Lloyds Design Verification Report or DNV Design Appraisal Document submitted for full technical assessment to the "CERTIFYING " body is M A N D A T O R Y . They shall also be NORSOK-501 Durability Rated.


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SCHEDULE B (continued) METAL SURFACES – COATINGS FOR MAINTENANCE or NEW FABRICATION ON DAS (All surfaces are carbon steel unless otherwise indicated) Coating Systems Ref. Location/Item

B -9 a

B- 9 b

B- 9 c

Buried Pipe works, Valves &Fittings (COAT & WRAP)

Coating system for Tank bottom plate back side (resting on the earth).

External fasteners coating (bolts, studs and nuts)

Surface preparation

Dry abrasive blast to:- IS0-8501-1, SA-3 (SSPC-SP5)

Dry abrasive blast to:- IS0-8501-1, SA3 (SSPC-SP5)

Priming and coating



Fluorocarbon polymer system, PTFE or equivalent to be approved by Company. Bolting shall be accomplished using the special tools and the instructions as supplied by the approved Vendor. Alternate coating will only be acceptable upon thorough investigation of such coating as to the type, application procedures and the results of necessary testing’s that prove to be equivalent. It is the Contractor’s responsibility to perform the necessary investigation and to advise the outcome to Company.

TOTAL Dry film thickness (Microns) Abrading+ Priming+ Wrapping Comments


600

600

Use of Cold Applied Tape Wrap primer. PVC Bitumen Backed Tape of 1.5mm (Denso-Tape)

NA

(Bitumen Based) Continuous spiral wrap, with a minimum 50% overlap. Prior to application of Wrap Primer the epoxy coat shall be light abraded to provide an adequate 'key'. 100% Holiday Detection to be carried out to ensure no holiday.

100% Holiday detection to be carried out to ensure no holiday.

Page 63

For coating repair / touch up application, compatible fluorocarbon based coating touch – up need to be applied. Super touch – up coating to be used when the film surface would be scratched during installation of Fluorocarbon coated fasteners. This is cold curing coating mainly composed of the same Fluorocarbon components. For selection of coating refer ADGAS approved manufacturer product list for system “B-9c”

SCHEDULE B (continued) METAL SURFACES – COATINGS FOR MAINTENANCE or NEW FABRICATION ON DAS (All surfaces are carbon steel unless otherwise indicated) B – 10 “a”

Systems Ref Location/Item

Location and Coating system Type

Both pipe and supporting member Option – B 10 “a” Corrosion protection system for pipe support area where there is no much or wall thickness loss. UV curing a multi reinforced sheet laminate of epoxy novolac vinyl ester matrix.

Surface Preparation


Application Procedure

1. Clean prepared surface with Acetone by brush applied. 2. Apply first coat UV resin and allow full cure. 3. For any unevenness (surface corrosion) use UV-Fill to provide even contour. 4. Apply second coat of UV resin (do not allow to cure to dry condition). 5. Whilst UV Resin is in a”Wet” condition, apply the UV Laminate and allow full c uring. 6. Apply a final coat of UV resin. 7. Follow Manufacturer technical data sheet for application technique. 8.Selection of proper composite material refer ADGAS approved manufacturer and product list for system “B-10a”


B – 10 ”b”

B – 10 “c”

Pipe and pipe fittings requires corrosion protection and wear resistance.

Pipe and pipe fittings requires corrosion protection and wear resistance.

Option – B – 10”b” Corrosion protection system for pipe support area/piping components where there is no much wall thickness loss. Fiberglass reinforced composite shell with ultra violet light inhibitor incorporated in the design matrix and supplied with a factory applied modified acrylic adhesive layer. Composite wear pad itself protects the interface area of pipe and support. Appropriate surface preparation a nd clean substrate for removal of loose free materials like sand or dirt or coatings with blast cleaning or wire brush and solvent for removal of oil or grease . Suitable for anti-corrosion and abrasion protection to piping and support surfaces that provide inherent corrosion protection for pipes or at the interface with a pipe support or sleeper and specifically designed for applications where the pipe can be expected to move, through expansion and contraction during service conditions. For selection of material refer ADGAS approved manufacturer product list for the system “B -10b”

Option B – 10 “c” Repair of pipe support area, welds, tees, elbows, pipe and jetty legs having severe corrosion or having wall thickness loss. Selection of proper composite material refer ADGAS approved Composite manufacturer and approved product list.

Page 64


1. Apply composite type wrap to the pitting a nd excessively corroded or wall thickness loss area as per manufacturer technical data sheet. a. Mix and prepare filler and adhesive. b. Apply filler to the pit or excessively corroded area. c. Apply adhesive to the marked corroded area. d. Apply composite wrap as per manufacturer technical data sheet. e. Seek manufacturer advice for proper selection, application and number of composite wrap based on severity of corrosion, wall thickness loss and operating pressure.

SCHEDULE C METAL SURFACES - TANK AND VESSEL INTERNAL LININGS (All surfaces are carbon steel unless otherwise indicated) Coating Systems Ref.

C1

Location/Item

Gas Separation Vessels and Storage Tanks in Condensate & Carbonate Service. Dry abrasive blast to ISO 8501-1, Sa3 (SSPC -SP5)

Surface Condenser Channels in Cooling Water (Sea Water Service)

Four coats of high performance epoxy Priming One coat of high performance epoxy at 75 microns. (Suitable thinned to “Wet In” Profile). Undercoats Three coats of high + Finish performance epoxy @ 50 microns per coat.

One coat of polyester resin primer at 75 microns. Two coats of glass flake polyester at 750 microns per coat.

One coat of epoxy primer at 75 m icrons dft. *Two coats of epoxy high build finish at 125 microns DFT per coat.

1575 Microns

325 Microns

Surface preparation

Coating System

Minimum Total Dry Film Thickness (Microns) Comments


225 Microns Lining to be resistant to Steam cleaning. 100% Holiday Test

C2

C3

Dry abrasive blast to ISO 8501-1, Sa3 (SSPC - SP5)

100% Holiday Test

Desalinated, De-Ionized and Dematerialized Water Storage Tanks. Dry abrasive blast to ISO 8501-1, Sa 3 (SSPC - SP5)

*Chemical solvent and water resistant Epoxy system. 100% Holiday Test

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SCHEDULE C (continued) METAL SURFACES - TANK AND VESSEL LININGS (All surfaces are carbon steel unless otherwise indicated) C4

Coating Systems Ref.

Location

Potable / Drinking Water Storage Tanks

Surface preparation

Dry abrasive blast to ISO 8501-1. Sa 3 (SSPC - SP5).

Priming

1 coat of epoxy primer at 75 microns dft.

Undercoats + Finish

2 Coats of epoxy high build at 125 Microns DFT per coat.

Minimum Total DFT (Microns) Comments

325 Microns

Coating system to have Abu Dhabi, UAE, and water authority approval for potable water. Operations are required to Fill tank and Flush once to ensure Non-tainting of Potable/drinking water, 100% Holiday Test


C5 Two component Ceramic coating system for high temperature equipment handling water and aqueous solution.(continuous immersion service up to 120 ° c)

Suitable for internal application for Amine tanks, condensate tanks, evaporators, heat exchanger barrels, oil/gas and oil/gas water separators, scrubber units, etc Dry abrasive blast to ISO 8501-1. Sa 2.5 (SSPC – SP10 Application method and wet film thickness as per manufacturer recommendation. Follow post curing mechanism as per manufacture data sheet recommendation. For service temperatures below 100°c single coat system at 600 to 750 microns. For service temperature between 100°c to 120°c apply two coats total 800 to 1000microns. 100%wet sponge holiday test. For selection of coating refer ADAGS approved coating manufacturer product list for coating system “C5”

Page 66

C6 Two component high temperature ceramic coating system designed to resist water, hydrocarbons, aqueous solutions and pressurized steam up to a temperature of 180 °c.

Suitable for internal application for condensate stripper water drum, heat exchangers, knockout drums, regenerators, scrubbers, etc

Dry abrasive blast to ISO 8501-1. Sa 3 (SSPC - SP5 Application method and wet film thickness as per manufacturer recommendation on case to case basis. Follow post curing mechanism as per manufacture data sheet recommendation. Suitable for resistant to thermal cycling, steam out process, chemical resistance, high pressure, corrosion resistance in immersed conditions, rapid depressurization. Suitable for internal application for equipment separators, heat exchangers, knock – out drums, regenerators, pumps,

100% wet sponge holiday test. Refer ADAGS approved coating manufacturer product list for coating system “C6”

SCHEDULE D CONCRETE SURFACES Coating Systems Ref.

D1

D2

Location

Internal Repairs to Cement Lined Pipe work

Structural Concrete Surfaces

Surface preparation

Dry abrasive blast clean or high pressure water jet to remove all laitance, surface contamination etc. Remove all dust and debris.

Dry abrasive blast clean or high pressure water jet to remove all laitance, surface contamination etc. Remove all dust and debris.

Priming Undercoats + Finish

Minimum Total Dry Film Thickness (Microns) Comments

N/A To prepared surface direct application of Rapid setting cement based – Water stopping mortar. As to Manufacturers Data Sheets.

One primer coat @50µm, Two mid coats @200µm and One top coat@75µm in accordance to the ADGAS approved materials list. All Surfaces irregularities, such as blow holes, cracks and Minor impact damage to be filled with an epoxy filler. 525 microns.

Refer to ADGAS Approved list for products. Rapid setting temporary patching and plugging of concrete segments cement repair. For injecting into cracks in concrete to temporarily stop the flow of moving water flow. To provides an effective system for crack sealing in wet condition.

* Refer to Manufacturer’s instructions. *** Confirm W.F.T’s at application.

SCHEDULE D (Continued) SOP 022 Issue-1 Revision-12

Page 67

CONCRETE SURFACES Coating Systems Ref.

D-3

Location

Structural Concrete Surfaces - Imm ersed, Brine, Hi-Flow-rate, Dis-Engaging Chambers, Cooling Water Flumes- Sluices, etc.

Surface preparation

Hi-pressure Water Jet to remove all surface contamination or Blast clean to remove all surface laitance, expose blowholes, cracks and other surface irregularities. Remove all dust and debris.

Filler/Fairing Coat All surface irregularities, such as blow holes, cracks and minor impact damage to be filled with an epoxy filler Two primer coat @25µm, Two mid coats @250µm in accordance to the ADGAS approved materials list. Undercoats + Finish

.

Minimum Total Dry Film Thickness (Microns)

Total Dry Film Thickness of 525 - 550 Microns.

Comments

**Confirm WFT’s application.


Page 68

APPENDIX B

SCHEDULE OF COLOURS FOR IDENTIFICATION OF PIPELINES AND SERVICES BS 1710 (1984) BS 4800 (1972)


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APPENDIX-B

:

SCHEDULE OF SAFETY COLOURS & CODE IDENTIFICATIONS

All colour references for BS 1710 “Identification of Pipe lines and Services” and ADGAS adopted safety colours shall be taken from BS 4800, unless otherwise stated. All plant equipments; piping and structure shall be coated the same colour BS Ref. No. 00- A05, “GREY” and shall be known as the general site background colour. All colours used for the basic identification colours and colour code indications used in conjunction with the ADGAS particular colour coding scheme shall be BS 4800 BS Ref. Nos. in general in accordance with BS 1710. Additional information such as Line Nos., Contents, or Equipment/Tag Numbers shall be stencilled in black or white on the safety colour code or on yellow information pane ls. Pipeline Identification Colour Scheme (Ref. to Section 11, 11.1 & 11.2): Pipe Content Gas Sour Gas Sweet Gas Sour Flare Gas Sweet Flare Gas Propane MCR

Identification Colour Yellow Ochre Yellow Ochre Yellow Ochre Yellow Ochre Yellow Ochre Yellow Ochre

Safety Colour Code Red Green Violet Blue Black White

Identification Colour Yellow Ochre Yellow Ochre Yellow Ochre Yellow Ochre Yellow Ochre Yellow Ochre

Pipe Content Air Plant Air Instrument Air Halon / CO2 Nitrogen Oxygen Hypochlorite

Identification Colour Light Blue Light Blue Light Blue Light Blue Light Blue Light Blue

Safety Colour Code White Black Green Orange Red Violet

Identification Colour Light Blue Light Blue Light Blue Light Blue Light Blue Light Blue

Pipe Content Oils

Lube Oil Hydraulic Oil Diesel Oil Sour Oil


Identification Colour

Black Black Black Black

Safety Colour Code

Green Purple White Red


Black Black Black Black

Page 81

Pipe Content Water Sea water C.W. Inlet Dirty Condensate Clean Condensate Sea water C.W.Outlet Higher Temp. Process / Jacket Water Potable Water Sour Water Boiler Feed Water Desalinated Water Dematerialized Water

Identification Colour Green Green Green

Safety Colour Code White Yellow Red

Identification Colour Green Green Green

Green

Orange

Green

Green Green Green Green Green Green

Brown Light Blue Purple Yellow Ochre Black Violet

Green Green Green Green Green Green

Pipe Content Fire Fighting Fire water Foam (FireFighting)

Identification Colour Grey Red

Pipe Content Steam Steam Steam Condensate


Safety Colour Code Red Yellow Ochre

Identification Colour Grey Red

Silver Grey

Safety Colour Identification Code Colour Silver Grey Green Silver Grey

Pipe Content Chemicals K2CO3 Carbonate UCON + Antifoam Di-ethylamine DEA OCENOL Antifoam

Identification Colour Yellow

Safety Colour Code Violet

Identification Colour Yellow

Yellow

Red

Yellow

Yellow

Light Blue

Yellow

Yellow

Purple

Yellow

Pipe Content Acids/Alkalis Acid

Identification Colour Violet

Safety Colour Code White

Violet

Alkalis

Violet

Black

Violet



Page 82

APPENDIX-B (Cont’d)

:

BS 1710 (BS 4800) COLOUR REFERENCE NOS.

Piping Colours

Grey Dark Red

BS Colour Ref. No.

Piping

00-A-05 04-D-45

Safe Colours Green Silver Grey Yellow Ochre Violet Light Blue Orange Black Red White Golden Yellow Auxiliary Blue Canary Yellow Purple

Carbon steel Stainless steel BS Colour Ref. No. Pipe Contents 12-D-45 Water 10-A-03 Steam 08-C-35 Gases 22-C-37 Acid & Alkalis 20-E-51 Air 06-E-51 Electrical 00-E-53 Oil 04-E-53 Fire Fighting 00-E-55 General Service 08-E-51 General Service 18-E-53 General Service 10-E-53 General Service 24-C-39 General Service

ADGAS PLANT & EQUIPMENT COLOUR SCHEME (Ref. 11.1 / 11.2)

Dark Red Grey Grey

BS Colour Ref.No. 04-D-45 00-A-05 00-A-05

Grey Red

04-E-53

Mushroom

08-B-21

Orange

06-E-51

Canary Yellow Black Golden Yellow Red M.I.O – Micaceous Iron Oxide as above

10-E-53 00-E-53 08-E-51 04-E-53 Grey R8047

Plant & Equipment Process Piping Stainless Steel Process Piping Carbon Steel All Structural steelwork including pipe supports, hangers, Storage Tanks, Vessels, Columns, Exchangers, Panels & Cladding. Active Fire Fighting equipment, Hydrants, Stang Monitors, loose boxes Rotating equipment, Pumps, Strainers and their supporting plinths Electrical motors with switch gear 440v, 3.3 Kv & 11 Kv Lifting Equipment/Runway Beams Safety Handrails Platform Gate Guards Deck Gratings ONSHORE ( - MIO) Deck Gratings OFFSHORE ( - MIO)


Colour

as above

Page 83

APPENDIX-B (Cont’d)

:

SCHEDULE OF PROCESS CODE IDENTIFICATION

The following list of codes as depicted below require stencilling on the pipework as per the product in question and/or directed by the Operations representative. CODE ACGA AGST AIR AMMO AP BBD BFW BP BUNF BUTL CAP CAUS CH CO COBA COMA CW DCVA DEAW DEOH DFRS DIES DISW FEGA FG FL FO GC HCCO HCLI HDRO HYDR HYWA JEWA IT

DESCRIPTION Acid Gas Acid Gas/Steam Air Ammonia Process Air Boiler Blowdown Boiler Feed Water Boiler Press. Above 68.5 Bar Bunker Fuel Butane Liquid Cap Gas Caustic Hot Condensate Control Oil Combustion Air Compressed Air Cooling Water D.C. Vapour Deaerated Water De-ethaniser Overheads De-frost Gas Diesel Desalinated Water Feed Gas Fuel Gas (Sweet & Dry) Flash Gas Fuel Oil Glycol Coolant H.C. Condensate H.C. Liquid Hydrocarbon Hydraulic Oil Hydrocarbon/Water Jetting Water Insulation Thickness


CODE AD AI DEA ANFO AU BD BOTT BRIN BUT BUTV K2CO3 CC CHST CO2 COIL COND DC3V DEBO DEWA DHYD DIST ETHA FEWA FGC FLUE FOAM FS H2S HCL HCVA HSO4 HYPT HYZN JW

DESCRIPTION Purge Air Instrument Air Di-ethanolamine Solution Antifoam Service Air Blowdown Bottoms Brine Butane Butane Vapour Potassium Carbonate Solution Cold Condensate CO 2, H2S Carbon Dioxide Crude Oil Condensate DC-3 Overhead Vapour De-ethaniser Bottoms Desalinated Water Dry Hydrocarbon Product Ethane Feed Water Fuel Gas Condensate Flue Gas Foam Fuel Gas (Sour & Wet) Hydrogen Sulphide Hydrochloric Acid H.C. Vapour Sulphuric Acid Hypochlorite Solution Hydrazine Jacket Water

Page 84

APPENDIX-B (Cont’d) CODE K LECA LNGL LNIT LPG LTHC MCR METH MR NGAC OVAP PD PENV PR PROP PROW PW R22 RGAS S SCH SEAW SL SO SOW SS SU SWG TC TEMW TIPG TSP WB WD WFG WHCV WJ WR WU

:

SCHEDULE OF PROCESS CODE IDENTIFICATION

DESCRIPTION Chemicals Lean Carbonate K2CO3 LNG Liquid Liquid Nitrogen Liquid Petroleum Gas Light H.C. Vapours Mixed Component Refrigerant Methane Mixed Refrigerant Natural Gas Condensate Overhead Vapour Process Hydrocarbons (Sweet & Dry) Pentane Vapour Process Refrigerant Propane C3 Process Water Process Hydrocarbons (Sweet & Wet) Freon 22 Reactivation Gas Molten Sulphur SH Steam Condensate Sea Water Steam 4.2 Bar Seal Oil Sour Water Sulphur Plant Steam Steam 1.5 Bar Sweet Gas Equip. Trim Lines Tempered Water TIP Priming Green Tri-Sodium Phosphate Boiler Feed Water Water Potable Wet Fuel Gas Wet HC Vapour Cooling Water (Jacket) Raw Water (Desalinated) Utility Water


CODE LDEA LNG LNGV LOSO LPGV LU MCRV MPFG N 2 NGAS OW PENT PG PROL PROV PS R12 RDEA RGGA SB SCL SH SM SOG SPRW ST SULF SWGE TE TIPB TIPR TT WC WF WGAS WHYD WP WT WV

DESCRIPTION Lean DEA Solution Liquefied Natural Gas LNG Vapour Sweet Lube/Seal Oil LPG Vapour Lube Oil MCR Vapour M.P. Feed Gas Nitrogen Natural Gas Oily Water Pentane Product Gas Propane Liquid Propane Vapour Process Hydrocarbons (Sour & Wet) Freon 12 Rich DEA Solution Regeneration Gas Steam SB 8.6 Bar SL Steam Condensate Steam 62.5 Bar Steam 34.5 Bar Sour Gas Spray Water Steam Sulfamic Acid Sewage Equip. Trim Line TIP Priming Blue TIP Priming Red Equip. Trim Line Cooling Water (Salt) Fire Water Waste Gas W et Hydrocarbon Flushing Water (Process & Pump) Treated Water Water Vapour

Page 85

APPENDIX-B (Cont’d) LINE NUMBERS shall be adopted to give assistance and clarity to the complex geometrical piping layout of the plant. Line numbers (where adopted) shall be black (BS 00-E-53) stenciling on golden yellow (BS 08-E-51) information panels, these shall be shown immediately after inlet/outlet nozzles (where possible) of all equipments, vessels and columns, and shall be repeated every 30 meters on straight line configuration of pipework, at change of direction they shall be repeated immediately after bends and elbows, located below the centre line of the pipe making it easily and clearly visible from ground level.

EXAMPLE

6-MR-1013-20”-C

6-E-0106

6-MR-1013-20”-C


Page 86

APPENDIX C

LIST OF APPROVED COATING SUPPLIERS AND GENERIC TYPES


Page 87

APPENDIX C ADGAS APPROVED COATING SUPPLIERS The following material suppliers are approved by ADGAS, this was determined after an extensive test and appraisal programme no other alternatives will be considered.

COATING SCHEDULES COATING SCHEDULE A (NEW CONSTRUCTION) Coating Schedule A – 1a Jetty Splash zone COATING SCHEDULE A-1b Jetty Atmosheric Zone

COATING SCHEDULE A-2a Jetty Upper Zone, Onshore Structure, etc. design o temperature up to 80 C

APPROVED MATERIAL SUPPLIERS RETRO WRAP JOTUN- BALTOFLAKE AMERON-AMERCOAT 4800 CARBOLINE-CARBOGLAS 1678 Or approved equivalent. JOTUN PAINTS AMERON PAINTS INTERNATIONAL PAINTS HEMPEL PAINTS CARBOLINE PAINTS SIGMA PAINTS BERGER PAINTS International Paints – “Intertherm 751 CSA” or approved equivalent.

Coating Schedule A – 2b Can be applied to hot surface design temperature up to 120 °c. Onshore process equipment & piping design temperature up to 120 °c (non – insulated). COATING SCHEDULE A-3 o JOTUN “EPOXY – HR” Process Equipment, design temperature up to 200 C – Insulated. COATING SCHEDULE A-4 A4-a deleted from the system. JOTUN PAINT – “JOTATEMP-650” 4-b - For application under design temperature conditions AMRON Paints supplied “HI-TEMP (Cyclic Service/Dual Service) for non-insulated or Insulated 1027” for paint system A4-b. equipment’s and piping’s.

JOTUN PAINTS AMERON PAINTS, SIGMA PAINTS, BERGER PAINTS, CARBOLINE PAINTS, HEMPLE PAINTS, INTERNATIONAL or approved equivalent JOTUN PAINTS, AMERON PAINTS, COATING SCHEDULE A-6 a o All stainless steel surfaces, design temperature from -162 C W&J LEIGH & CO SIGMA PAINTS, BERGER PAINTS, to 80ºC - (Non-insulated) INTERNATIONAL PAINTS, Coating Schedule A-6, b – design temperature in Elevated o o CARBOLINE PAINTS, HEMPLE. Temperatures 80 C> - 600 C (Non-insulated) COATING SCHEDULE A-5 a, b, c Process Equipment, design temperature between 80ºC - 600ºC


Page 88

COATING SCHEDULE A-7 Galvanized Surfaces – New COATING SCHEDULE A-8 a, b,c Passive Fire Protection system

Same As above “A-6” LEIGH's FIRETEX M89/M90 International Paint – Chartek – 7 PPG – PITT-CHAR XP or approved equivalent.

Jotun, International, Sigma, Hempel, Berger,Ameron, Carboline, W&J Leigh & Co Jotun, International, Sigma, Hempel, Coating chedule A – 9b Berger, Ameron, Carboline, W&J Coating system for Tank bottom plate back side resting on Leigh & Co the earth TAKENAKA SEISAKUSHO CO of Coating Schedule A – 9c Osaka, Japan product. TAKECOAT External fasteners coating – 1000, PTFE or approved (bolts, studs and nuts) equivalent. SOLARTEC VE 55 or approved Coating Schedule A – 10a equivalent. Coating system for pipe support area MASAD Trading Est – DYNAGARD “Coating Schedule A-10b” Coating system for Pipe or approved equivalent. support area corrosion prevention and wear resistance. SCHEDULE B - MAINTENANCE PAINTING or NEW FABRICATION ON DAS COATING SCHEDULE A-9a Buried Pipework, Valves and Fittings

SCHEDULE B-1a Jetty Splash Zone Areas SCHEDULE B – 1b Jetty Atmosheric zone

SCHEDULE B-2,A Onshore structural steel works, Uninsulated Pipe work and Equipment, Design temperature up to 80ºC

Schedule B – 2b Can be applied to hot surface design temperature up to 120 °c. Onshore process equipment & piping design temperature up to 120 °c (non – insulated). SCHEDULE B-2c Onshore Structural steelworks, etc. etc. o Operating upto >80 C SCHEDULE B-2d Onshore Structural steelworks, etc. etc. o Design temperature up to 80 C


“RETRO WRAP” JOTUN- “BALTOFLAKE”, AMERON – “ AMERCOAT 4800”, CARBOLINE-“CARBOGLAS 1678” or approved equivalent. JOTUN PAINTS AMERON PAINTS W&J LEIGH & CO. BERGER PAINTS SIGMA PAINTS INTERNATIONAL PAINTS CARBOLINE PAINTS HEMPLE PAINTS International Paints – “Intertherm 751” CSA or approved equivalent.

JOTUN,AMERON,W&J LEIGH & CO, BERGER, SIGMA, Hempel International, CARBOLINE PAINTS or approved equivalent. JOTUN,AMERON,W&J LEIGH & CO, BERGER, SIGMA, Hempel International, CARBOLINE, PAINTS or approved equivalent.

Page 89

SCHEDULE B-3 Process Equipment / Pipework, Design temperature up to 200ºC and thermally insulated (Ambient/shutdown) CHEDULE B-4 a Process Equipments/Pipe works, design temperature up to o 150 C For application under operational conditions "ON-LINE" constant temperature - elevated. SCHEDULE - B-4 b For application under design temperature conditions (Ambient/shutdown/on-line/cyclic) for non-insulated or Insulated equipment’s and piping’s. For application 'on-line' under operational conditions Apply between 10 °C to 316 °C, SCHEDULE B-5 a, b, c Process Equipments/Pipe works, design temperature from 80ºC >600ºC SCHEDULE B-6 a All stainless steel surfaces, design temperature from o 162 C to 80ºC - (Non-insulated) Coating Schedule A-6, b – design temperature in Elevated o o Temperatures 80 C> - 600 C (Non-insulated) SCHEDULE B-7 Galvanized Surfaces (Weathered) SCHEDULE B-8 a,b,c Passive Fire Protection. SCHEDULE B-9a Buried Pipeworks, Valves and Fittings Compliant Epoxy H/B (Cumarone Indene Resin) Schedule B – 9b Coating system for Tank bottom plate back side

Schedule B – 9c External fasteners coating (bolts, studs and nuts)

Schedule B – 10a Corrosion protection system for pipe and supporting member. Schedule B – 10b Corrosion protection and wear resistance for pipe and pipe fittings for less wall loss. Schedule B – 10c Corrosion protection and wear resistance for pipe and pipe fitting at wall thickness losses areas.


JOTUN “EPOXY – HR” JOTUN “EPOXY – HR” for paint system B4-a.

{JOTUN PAINT “JOTATEMP-650” AMERON Paints supplied “HI – TEMP 1027” for paint system B4-b}.

JOTUN,AMERON,W&J LEIGH & CO, BERGER, SIGMA, INTERNATIONAL, CARBOLINE, HEMPEL PAINTS JOTUN, AERMON, W&J LEIGH & CO, SIGMA, BERGER, INTERNATIONAL, CARBOLINE, HEMPLE PAINTS or Approved equivalent.

As above or approved equivalent LEIGH's FIRETEX M89/M90 International Paint – Chartek – 7 PPG – PITT-CHAR XP or approved equivalent. JOTUN, AERMON, W&J LEIGH & CO, SIGMA, BERGER, INTERNATIONAL, CARBOLINE, HEMPLE PAINTS or Approved equivalent. JOTUN, AERMON, W&J LEIGH & CO, SIGMA, BERGER, INTERNATIONAL, CARBOLINE, HEMPLE PAINTS or Approved equivalent. TAKENAKA SEISAKUSHO CO of Osaka, Japan product Super touch – up paint for “TAKECOAT – 1000” or approved equivalent. “SOLARTEC VE 55” or Approved equivalent. MASAD Trading Est – “DYNAGARD” or Approved equivalent. “CLOCK – SPRING”, “IMG”, “3X”, or Approved equivalent

Page 90

SCHEDULE C - METAL SURFACES TANKS & VESSELS (NEW CONSTRUCTION & MAINTENANCE) All surfaces are carbon steel unless otherwise stated. SCHEDULE C-1 Gas Separator Vessels, and Storage Tanks in Carbonate and Condensate Service. Jotun Tank guard Storage Epoxy or Equivalent

SCHEDULE C-2 Surface Condenser Channels in Cooling Water (Sea Water) Service. Flake line 164 (Ceil coat), Chemflake or equivalent.

SCHEDULE C-3 Desalinated, De-Ionized and De-mineralized Water Storage Tanks. Epigrip H735/H736 (W & J. Leigh) Or Jotun Tank guard Storage or equivalent.

SCHEDULE C-4 Potable / Drinking Water Storage Tanks Schedule C – 5 Suitable for application of internal coating for protection of equipment operating at elevated temperatures for Condensate tanks, distillation units, heat exchangers, condensate extraction pumps, etc Schedule C – 6 Suitable for internal (immersion service) application for design temperature up to 180 °c equipment separators, heat exchangers, knock – out drums, condensate stripper water draw drum, regenerators, pumps, absorbers, scrubbers, return tanks, steam turbine casings, distillation units and isolation spools.


JOTUN PAINTS AMERON PAINTS W&J LEIGH & CO. SIGMA PAINTS BERGER PAINTS INTERNATIONAL PAINTS CARBOLINE PAINTS HEMPLE PAINTS E. WOODS (COPON) LTD. or Approved equivalent. JOTUN PAINTS AMERON PAINTS W&J LEIGH & CO SIGMA PAINTS BERGER PAINTS INTERNATIONAL PAINTS CARBOLINE PAINTS HEMPLE PAINTS GEN. SIGNAL “FLAKELINE” or approved equivalent. JOTUN, AMERON, BERGER PAINTS W&J LEIGH & CO. SIGMA PAINTS INTERNATIONAL PAINTS CARBOLINE PAINTS HEMPLE PAINTS As above or Approved equivalent. “BELZONA 1391 Ceramic HT” or approved equivalent.

“BELZONA 1591 Ceramic XHT” or approved equivalent.

Page 91

APPENDIX C ADGAS APPROVED COATING SUPPLIERS COATING SCHEDULE-D SCHEDULE D - CONCRETE SURFACES SCHEDULE D-1 Internal repairs to cement lined pipeworks FOSROC – RENDERLOC PLUG or approved equivalent for Rapid setting temporary patching and plugging of concrete segments cement repair. FOSROC – NITOFILL UR 63 / NITOFILL WS60 or approved equivalent for injecting into cracks in concrete to temporarily stop the flow of moving water flow. When used Nitofill WS 60 inconjection with Nitofill UR63 provides an effective system for crack sealing in wet condition.

APPROVED MATERIAL SUPPLIERS

FOSROC PAINT or approved equivalent.

SCHEDULE D-2 FOSROC Structural Concrete Surfaces. JOTUN PAINTS 1 coat of FOSROC NITO primer SP or approved equivalent. AMERON PAINTS FOSROC Nito mortar FC or approved equivalent. 2 coats of FOSROC Nito Coat EP 403 or equivalent at 200 BERGER PAINTS W&J LEIGH & CO. microns DFT per coat. 1 coat of FOSROC Deckguard Polyurethane at 75 microns or SIGMA PAINTS INTERNATIONAL PAINTS equivalent CARBOLINE PAINTS FOSROC or approved equivalent. Follow FOSROC Technical data sheet instruction for the primer HEMPLE PAINTS NITO primer SP requirement if the total thickness is more than or Approved equivalent. 400 microns. SCHEDULE D-3 As above or approved equivalent. Apply: FOSROC Nitomortar FC or approved equivalent. Apply: 1 coat FOSROC NITOPRIME 25 @ 25-=50 microns or approved equivalent. Apply: 2 coats FOSROC NITOCOTE EP410 @ 250 microns per coat or approved equivalent Structural Concrete Surfaces - Immersed Dis-Engaging Chambers, Cooling Water Outlets - Flumes, Sluices, etc.


Page 92

APPENDIX D

APPROVAL FOR SITE BLASTING Inclusive of:Attachment-1 “Noted Areas of Exception (Not to be blasted)” Attachment-2 “Lifting Procedure on 4” and Below Pipelines”


Page 93

APPENDIX D

The approval for obtaining acceptance for site blasting using garnet type material shall be obtained in accordance with the enclosed form with all appropriate signatures obtained. Any areas subject to reservations shall be made know on the exceptions sheet and clearly marked “DO NOT BLASTCLEAN”. Contractor shall further highlight these areas physically on site by the use of Safety “Tiger” Tape.


Page 94

ENGINEERING DIVISION HOT WORK PERMIT NO._____________

CHECKLIST FOR DRY ABRASIVE BLASTING Description This checklist must be adhered to and initiated at each stage of progress by relevant authorities and used in conjunction with Plant Maintenance & Engineering Standing Instructions No. H-10-1 (Rev. 5).

1

WORKSITE PREPARATION 1.1 Discuss proposed worksite.

1.2

B&PS/OPS/C&ID Name Signature

Blasting & Painting(B&PS) Operations(OPS) Corrosion(C&ID) Decide and allocate area Category Classification C1, C2, C3 & C4.

OPS Name

1.3

1.4

Apply for Cold Work Permit (24 hours notice), stating Category classification

Signature B&PS

Name

Signature

Name

OPS Signature

Name

B&PS Signature

B&PS Issue Cold Work Permit for site preparation and inspection. OPS

1.5

Type of screening to be specified. B&PS

2

SITE INSPECTION CHECKS Following the completion of worksite preparation an scaffold erection the site inspection checks shall be undertaken and listed items checked: 2.1 Scaffold structure, access satisfactory. B&PS/R&SS/OPS Name Signature B&PS R&SS OPS 2.2 Check the integrity of equipment/lines to be blast cleaned or PIE/OPS/B&PS issue exceptions list as per attachment # 1. Name Signature PIE OPS B&PS 2.3 If removal of clamps, U-bolts, pipe lifting etc. are required refer PIE/Planner/MS/ R&SS to attachment # 2. Name Signature PIE Planner MS R&SS


Page 95

2.4

ED Inspection to ensure worksite screening in accordance with 1.2 above, comprising: 2.3.1 Light fittings, cables, electrical services, etc. 2.3.2 Instrument fittings, stands, etc. 2.3.3 Drainage venting systems. 2.3.4 To ensure no work on open bearings of rotating machinery is either in progress or planned during the grit blasting activities.

OPS ES/LS/HSED IS/HSED CMS/HSED MS/HSED

Name

2.5

OPS ES LS HSED IS CMS MS Final check to ensure worksite screening complies with 1.2 Name

Signature

B&PS/OPS Signature

B&PS OPS 3

APPLICATION TO BLAST CLEANING 3.1 Submit Hot Work Permit, with any noted exceptions listed (As per attachment # 1).

B&PS Name

3.2

B&PS Ensure any areas of exception(s), Not to be blast-cleaned, are noted to Permit Signatory and his designated person(s) – Work are cordoned off using “tiger tape” with warning signs posted.

B&PS/PIE/HSED Name

3.3

Signature

B&PS PIE HSED Ensure all equipment complies with ADGAS Health, Safety & Environmental Manual, Chapter 6, Section 7, and any other specific requirement.

Signature

OPS/HSED

Name

Signature

Name

OPS Signature

OPS HSED 3.4

If all above satisfied, issue Hot Work Permit. OPS

4

RENEWAL OF HOT WORK PERMIT When a blast cleaning operation needs to continue next day the following applies, the Permit Signatory shall:4.1 At the end of each working day, ensure a clean area and adequate access for operational and safety purposes. B&PS Name Signature B&PS 4.2 Ensure all equipment is safely stored. B&PS Name Signature B&PS 4.3 Submit Hot Work Permit for renewal. B&PS Name Signature B&PS


Page 96

5

ON COMPLETION OF WORKS 5.1 Confirm blast cleaning/painting completed. Name

P&II Signature

P&II 5.2

Insert Teflon pads.

PIE/Planner/MS Name Signature PIE Planner MS

5.3

PIE to write report for line and endorse SAP’s. Name

PIE Signature

PIE Renewal of Hot Works Permits on daily basis shall be in full accordance with instructions given in Part 1, Item 4. Abbreviations: B&PS OPS PIE MS HSED P&II

-

Blasting & Painting Supvr. Operations Div. Plant & Inspection Engineer Mechanical Supvr. Health, Safety & Environment Div. Plant & Insulation Dept.


R&SS ES IS CMS LS

-

Rigging & Scaffolding Supvr. Electrical Supvr. Instrument Supvr. Civil Maintenance Supvr. Lighting Supvr.

Page 97

Attachment “ 1”

PLANT MAINTENANCE & ENGINEERING DIVISION NOTED AREAS OF EXCEPTION (not to be blasted) Plant Item/Line No. Example: 6-PR-1067-6”-A: Lm Heavy pitting for approx. 2


Location, Column & Level

C&ID/B&PS

Plant 6 E/W Piperack, “K” – 1 Sectional Replacement Shutdown R&R raised with Isometric Drawing as required.

Page 98

Painting Specification for Equipments, Piping & Structures.pdf

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