Petronas Technical Standard (Pts 30.48.0031 Sept2012)

PTS 30.48.00.31 September 2012 Page 0 of 78

PETRONAS TECHNICAL STANDARDS

TECHNICAL SPECIFICATION

PROTECTIVE COATINGS AND LININGS

PTS 30.48.00.31 SEPTEMBER 2012

 2012 PETROLIAM NASIONAL BERHAD (PETRONAS) All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright owner.


PTS Circular 2012 PTS No:

30.48.00.31

PTS Title:

Protective Coatings and Linings

This revision of PTS 30.48.00.31 – Protective Coatings and Linings has been updated to incorporate PETRONAS Lessons Learnt, Best Practice and new information issued by relevant industry code and standards. All updates in the document are highlighted in blue font. The previous version of this PTS 30.48.00.31-P (September 2009) will be removed from PTS binder / e-repository from herein onwards. The custodian of this PTS is: Name

: Nurul Asni Mohamed

Contact. No

: 603 2783 6063

Please direct any questions regarding this PTS to the above-named.

Revision History Rev No. 1

Reviewed by

Approved by

Date

Nurul Asni Mohamed

Zamaluddin Ali

December 2011

Hasbullah Abu Hassan 2

Nurul Asni Mohamed

M Hawari Hasan

June 2012

3

Nurul Asni Mohamed

M Hawari Hasan

September 2012

PTS 30.48.00.31 September 2012 Page 2 of 78 PREFACE

PETRONAS Technical Standards (PTS) publications reflect the views, at the time of publication, of PETRONAS OPUs/Divisions. They are based on the experience acquired during the involvement with the design, construction, operation and maintenance of processing units and facilities. Where appropriate they are based on, or reference is made to, national and international standards and codes of practice. The objective is to set the recommended standard for good technical practice to be applied by PETRONAS' OPUs in oil and gas production facilities, refineries, gas processing plants, chemical plants, marketing facilities or any other such facility, and thereby to achieve maximum technical and economic benefit from standardisation. The information set forth in these publications is provided to users for their consideration and decision to implement. This is of particular importance where PTS may not cover every requirement or diversity of condition at each locality. The system of PTS is expected to be sufficiently flexible to allow individual operating units to adapt the information set forth in PTS to their own environment and requirements. When Contractors or Manufacturers/Suppliers use PTS they shall be solely responsible for the quality of work and the attainment of the required design and engineering standards. In particular, for those requirements not specifically covered, it is expected of them to follow those design and engineering practices which will achieve the same level of integrity as reflected in the PTS. If in doubt, the Contractor or Manufacturer/Supplier shall, without detracting from his own responsibility, consult the Principal.

The right to use PTS rests with three categories of users:

1)

PETRONAS and its affiliates.

2)

Other parties who are authorised to use PTS subject to appropriate contractual arrangements.

3)

Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred to under 1) and 2) which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said users comply with the relevant standards.

Subject to any particular terms and conditions as may be set forth in specific agreements with users, PETRONAS disclaims any liability of whatsoever nature for any damage (including injury or death) suffered by any Company or person whomsoever as a result of or in connection with the use, application or implementation of any PTS, combination of PTS or any part thereof. The benefit of this disclaimer shall inure in all respects to PETRONAS and/or any Company affiliated to PETRONAS that may issue PTS or require the use of PTS. Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, PTS shall not, without the prior written consent of PETRONAS, be disclosed by users to any Company or person whomsoever and the PTS shall be used exclusively for the purpose they have been provided to the user. They shall be returned after use, including any copies which shall only be made by users with the express prior written consent of PETRONAS. The copyright of PTS vests in PETRONAS. Users shall arrange for PTS to be held in safe custody and PETRONAS may at any time require information satisfactory to PETRONAS in order to ascertain how users implement this requirement.

TABLE OF CONTENTS


1

PURPOSE

4

2

SCOPE AND DEFINITIONS

5

2.1

DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS

6

2.2

DEFINITIONS

6

3

WARRANTY AND PAINTING CONTRACTORS RESPONSIBILITIES

10

3.1

WARRANTY

10

3.2

PAINTING CONTRACTORS RESPONSIBILITIES

10

4

SURFACE PREPARATION

14

4.1

GENERAL

14

4.2

PRE-CLEANING

14

4.3

SURFACE PREPARATION BY BLAST CLEANING

15

5

APPLICATION

20

5.1

PRE-APPLICATION PROCEDURES

22

5.2

APPLICATION CONDITIONS

22

5.3

APPLICATION METHODS

23

5.4

REPAIRS AND TOUCH UP PAINTING

26

6

PAINTING AND COATING SYSTEMS

28

6.1

COATING SYSTEMS SELECTION

28

6.2

PAINTING AND COATING SYSTEM SCHEDULES FOR EXTERNAL APPLICATION

29

6.3

PAINTING AND COATING SYSTEM SCHEDULES FOR INTERNAL APPLICATION

36

6.4

PAINT MATERIALS STORAGE, SHELF-LIFE AND HANDLING

42

6.5

COATING SYSTEMS PRODUCT APPROVAL REQUIREMENT

42

7

QUALITY CONTROL

46

7.1

INSPECTION

46

7.2

PROJECT PRODUCTION TESTING

46

8

RESOURCE EQUIREMENT

47

8.1

PAINTING CONTRACTOR

47

8.2

PAINTING INSPECTOR

47

8.3

BLASTING AND PAINTING SUPERVISOR

48

8.4

COATING AND QUALITY CONTROL TECHNICIAN (QC)

49

8.5

THERMAL SPRAY APPLICATOR

50

8.6

BLASTER / PAINTER

51

8.7

PAINT SUPPLIER COATING ADVISOR

51

8.8

INSPECTION EQUIPMENT

52

9

HEALTH, SAFETY AND ENVIRONMENT (HSE)

53

9.1

SAFETY AND HEALTH REGULATIONS

53

9.2

ENVIRONMENT REGULATIONS

53

10

COLOUR SCHEMES

55

11

REFERENCES

56

12

APPENDICES

59

PTS 30.48.00.31 September 2012 Page 4 of 78 1

PURPOSE

The Purpose of this industrial standard is to standardise and to improve Protective Coating Specification to optimise cost of painting without compromising Quality and Coating Performance in accordance with the guideline stipulated in Appendix 1. This standard is also intended for use by Engineers to select Painting Systems and Coating Systems to be used and applied on metallic substrates requiring protection from corrosion. Decision to implement all works described herein shall be justified in view of its potential value creations and annual cost savings and to fulfil the philosophy stated herein: a) b) c)

To maintain the integrity of oil and gas production facilities by minimising materials degradation caused by corrosion To enhance in-service performance of coating systems through proper paint materials selection, quality control during application, continuous monitoring and proper maintenance. Continuous improvement towards cost effective painting practices by acquiring, testing and utilising new coating systems and technology through : ! ! !

d) e)

Collective efforts and systematic feedback by all Users. Centralised Committee and PETRONAS Protective Coatings and Linings Technical Committee (PCLTC). Close co-operation and alliancing between PSCs, Paint manufacturers, Independent bodies and research institutes.

To create high level of corporate awareness in PETRONAS OPUs/Divisions, all PSCs and other service companies on the importance of protective coating in controlling corrosion. To promote Health, Safety and Environmental (HSE) awareness in the Malaysian Protective Coating industry.


SCOPE AND DEFINITIONS The scope of this specification is to provide minimum requirements for both external and internal coating of both onshore and offshore facilities in the oil and gas industry. It shall also include initial and maintenance painting guidelines. The specification is not applicable to buried and submerged structures below the splash zone. Specialised equipment supplied by vendors such as valves, pumps, compressors, etc. will be coated in compliance with the User's respective functional specification; as such they are not covered under this publication. This revision has included two types of coating system recommended for the protection of bolts and nuts. Refer to Appendix 11.

2.1

DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS Unless otherwise authorised by PETRONAS, the distribution of this PTS is confined to companies forming part of PETRONAS or managed by a Group Company, and to Contractors and Manufacturers/Suppliers nominated by them. This PTS is intended for use in oil refineries, chemical plants, gas plants, exploration and production facilities and supply/marketing installations. If national and/or local regulations exist in which some of the requirements may be more stringent than in this PTS, the Contractor shall determine by careful scrutiny which of the requirements are more stringent and which combination of requirements is acceptable as regards to safety, environmental, economic and legal aspects. In all cases, the Contractor shall inform the Principal of any deviation from the requirements of this PTS which is considered to be necessary in order to comply with national and/or local regulations. The Principal may then negotiate with the authorities concerned with the object of obtaining agreement to follow this PTS as closely as possible.

2.2

DEFINITIONS

2.2.1

General Definitions The Contractor is the party which carries out all or part of the design, engineering, procurement, construction, commissioning or management of a project or operation of a facility. The Principal may undertake all or part of the duties of the Contractor. The Manufacturer/Supplier is the party which manufactures or supplies equipment and services to perform the duties specified by the Contractor. The Principal is the party which initiates the project and ultimately pays for its design and construction. The Principal will generally specify the technical requirements. The Principal may also include the Subject Matter Expert (SME), an agent or consultant authorised to act for, and on behalf of, the Principal. The Custodian is the Owner of this specification ie. PETRONAS Group Technical Solutions. Painting system is a term intended to include, with equal emphasis, not only the well accepted components of a system such as surface preparation and paint materials but also application, inspection and safety functions. Coating system is a term which refers to the applied and cured multilayer film or to the components of a system based on non-paint type coating.

PTS 30.48.00.31 September 2012 Page 6 of 78 Initial painting is a term which refers to the painting of new facility or complete recoating of existing asset during major maintenance. Maintenance painting is a term which refers to the periodic painting after initial painting (repair, touch up of corroded areas or deteriorated paintwork). The word shall indicates a requirement. The word should indicates a recommendation. 2.2.2

2.3

Specific Definitions DFT

Dry Film Thickness; the thickness of the dried/cured paint or coating film.

Equipment

The equipment to be painted is listed in Appendix 1 and includes piping, vessels, columns, exchangers, reactors, structural steel, fire-fighting systems, tanks, LPG storage vessels, furnaces, stacks, flare stacks, flue ducts, offshore structures and topside facilities.

Grit

Particles that are predominantly angular, have fractured faces and sharp edges and are less than half round in shape.

Operating Temperature

See PTS 01.00.01.30

Shot

Particles that are predominantly round, that have a length of less than twice the maximum particle width and that do not have edges, broken faces or other sharp surface defects.

TDFT

Total Dry Film Thickness; the thickness of the total number of coatings specified.

WFT

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

PSC

Production Sharing Contractors

PCLTC

PETRONAS Protective Coatings and Linings Technical Committee

SUMMARY OF CHANGES

This PTS is the revision of old PTS dated September 2009. Table below provides summary of changes made to this latest PTS. This includes the adoption of the latest ISO 8501-1:2007 which replaces the old standard ISO 8501-1:1988. This PTS also made reference to the latest available ISO 8502-1:2002 and ISO 8504-2:2000. Old Section

New Section

All

1

Summary of Changes

• • • 1

Change the word “Owner” to “Principal”. Revise and edit grammatical errors. Revise reference of ISO 8501-1:1988 to latest released, ISO 8501-1:2007.

Added and revised sub-topic under “c)” as follows: Centralised Committee and PETRONAS Protective Coatings and Linings Technical Committee (PCLTC) ! Close co-operation and alliancing between PSCs, Paint manufacturers, Independent bodies and research institute.

2

2

Added statement on another type of coating available for bolts and nuts as follows: This revision has included two types of coating system recommended for the protection of bolts and nuts. Refer to Appendix 11.

PTS 30.48.00.31 September 2012 Page 7 of 78 2.2.1

2.2.1

Remove PRSB and rename GTS as the Custodian referred in this PTS as follows: The Custodian is the Owner of this specification ie. PETRONAS Group Technical Solutions. Rephrase the following sentences: “Initial painting is a term which refers to the painting of new facility or complete recoating of existing asset during major maintenance. Maintenance painting is a term which refers to the periodic painting after initial painting (repair, touch up of corroded areas or deteriorated paintwork).”

2.2.2

2.2.2

Added the following specific definition: • PSC - Production Sharing Contract. • PCLTC - PETRONAS Protective Coatings and Linings Technical Committee.

3.2.1

3.2.1

Rephrase the following paragraph into: Copies of this PTS, work planning and the quality plan shall be made available to the Coating Contractor's representative at site and the representative shall understand its contents.

3.2.2

3.2.2

Added the following sentence: Site safety regulations shall be adhered to.

3.2.7

3.2.7

Added a word in the following sentence: Access for coating work should be constructed bearing in mind that it should provide safe, easy and sufficient access for surface preparation, painting and inspection of all surfaces.”

4.2

4.2

Rephrase a sentence as follows: For the treatment of stainless steels, the level of free halides in materials to be used shall be confirmed and reviewed by Principal. Added a sentence as follows: Flushing activity shall be less than 10ppm while the actual concentration shall be maintained between 20 to 30ppm.

4.3.1

4.3.1

Rephrase a sentence as follows: Should Thermally Sprayed Aluminium be used to coat carbon steel, low alloy steels and stainless steels, the surface profile shall be between 70 µm to 110 µm.

4.3.4

4.3.4

Amend Table 3 according to latest DEP. Abrasive blast cleaning

SSPC

ISO 8501-1

NACE

White metal blast cleaning

SP5

Sa 3

Ne r white metal cleaning

SP10

Sa 2.5

No. 2

Commercial blast cleaning Brush-off (Sweep) blast cleaning

SP6 SP7

Sa 2 Sa 1

No. 3 No. 4

Power-tool cleaning (to bare metal)

SP11

-

-

Commercial grade power tool

emarks

No. 1

SP 15

-

-

Power-tool cleaning

SP3

St 3

-

Hand-tool cleaning

SP2

St 2

-

Solvent cleaning

SP1

-

-

High and ultrahigh pressure water jetting

SSPC

ISO 8501-1

NACE

Water jet cleaning

SP12

No. 5

Wet abrasive blasting

TR2

6G198

WJ1-WJ4


4.3.6

Revise the following sentences into: Abrasive blasting shall not be conducted in open areas close to painting operations or wet coated surfaces to prevent dust and grit contamination. Normally, grit blasting shall be permitted only during daylight hours. However, rough abrasive blasting is allowed during the night provided that the surface is subsequently blasted to the specified standard under good light conditions. The illumination of the surface during final blasting shall be at least 500 Lux and all environmental restrictions shall be observed.”

4.3.7.2

4.3.7.2

Potable water was identified to be the source of water for cleaning the blasted surface under abrasive blasting and jet cleaning

4.3.7.3

4.3.7.3

Portable water was specified as the source of water to be used

6.2.5

6.2.5

Remove first coat system of Inorganic Zinc Silicate. Added note as follows: To ensure good adhesion to the metal surface, surface tolerant aluminum paint shall be used.

6.2.11

6.2.10

Revise the sections numbering due to missing Section 6.2.10 from old PTS

6.2.12

6.12.11

Revise the sections numbering due to missing Section 6.2.10 from old PTS Added painting specification as follows: Surface preparation: Degrease as SSPC-SP1 and wash with fresh clean water, light abrade or sweep blast surface to provide anchor pattern of 25micron. Coating System st

1 Coat Total 6.3.4.3

6.3.4.3

6.5

6.5

6.5.2

6.5.2

Aliphatic polyurethane

DFT 50

µ

50

µ

Retained PTS 2008 coating system to “Epoxy” instead of “Amine” Remove PRSS and ANM as recognised body to conduct paintings and coatings testing in the below paragraph and rephrase the sentence to indicate not limited to the stated laboratories/ bodies only. Remove PRSS as approved test house as per below paragraph: “The test panels shall be submitted to an approved third party testing agency for laboratory testing.”

8.2.1.1

8.2.1.1

Amend certificate name to include “Coating” as per below: “NACE International Certified Coating Inspector Level III”

8.2.1.2 8.3.1 8.4.1 8.5.1 8.6.1 8.5 8.8

8.2.1.2 8.3.1 8.4.1 8.5.1 8.6.1 8.5 8.8

Added “equivalent” to each required certification to allow contractor with different but similar accreditation level to perform each specific task.

Revise the title from “Thermal Sprayer” to “Thermal Spray Applicator” Added statement to indicate possible utilising other equipment to perform inspection as follows: “The painting inspection equipment shall be provided by the Inspection agency and the Contractor. The appropriate instruments with valid calibration where applicable, to be used at various inspection points are listed but not limited to the following:”

PTS 30.48.00.31 September 2012 Page 9 of 78 11.4

11.4

Amend specification to the latest standards as follows: Standard Description /Publication No. ISO 8501-1: 2007 Preparation of steel substrates before application of paints and related products - Visual assessment of surface cleanliness - Part 1 : Rust grades and preparation grades of uncoated steel substrates and steel substrates after overall removal of previous coatings. ISO 8502-1: 2002 Preparation of steel substrates before application of paints and related products - Tests for the assessment of surface cleanliness - Part 1 : Field test for soluble iron corrosion products

11.6

11.6

12

12

ISO 8502-3: 1992

Preparation of steel substrates before application of paint and related products Test for the assessment of surface cleanliness - Part 3 : Assessment of dust on steel surfaces prepared for painting (pressuresensitive tape method)

ISO 8504-2:2000

Preparation of steel substrates before application of paint and related products - Surface preparation methods - Part 2: Abrasive blast-cleaning

Add reference on Protective coatings for onshore facilities to Shell standard Remove Appendix 10, PETRONAS Corporate Policy Statement on Health, Safety and Environment, from this latest PTS and amend the chapter number. Amend Appendix 11 title from “Specification of Fluorocarbon Coating of Bolt and Nuts” to “Specification for Bolts and Nuts Coating”

Appendix 7

Appendix 7

Added “Heat Resistance” test as required Coating System Testing for “Coating System 5A (1), 4A and 4B.

Appendix 10 to 12

Appendix 10 to 11

Remove old Appendix 10 on PETRONAS corporate policy statement on health, safety and environment and rename section. Appendix 11: Amend Appendix 11 title from “Specification of Fluorocarbon Coating of Bolt and Nuts” to “Specification for Bolts and Nuts Coating” Revamp and added new scope according to PETRONAS Carigali Standard Procedure (July, 2012).


WARRANTY AND PAINTING CONTRACTORS RESPONSIBILITIES

3.1

WARRANTY Contractors, undertaking painting and/or coating work, which are to be carried out in accordance with this PTS, shall guarantee the quality of their coating work. Before any painting or coating work shall commence, warranty period and coating condition shall be agreed with the Principal. A minimum warranty period of five (5) years or ten (10) years is required for special coatings such as Thermally Sprayed Aluminium. The use of coating systems as described in this PTS and approved by the Principal shall not affect the warranties to be agreed by the contract parties involved. If reference areas are proposed and agreed, they shall be in accordance with requirements as specified in ISO 12944-7 Clause 7 and ISO 12944-8 Table 1, No.1.13. Surfaces that have deteriorated beyond the acceptable level of breakdown within the warranty period shall be repaired by the Contractor. The Contractor shall also bear the cost for materials, equipment, labour, onshore transport and onshore storage necessary for the repair. Only surfaces that have suffered from mechanical damage or chemical spillage as a result of operational activities fall outside this warranty. Initial acceptance of any new coating work by the Principal will not relieve the Contractor of his obligations under this section until the final inspection has been carried out and acceptance of the completed work has been agreed in writing. A final inspection shall be carried by a party to be agreed between the Contractor and the Principal before expiry of the coating work warranty period. In case of a dispute on the condition of the coating work that has been inspected, an agreed independent expert body shall conduct a review inspection at the Contractor’s cost. Both the Principal and the Contractor shall accept the findings of the inspection by this independent consultant.

3.2

PAINTING CONTRACTORS RESPONSIBILITIES

3.2.1

General The Contractor, in addition to his responsibilities under the general conditions of the contract is responsible for the quality of the work which shall be performed in strict accordance with this PTS and all other relevant documents, such as site regulations, safety rules and requirements, product data sheets, referenced standards and codes. The Contractor is fully responsible for all Quality Assurance and Control activities. The contractor shall schedule a pre-job meeting to ensure that job and quality requirements are fully understood. Attendees should be a representative of the Principal, contractor’s job superintendent and coating supervisor, the coating inspector and the coating manufacturer’s representative. The Contractor shall submit for any major coating work an appropriate work planning and a quality plan for implementing this PTS for review by the Principal.

PTS 30.48.00.31 September 2012 Page 11 of 78 Copies of this PTS, work planning and the quality plan shall be made available to the Coating Contractor's representative at site and the representative shall understand its contents. 3.2.2

Safety and Environment The Contractor shall be responsible for all aspects of safety and personal protection related to the painting work to be done. Environmental regulations and rules shall be met. Safe working is of the greatest importance particularly during paintwork in confined spaces such as tanks and vessels. Site safety regulations shall be adhered to. All personnel shall be provided with approved personnel protection e.g. protective clothing, safety glasses, safety shoes, hard hats, goggles, respirators, earplugs, fresh-air-fed hood and any other necessary safety equipment. All safety equipment shall be maintained to a good working condition. Adequate warning signs shall be prominently displayed on each access way to all areas where abrasive blasting and painting is in progress. Handling and disposal of hazardous waste resulting from the Contractor's painting activities shall be in accordance with regulations and specific contract requirements. However, the Principal’s regulations on chemical management or banned materials shall be strictly adhered to.

3.2.3

Hazardous coating components The Contractor shall ensure that all layers of a coating system and blasting materials comply with any local and/or regional standards or regulations on banned materials such as lead, chromate, crystalline silica, and coal tar. The Principal’s regulations on chemical management or banned materials shall be strictly followed. Any coating system shall fully comply with any local and/or regional air quality or Volatile Organic Compounds (VOC) levels or emission standards or regulations. Coatings shall contain maximum 0.1% Monomeric Isocyanate at the time of painting. Before commencing of any surface preparation, the existing coating system shall be checked for hazardous components.

3.2.4

Personnel Only professional skilled blasters and painters shall be employed. Blasters and painters working on every painting job shall be certified in accordance with a scheme approved by the Principal. A certified foreman shall supervise the blasters and painters. Before commencing any work or awarding a contract, the certificates shall be submitted to the Principal. Certifying bodies shall comply with ISO 17024. A skilled foreman shall supervise the blasters and painters. If not certified, the skill of all blasting and painting personnel shall be verified before commencing any painting or coating work. The blasters shall blast a representative structural steel part (min. 2m²) using the equipment to be used for the actual surface cleaning. The painters shall coat a representative structural steel part (min. 2m²) with an agreed coating system. The test area shall be fully coated with all coats of the agreed coating system using the tools and equipment to be used for the actual coating work. The painted test area shall be maintained for the duration of the project as a reference. The Principal shall witness all tests.


Protection of equipment and structural members The painting Contractor shall protect all equipment, structures and any other areas from mechanical damage, environmental damage, blockage or obstruction, damage caused by over blasting, paint droppings and splashes or overspray.

3.2.6

Blasting and spraying equipment The Contractor shall demonstrate that blasting and spraying equipment to be used are in good condition and well maintained. Blasting and painting equipment shall fully comply with any local and/or regional regulation. The compressed air shall be free of water and oil. Adequate separators and traps shall be provided, installed in the coolest part of the system. The presence of oil and water shall be determined in accordance with ASTM D 4285-83 at least two (2) times per twelve (12) hours. In no case shall the temperature of the compressed air be allowed to exceed 110°C. Blast cleaning air, when blown through a white cloth or onto white paper for one minute shall leave no visible residue. Blasting nozzles shall be discarded and replaced when the nozzle diameter has increased through wear by more than 50% of the original diameter. Blasting equipment, its operators and the equipment being blasted shall be properly earthed to prevent the occurrence of electrostatic discharges. Abrasive blast cleaning equipment shall of intrinsically safe construction and equipped with a remote shut-off valve triggered by the release of a dead man's handle at the blasting nozzle. Where air-operated equipment is used, the operator's hood or headgear shall be ventilated by clean, cool air supplied through a filter, to prevent blast cleaning residues from being inhaled. When working in confined spaces, ventilation and/or spark-proof lighting shall be used.

3.2.7

Access Access for coating work should be constructed bearing in mind that it should provide safe, easy and sufficient access for surface preparation, painting and inspection of all surfaces. Scaffolding shall be constructed in accordance with local regulations and the requirements of the Principal or as otherwise agreed with the Principal.

3.2.8

Handling and coated parts/components To minimise the risk of damage, no lifting, transportation, erection or fabrication operations shall be done before the paint has been fully dried and/or cured. Welding shall not be carried out on the external surfaces of internally coated tanks or vessels. Canvas or nylon slings shall be used for lifting, and wooden blocks shall be applied during transportation.

3.2.9

Storage protection The Contractor shall supply all the necessary protection when prefab coated steel or coated steel for climate controlled areas has to be stored in the open air prior to erection, to avoid premature failure of the applied paint layers.

PTS 30.48.00.31 September 2012 Page 13 of 78 3.2.10 Weather protection Unless otherwise agreed, the Contractor shall supply all weather protection, scaffolding and any other equipment necessary to ensure that the work is carried out in accordance with this PTS and to the agreed program. This includes, for example, heating and air-drying equipment.

PTS 30.48.00.31 September 2012 Page 14 of 78 4.

SURFACE PREPARATION

4.1

GENERAL For optimum paint performance surfaces to be painted or coated shall be completely dry and free from burrs, weld spatter, flux, rust, loose scale, dirt, dust, grease, oil and other foreign matter before any paint is applied. If the surface has been exposed to a pollutant, e.g. salt-laden, atmosphere, it shall be washed down with clean, fresh water prior to blasting or power tool cleaning. Cleaning of surface shall, as general rule, be done by dry blast cleaning (hereafter referred to as blast cleaning) as outlined in ISO 8504-2. The surface profile and the anchor pattern shall be in accordance with the requirements in this document. Fabrication should be completed before surface preparation begins. However, surface preparation and application of the base layers of the specified coating system before assembly will be allowed. Prefabrication primers are allowed. However, after assembly these primers shall be removed by blasting and the surface shall be blasted to the initial specified surface cleanliness unless otherwise agreed by the Principal. Alternative surface cleaning is only acceptable after written approval by the Principal. Alternative surface preparation such as power tool cleaning is not acceptable for areas difficult to access such as areas exposed to water, steelwork to be insulated or to be buried and the internal surfaces of equipment and tanks. Stainless steel surfaces shall not be treated with carbon steel cleaning tools. After preparation of the substrate surface, any grit, dust etc. shall be removed and a layer of primer applied before any corrosion or recontamination occurs, normally within 4 hours after blasting. Surface preparation shall be carried out by dry blast-cleaning wherever possible. The surface preparation grades shall be as specified in Appendix 2 for the various paint systems.

4.2

PRE-CLEANING

Prior to the blast cleaning and/or prior to any painting works, the surface shall be free of any contamination and any excessive rust scale shall be removed by impact cleaning tools or high pressure water jetting. All edges shall be ground to a minimum radius of 2 mm or otherwise agreed with the Principal and flame cut areas should have been ground flush. Weld spatter shall have been ground flush. If this is not the case, the Principal shall be informed, and corrective action shall be taken prior to the application of the first layer of the coating system. All bolt holes shall be solvent cleaned prior to the commencement of blast cleaning. Solvent cleaning shall be carried out in accordance with SSPC, SP1 “Solvent Cleaning”. When emulsion or detergent type degreasers or Teepol/fresh water solutions are used, this treatment shall be followed by copious rinsing using fresh and clean potable water or pressure water/steam wash. These types of degreasers shall be proven to be biologically degradable.

PTS 30.48.00.31 September 2012 Page 15 of 78 Maintenance coating should always start with a high pressure steam/detergent cleaning to remove dirt, grease and/or salt deposits. In addition, after a long interval prior to the application of the subsequent layers of a coating system or exposure to a storm at offshore, the surface shall be cleaned by using high-pressure water/steam or water wash before the application of the next coating layer. In the specific case of uncoated stainless steel components, water/steam cleaning shall not be allowed using water with a temperature of > 50 degrees C. However, the requirements regarding the soluble salts and other surface contaminants in this document shall be adhered to at all times. All welded areas and appurtenances shall be given special attention for removal of welding flux in crevices. Welding splatter, slivers, laminations and underlying mill scale which are not removed during fabrication shall be removed prior to painting activities by the best mechanical means and the edges smoothed or rendered flush. Before performing abrasive blast cleaning, all equipment which could be damaged by blast, dust or particulate matter shall be suitably protected by masking, wrapping, taping or other means to prevent damage. Where required, the degree of contamination shall be assessed in accordance with procedures described in ISO 8502-3. This equipment shall include but not necessarily limited to the following: • • • • • • • • • • • •

Bearings Control panels Control valves Conduit Instrument dials Expansion joint bellows Machined surfaces Shafts Push buttons Tags Screws Exposed moving parts

Adequate blocking or enclosure of the work area by either canvas, tarpaulin or suitable material shall be constructed and accepted by the Principal in order to avoid damage to other areas or equipment. This enclosure shall be constructed such as to contain any waste produced from the surface preparation activity. Any necessary equipment i.e. exhaust fan, air cooler, lighting for night work and other related HSE requirement shall be installed within this enclosure. Where rectification has been necessary on blast-cleaned surfaces, the dressed areas shall be pre-cleaned as initially specified. For the treatment of stainless steels, the level of free halides in materials to be used shall be confirmed and reviewed by Principal. Particular care shall be taken to dry areas, which are not self-draining, so that water collected is removed and not allowed to evaporate leaving salt deposits on the surface. Flushing activity shall be less than 10ppm while the actual concentration shall be maintained between 20 to 30ppm. Detergents with a pH >9 shall not be used on aluminium substrates.

4.3

SURFACE PREPARATION BY BLAST CLEANING

4.3.1

General

Blast cleaning shall be carried out through ISO 8504-2 to the required visual standard in accordance with ISO 8501-1 or equivalent. The minimum requirement for successful surface preparation shall be Sa 2.5 at the time of coating, unless specified by paint manufacturer on their surface tolerant coating systems.

PTS 30.48.00.31 September 2012 Page 16 of 78 The blast cleaning of stainless steel shall be carried out by sweep blasting using a fine abrasive not containing iron (e.g. garnet, Aluminium Oxide, Aluminium Silicates), glass pearls or stainless steel shots. To reduce the risk of unacceptably damaging the substrate while sweep blasting stainless steel or hot dip galvanized surfaces, it is recommended that a reduced nozzle pressure be used in combination with a small size abrasive. Blast clean shall not be done close to painting operations or wet coated surfaces to prevent dust and abrasive contamination. Environmental restrictions shall be observed. Rough grit blasting will be allowed during the night providing that the surface is subsequently blasted under good light conditions to the specified Standard. Blast clean steel surfaces shall not be touched by bare hands. If the surface being cleaned lies adjacent to a coated surface, which is not to be repaired, the blast cleaning shall overlap the coated surface by at least 50 mm. The edges of the existing coating system shall be feathered. The remainder of the existing coated surface shall be properly protected with shields or screens to prevent any over blast damage. No acid wash, cleaning solvents or other chemical treatments shall be used on metal surfaces after they have been (dry) blast cleaned. This restriction includes inhibitive washes intended to prevent rusting. The surface profile or anchor pattern for carbon steel and low alloy steels to be coated with liquid organic coatings shall be in accordance with the written recommendation of the paint manufacturer. When not specified by the paint manufacturer or when otherwise specified in this document, the surface profile shall be between 40 µm and 70 µm. If stainless steel, galvanised or non-ferrous metal surfaces are to be painted with liquid (organic) coating materials, blast cleaning of these surfaces shall be carried out by smooth sweep blasting, using a small size non-iron containing abrasive (e.g. aluminium oxide). On galvanised surfaces, the zinc layer shall not be damaged, a smooth uniform surface roughness shall be achieved, no defects such as break through or crisping of the zinc layer shall occur. Surface roughness shall be in the range of 20 µm to 30 µm or shall be agreed with paint manufacturer. After approval by the Principal, abrading with sandpaper or light grinding with a suitable (flexible) disc maybe used for surface preparation if sweep blasting is impossible. In addition, when aluminium or galvanised components have to be painted, white zinc or aluminium corrosion products and/or rust present shall be removed. Should Thermally Sprayed Aluminium be used to coat carbon steel, low alloy steels and stainless steels, the surface profile shall be between 70 µm to 110 µm.

4.3.2

Blast cleaning equipment The compressed air supply used for blast cleaning shall be free from water and oil. Adequate separators and traps shall be provided, installed in the coolest part of the system. They shall be emptied regularly to prevent carry-over of water and oil. Accumulations of oil and moisture shall be removed from the air receiver by regular purging. Conduct ‘Blotter Test’ ASTM 4285 to check for air cleanliness at appropriate intervals. Air compressors shall not be allowed to deliver air at a temperature above 110 °C. Abrasive blast cleaning equipment shall be of intrinsically safe construction and equipped with a remote shut-off valve triggered by the release of a dead man's handle at the blasting nozzle. Where air-operated equipment is used, the operator's hood or head gear shall be ventilated by clean, cool air served through a regulator filter, to prevent blast cleaning residues from being inhaled.


Blasting Abrasives

4.3.3.1 International standards and characteristics of abrasives Blasting abrasives for use in blast cleaning carbon steels and low alloy steels are specified in ISO 8504-2. Recommended blasting abrasives are as follows but not limited to: • • • •

Chilled iron grit or shot Steel and malleable iron grit or shot Natural mineral abrasives Non-metallic abrasives

Where abrasives which are specified as a Scheduled Waste are used, the waste shall be collected and disposed off at prescribed premises as per the requirement of the Environmental Quality Act (EQA) 1974. Sand or other materials producing silica dust shall not be used. All metallic blast cleaning abrasives shall meet the requirements of ISO 11124 and be tested in accordance with test methods specified in ISO 11125 Part 1-7. All non-metallic blast cleaning abrasives shall meet the requirements of ISO 11126 and be tested in accordance with test methods specified in ISO 11127 Part 1-7. Product shall be sealed in hermetic packaging. Any product delivered in defective packaging shall be rejected. Products must be stored sheltered from the elements. The blast profile and angular anchor pattern shall be that recommended by the paint manufacturer to suit the minimum requirement of their respective primers and the minimum peak-to-valley height shall be 25 microns. Roughness or anchor pattern measurement shall be carried out by the painting contractor using instruments and procedures approved by the Principal. Where anchor patterns are not specified in the paint manufacturer’s technical data sheet, Table 1 below shall be used as a guide for determining the anchor pattern. Table 1 - Relationship between coating thickness and anchor pattern Dry film thickness

Anchor pattern

125-200 microns (5-8 mills)

25-50 microns (1 -2 mills)



> 500 microns (>20 mills)


Abrasives for use in blast cleaning steels shall be in accordance with ISO 8504-2 and Table 2 - Abrasive specifications. Table 2 – Abrasive specifications Type of abrasive Metallic Non-metallic Natural mineral Non-metallic Synthetic mineral/ Industrial byproduct

Generic Name

Characteristics

Standard

Iron grit Steel grit Olivine Staurolite Specular hematite Garnet Coal furnace slag Aluminium oxide

>1.7% carbon 0.8% to 1.2% carbon Magnesium/iron silicate Iron/aluminium silicate Crystaline Fe2O3 Calcium iron silicate Aluminium silicate Crystalline corundum

ISO 11124-2 ISO 11124-3 ISO 11126-8 ISO 11126-9

Iron furnace slag

Calcium silicate

ISO 11126-6

ISO 11126-10 ISO 11126-4 ISO 11126-7

PTS 30.48.00.31 September 2012 Page 18 of 78 4.3.3.2 Selection of abrasives

There is a wide variation in performance between the products within a given generic class of abrasives. Surface anchor profile is directly proportional to the abrasive particle size (the larger the abrasive particle size, the deeper the profile). Cleaning rate is inversely proportional to the abrasive particle size (the larger the abrasive particle size, the slower the cleaning rate). A balanced mixture of particle sizes will produce the optimum level of cleanliness, cleaning rate and surface profile. Pre-qualification of the blast cleaning abrasives shall be conducted subject to acceptance and approval by the Principal prior to their use. The pre-qualification test shall be carried out in accordance with a set of procedure covering field trials and laboratory testing to determine their physical and chemical properties, efficiency and effectiveness that can support the economics for their usage. Steel or iron grit is commonly used as recyclable abrasives. In general, when steel shot is used, it shall be used together with steel grit and approved by the Principal. The abrasives shall be free from oil, grease, moisture, chloride contamination etc. Each batch of abrasive should be tested to check the abrasive meets the requirements as specified in the relevant ISO standard. The conductivity of abrasives to be used on carbon steels shall be less than 150 µS/cm. 2

The salt contamination of abrasives shall be less than 30 mg/m . 4.3.4

Grades of surface finish

The recognized surface finish grades are summarized in Table 3. Table 3 – Surface finish grades Abrasive blast cleaning

SSPC

ISO 8501-1

NACE

White metal blast cleaning

SP5

Sa 3

No. 1

Near white metal cleaning

SP10

Sa 2.5

No. 2

Commercial blast cleaning

SP6

Sa 2

No. 3

Brush-off (Sweep) blast cleaning Power-tool cleaning (to bare metal) Commercial grade power tool

SP7

Sa 1

No. 4

SP11

-

-

SP 15

-

-

Power-tool cleaning

SP3

St 3

-

Hand-tool cleaning

SP2

St 2

-

Solvent cleaning

SP1

-

-

High and ultrahigh pressure water jetting

SSPC

ISO 8501-1

NACE

Water jet cleaning

SP12

No. 5

Wet abrasive blasting

TR2

6G198

Remarks

WJ1-WJ4


Removal of residual salts from pitted areas Where pitting corrosion has been located, pressure water/steam wash with fresh water shall be performed after the initial abrasive blasting. Should instant “rust-back” or black-spotting occur, the pressure wash shall be repeated to remove the residual salts residing in the micro pits.

4.3.6

Techniques and Restrictions As a guide, blast cleaning shall not be carried out when the temperature of the surfaces to be blasted is less than 3 degree C above dew point and when the relative humidity of the air is greater than 85 %. For dew point determination, refer to procedure described in ASTM E 337. In enclosed areas such as in tanks and vessels where some adverse conditions (i.e. environmental conditions outside the range of the specifications or short turnaround time allotted) may prevail, dehumidification is recommended to prevent flash rusting. In the event that dehumidification is employed. The Relative Humidity (RH) within such environment shall be maintained at a maximum of 50% except for inorganic zinc silicate. NACE publication 6A 192 may be referred to determine the types of dehumidification equipment suitable for the work. Abrasive blasting shall not be conducted in open areas close to painting operations or wet coated surfaces to prevent dust and grit contamination. Normally, grit blasting shall be permitted only during daylight hours. The illumination of the surface during final blasting shall be at least 500 Lux and all environmental restrictions shall be observed. Maximum speed and most effective cleaning are obtained by systematic even blasting. Work should be blocked out in 30cm square and each square blasted evenly until complete. Blasting shall continue a minimum of 25 mm into any adjacent coated areas, and the edges shall be feathered. Any blast cleaned steelworks on which rust develops shall be re-blasted prior to being painted.

4.3.7

Alternative Methods of Surface Cleaning

4.3.7.1 General Alternative surface cleaning is only acceptable after obtaining written approval from the Principal. Alternative surface preparation such as power tool cleaning is not acceptable for areas difficult to access such as under cellar and helidecks, areas exposed to water, steelwork to be insulated, steelwork to be buried and internal surfaces of equipment and tanks. Alternative primers such as surface tolerant primers may be required for alternative methods of surface cleaning and be in accordance with paint manufacturers recommendations. Alternative primers need the approval of the Principal.

PTS 30.48.00.31 September 2012 Page 20 of 78 4.3.7.2 Wet abrasive blasting and water jet cleaning Wet abrasive blast cleaning techniques using potable water can be used to avoid dust or in cases where fire and/or explosion risks are present. The cleaned surface should be washed off immediately after blast cleaning using potable water. Corrosion inhibitors should not be used unless written approval from the Principal has been obtained. Corrosion inhibitor such as 0.3% sodium nitrite and 1.2% ammonium phosphate may be used. However, use of Chromate inhibitor is not permitted. Disposal of corrosion inhibitor into the sea should not be allowed. The paint Manufacturer shall approve the use of an inhibitor or the removal of residues of the inhibitor before painting. The cleaned surface shall be dry at the time of painting. Particular care shall be taken to dry areas, which are not self-draining, so that water collected is removed. 4.3.7.3 Water Jetting High-pressure and ultrahigh-pressure water jetting utilising potable water may be used, if abrasive blasting is not permitted for certain areas where dusting and over-blasting may damage process equipment. It is restricted to maintenance painting. Water jetting is a hazardous operation and requires the use of well-trained, experienced operators. Where black spots occur in pits or other surface defects, the surface shall be cleaned again at higher pressure to remove the residual salts. Only after written approval from the Principal is obtained, a suitable corrosion inhibitor such as 0.3% sodium nitrite and 1.2% ammonium phosphate may be used to prevent flash rusting. However, use of Chromate inhibitor is not permitted. The paint Manufacturer shall approve the use of an inhibitor or the removal of residues of the inhibitor before painting. The cleaned surface shall be thoroughly dry at the time of painting. Particular care shall be taken to dry areas, which are not self-draining, so that water collected is removed. 4.3.7.4 Sponge Jet Blasting Sponge Jet blast cleaning is recognized as a dry and low dust system. This cleaning type shall only be used upon agreement with the Principal. Metallic or non-metallic abrasive used in the sponge jet media matrix shall conform to the ISO 11124 or ISO 11126 blast abrasive classification. It shall be conducted in accordance with the vendor/manufacturer recommendation which includes proper site preparation, equipment set-up, choice of media and their application. A range of surface profile 25, 50, 75 and 100 microns shall be achieved using the different sponge jet media. A recycler shall be used to segregate light debris, dust and heavy collected waste from the spent sponge jet media before being used again for blast cleaning. Personnel carrying out the blast cleaning shall be qualified and trained on the use of sponge jet equipment and operation. A vendor technical representative shall be present at the work site to assist during the execution of the blast cleaning activity. 4.3.7.5 Centrifugal Abrasive Blasting A portable blasting machine may be used to prepare steel decks and tank floors using recyclable steel abrasives.

PTS 30.48.00.31 September 2012 Page 21 of 78 4.3.7.6 Vacuum Blasting Vacuum blasting may be used in the areas where open abrasive blasting is not permitted or desirable for spot repair of damaged or corroded areas. 4.3.7.7 Power-tool Cleaning Power-tool cleaning should be confined to minor areas and preferable to bare metal. Unless otherwise specified, it shall be done as outlined in ISO 8504-3. Power-tool cleaning to bare metal shall be done in accordance with SSPC SP11. When power-tool cleaning to bare metal is not feasible, the surface cleanliness shall at minimum meet the visual standard St 3 in accordance with ISO 8501-2 at the time of coating. Care shall be taken to ensure that the steel surface does not become polished after power-tool cleaning. Hand-tool cleaning is permitted prior to power-tool cleaning. If the surface being prepared lies adjacent to a coated surface, the power-tool cleaning shall overlap the coated surface by at least 25 mm and the coated surface shall be feathered.


APPLICATION

5.1

PRE-APPLICATION PROCEDURES

5.1.1

Materials Storage and Handling Storing, thinning, mixing and handling of paint materials shall be in accordance with the Paint manufacturer’s recommendation. All paint materials and solvents shall be stored in the closed original container bearing the manufacturer’s label until required for use. Each container must have full identification, information including Paint manufacturer’s name, product identification, batch number and colour. Hazardous chemicals shall be classified, packaged and labelled appropriately in compliance with the Occupational Safety and Health (Classification, Packaging and Labeling of Hazardous Chemicals) Regulations 1997. All related safety aspects to the use of paints and associated thinners shall comply to Paint manufacturer’s requirement namely MSDS (Material Safety Data Sheet). The Manufacturer’s pot-life and induction time (if any) requirements shall be followed. Mixing of different brands or generic types of paint material is not permitted unless respective manufacturer’s consent has been received. Paint shall be applied to dry, clean, prepared surface under conditions recommended in the manufacturer’s product data sheet.

5.1.2

Material Mixing and Thinning All materials shall be mixed by solvent proof mechanical agitator for a sufficient time in order for proper mixing of one or two packs paint so as to ensure uniformity. Sticks or similar tool shall not be used to avoid contamination. Continuous agitation type spray pots shall be used when applying heavily metal-pigmented paint such as Zinc or Aluminum loaded paint to avoid sedimentation.

Thinner shall not be added to primer or paints unless necessary for proper application according to Paint manufacturer’s recommendation. The type of thinner used must comply with the Paint manufacturer’s recommendation.

5.2

APPLICATION CONDITIONS Unless otherwise recommended by Paint manufacturer and accepted by the Principal, paints shall not be applied when: • • • • • • •

•

The surface temperature is less than 3ºC above dew point. The surface temperature is below 5ºC as it could adversely affect the curing of paints. The relative humidity is more than 85%, except for Inorganic Zinc Ethyl Silicate which can go up to 90%. The metal surface temperature is higher than that recommended by Paint manufacturer for application. Surface preparation has not been completed or oil, grease and dust are present on the substrate to be painted. Poor weather conditions for painting exist or are expected within two hours of application such as blowing sand or rain. When there is a deposition of moisture in the form of rain, condensation etc. on the surface. Probability of condensation may be determined in accordance with procedures described in ISO 8502-4. Where the available light is less than 500 lux.


APPLICATION METHODS

5.3.1

General Requirements Coatings shall be uniformly applied without runs, sags, solvent blisters, dry spray or other blemishes. All blemishes and other irregularities shall be repaired or completely removed and recoated. Special attention shall be paid to crevices, corners, edges, weld lines, bolt heads, nuts and small brackets and apply the specified minimum dry film thickness by brush application if spray is inaccessible to cover all areas. Edges of existing coating shall be feathered towards the substrate prior to over-coating to ensure good adhesion. Surface which is inaccessible after assembly, including the surface of lap joint flanges, nozzle necks, lap joint stub ends, lap rings, bolt holds and some welded joints, shall receive the complete painting system before being assembled. Contact surface of bolted connections are to be primed only. On structural steel areas subject to be assembled by high tension bolts, contact surface shall be primed only with Inorganic Zinc Ethyl Silicate. Intermediate and final coat shall not be applied. Primers should not be over coated with the second coat paint until the specified minimum over-coating time is achieved. Surface preparation is required if the over-coating time is exceeded. Contact the Paint manufacturer for the type and surface preparation required. Intercoat contamination shall be minimized by maintaining proper cleanliness and by applying the intermediate and finish coats within the over-coating time recommended by the manufacturer. If contaminants are present, they shall be removed before applying subsequent coats. Contrasting colour shall be used for each coat of paint so as to ensure different coats are applied to meet the required dry film thickness. Each coat shall be applied with acceptance limits of Dry Film Thickness (DFT) as specified in section 6. It must be ensured that solvent retention in any of the coats, caused by the application of excessive coating thickness is avoided.

5.3.2

Spray Application Paints shall be applied by Air Spray or Airless Spray. Hose and containers shall be thoroughly cleaned before addition of new materials. The spray gun shall be held no closer than 300mm or more than 600mm from the surface to be coated. During application, the spray gun shall always be held at a right angle (90º) to the substrate. Each pass shall overlap the previous one by 50%. In order to achieve a uniform application when applying large surface areas, application shall be made in two directions so that the passes are at right angles to each other i.e. cross spray at 50% over lapping. Pressures and spray fan shall be adjusted so that the optimum spray pattern is obtained for the surface being coated. Cover is to be kept on opened container of paints when not in used.


Brush Application Application with brush is acceptable under the following conditions subject to Principal approval: • • •

• • • •

When areas cannot be properly coated by spray for any reasons. When spray application is difficult due to accessibility. Above ground level when it is considered that loss of paint under prevailing conditions is excessive e.g windy and progress of work has to be maintained and personnel in or near the work site or requirement property, may be affected by spray particles. For touch-up or repair of localized damaged paint or areas of incorrectly applied paint. For painting of stripe coat e.g when applying the initial coat of paint to corners, edges, crevices, holes, welds or other irregular surface prior to spray application. When the substrate material to be applied are suitable for brush application. The number of coats shall be adjusted to the dry film thickness to match.

Paint brushes used shall be of a style and quality that will permit appropriate application of the material being applied. Material applied by brush shall be smooth, uniform in thickness, without any apparent surface defect such as brush marks, runs, sags, or curtains.

5.3.4

Roller Application Roller application shall only be used with written approval from the Principal. Roller application may be used only when: • • •

5.3.5

Spraying is not feasible. Primer coat is applied by brush. Paint application by roller method is acceptable to paint manufacturer and is in accordance with the application data.

Thermal Spray Application Spraying process used for applying melted droplets of pure metals, alloys, plastics, carbide and various oxides to a surface. Substrate must be cleaned completely. It shall be abrasive blast cleaned by sharp edge abrasives to a degree of cleanliness of Sa 2.5 (ISO 8501:1:2007). It shall be free from grease, dust and other contaminants. The specified cleanliness shall be maintained during the spraying process. A roughness of 50 to 100µm is recommended. List of typical spray methods are as follows: !

Powder Flame Spraying The coating material which is in the form of powder is fed into a gas flame either from a small cup mounted on the nozzle or from a larger stand alone container. Flame temperature is recommended at approximately 3100ºC. Particle velocity shall be in the range of 40 to 70 m/s, coating porosity within 7 to 15% (Volume) and oxide content shall be in the range of 7 to 10% (Volume). The adhesion property is recommended between 10 to 20Mpa.

PTS 30.48.00.31 September 2012 Page 25 of 78 !

Wire Flame Spraying Fuel gases are mixed with oxygen to propagate the combustion for melting the material to be applied. The temperature is recommended to be in the range of 2700ºC to 3100ºC so as to melt the wire which is fed through the nozzle at the centre of the gas. It is necessary to add clean and dry compressed air for atomizing and transporting the molten material to the work piece or substrate. Recommended spraying distance is within 130mm to 200mm.

!

Arc Spraying The material to be applied is in the form of two wires fed through the spray gun in such a way that they intersect at the front of the gun. Electric is transferred to the wires and an electric arc is formed at the intersection, melting the material. The temperature in the electric arc is recommended at approximately 5500ºC.

!

Plasma Spraying Plasma gun consists of an annular copper anode and a wolfram cathode, which are water cooled. A gas is fed into the electric arc formed between the anode and cathode. The material in powder form is transported by a carrier gas into the plasma stream form. The intense generation of heat up is recommended between 10000 to 25000ºC so as to melt the powder at the same time as it is propelled at great velocity towards the workpiece or substrate. Power levels up to 40kW are designated “Low”, whereas power levels between 40 and 80 kW are designated “High”.

!

High Velocity Oxy-fuel Spraying The gun works in such a way that propane and oxygen flame melts and propels molten material particles against the workpiece with a very high energy. The material to be applied is in a powder form. The recommended velocity is approximately 1000m/s while the flame temperature is recommended at approximately 2700ºC.

!

Detonation Spraying Powder, by means of a carrier gas is fed into a flame barrel filled with a mixture of acetylene and oxygen which ignited by a spark.

The recommended particle velocity is 700m/s so as to produce a low porosity coating. 5.3.6

Hot Dip Galvanizing Steel is coated with zinc by means of dipping into a molten zinc bath keeping at a recommended temperature around 450 to 460ºC. The recommended thickness is about 100µm. The substrate should be completely clean, free from grease by degreasing in a hot alkaline solution and rinsed with clean water. Mill scale and rust are to be removed in an acid bath (pickling), followed by rinsing with water.

PTS 30.48.00.31 September 2012 Page 26 of 78 After this process, it shall be dipped in flux preferably zinc ammonium chloride at a recommended temperature of 40 to 60ºC. It shall be dried in an oven and a thin layer of flux is left on the steel surface. 5.4

REPAIRS AND TOUCH UP PAINTING

5.4.1

General requirements Procedure for repair and/or touch up painting for each generic coating system shall be submitted by contractor to the Principal for approval. Before application of any subsequent coat of material, all damages from previous coats shall be repaired. All loose paint shall be removed to a firm edge. All surface irregularities and contaminations shall be removed. Hard, glossy surface may require abrading to obtain a suitable surface for painting. Contact Manufacturer for the type and surface preparation required. If the surface being prepared lies adjacent to a sound coated surface which is not to be repaired, the surface preparation shall overlap the coated surface by at least 25mm. The remainder of existing coated surface shall be properly protected with shields or screens to prevent any possible damage to the coating. Inorganic Zinc primer shall not overlap adjacent intermediate and finish coats. Areas with inadequate coating thickness shall be thoroughly cleaned and if necessary, abraded, and additional compatible coats applied until meeting the specification. These additional coats shall blend in with the final coating on adjoining areas.

5.4.2

Damaged Coating Not Exposing Substrate Surface Surface to be overcoated which has been contaminated or damaged shall be cleaned by solvent cleaning and/or lightly brush blasted to ensure that the surface is free from contaminants. Contaminants shall be removed by dry compressed air and wiped by hand with clean, dry rags. The coating around the damaged area shall be chamfered by sanding to ensure continuity of the patch coating. The full coating system shall then be reapplied strictly in accordance with this specification.

5.4.3

Damaged Coating Exposing Substrate Surface The damaged area shall be cleaned to the original or maintenance painting system specified for that item and the full coating system reapplied in accordance with the application data. The cleaning shall carry over onto tightly adhering surrounding coating for not less than 25 mm all around and the edges shall be chamfered by sanding to ensure continuity of the patch coating.

5.4.4

Repair of Zinc Ethyl Silicate Primer Damaged surface of zinc primer shall be cleaned to remove all loose materials and blast cleaned with a portable vacuum blast cleaning unit. The surface shall be coated with one coat of the primer which is the same as the damaged primer. If blast cleaning is not practical, power tool cleaning may be used subject to Principal and Contractor agreement. In such cases, subject to operating temperature limitations, one or two packs recoatable zinc primer may be used in lieu of zinc silicate primer subject to Principal and Contractor agreement.


Repair of Fully Cured Epoxy Coating In case of repairing damage on fully cured epoxy coatings and aged epoxy coating, the coating work shall only be carried out after the surface has been suitably abraded to provide an adequate anchor for the coating to be applied. The repair coating shall be compatible with the existing coating. A test for compatibility is described in ASTM D 5064.

5.4.6

Inadequate Coating Thickness Areas with inadequate coating thickness shall be thoroughly cleaned and if necessary abraded and additional coats applied shall blend in with the final coating on adjoining areas.

5.4.7

Handling and Shipping of Coated Items Coated items shall be carefully handled to avoid damage to coated surface. No handling shall be performed before the coating system is cured to an acceptable level. Packing, handling and storage facilities shall be non-metallic type.


PAINTING AND COATING SYSTEMS

6.1

COATING SYSTEMS SELECTION

6.1.1

General The coating systems generally acceptable for the intended service are listed in Section 6.2 for external application and Section 6.3 for internal application. Selection and acceptance of coating systems and products for a specific and specialised application which are not listed herein shall be the prerogative of individual Principal in consultation with the respective Paint Manufacturer. When selection an approved product for a particular project, the Contractor in consultation with the Principal shall consider the following factors: A.

Coating characteristics 2 ! Coverage cost (RM/m ) ! Application time ! Drying time ! Curing time ! Overcoating time ! Recoating time ! Compatibility

The maintenance and touch-up coating systems shall be compatible with the Initial/New Construction coating systems. Coating system compatibility shall be tested using patch test methods described in ASTM D 5064. B. C. D. E. F.

Nature of substrate Basic Function of Coating on Substrate Accessibility (time or space) and availability of appropriate equipment for satisfactory surface preparation and application. Environmental factors. Life Cycle Costs.

The coating systems shall demonstrate low Life Cycle Costs in combination with: ! !

An “Ideal/Optimum” Service Life of minimum one (1) year for the first 10 to 12 years of service life and A “Practical” Service Life of minimum ten (10) years.

The dry film thickness of the coating systems specified herein is the minimum requirement to achieve the desired system performance.

6.1.2

Organic and Inorganic Zinc-Filled Coatings The metallic zinc content in the zinc dust shall be a minimum of 94%. Zinc content by percentage weight for inorganic zinc silicate and epoxy zinc should comply with SSPC-Paint 20 (Zinc rich primer, Type I 'Inorganic ' and Type II 'Organic') requirement or equivalent. Any new formulation related to zinc coating shall be subjected to qualification testing stated in this standard. The zinc coating systems shall pass the respective tests as shown in Appendix 7. If shop primer (for temporary protection) is applied, then it must be 100% full blasted to the requirement stated in section 4 prior to the application of the full coating system.

PTS 30.48.00.31 September 2012 Page 29 of 78 For primed surface secondary surface preparation: All zinc salt formation shall be sweep blasted. All other possible contaminants shall be sanded down and solvent cleaned before topcoating. For damages, welding joints and rusty area, spot blast to Sa 2.5 followed by one coat of epoxy zinc rich or power tool cleaned to St3 and followed by Surface Tolerant epoxy, subject to Principal approval. 6.1.3

Selection and Application of Top Coats For areas to be applied with polyester glassflake, all shop primer shall be removed completely, i.e. Sa 2.5. Prior to topcoating zinc rich primers, SSPC-PS Guide 8 shall be consulted to select compatible topcoats. The selection process requires identification of the generic type of primer, compatibility considerations, and selection of compatible topcoats. The minimum volume solids for high solid epoxy shall be 75%. As an alternative, surface tolerant high solid epoxy paint can be applied. When topcoating inorganic zinc silicate primed surface, a mist coat (wet to wet technique) i s required to eliminate pinholing.

6.2

PAINTING AND COATING SYSTEM SCHEDULES FOR EXTERNAL APPLICATION

6.2.1

Carbon Steel Design Temperature < 110°C Non Insulated in the Atmospheric Zone

6.2.1.1 Coating System No. 1A: Initial Painting Surface preparation : Blast Cleaning to ISO 8501-1:2007, Sa 2.5 Coating system st 1 coat Inorganic Zinc Silicate / Epoxy Zinc Rich nd 2 coat High Solid Epoxy rd 3 coat Aliphatic Polyurethane Total

DFT 75 150 50 275

µ µ µ µ

6.2.1.2 Coating System No. 1B: Maintenance Painting for Blast Cleaned Surface Surface preparation : Blast cleaning to ISO 8501-1:2007, Sa 2.5 Coating system st 1 coat Epoxy Zinc Rich nd 2 coat High Solid Epoxy rd 3 coat Aliphatic Polyurethane Total

DFT 75 150 50 275

µ µ µ µ

6.2.1.3 Coating System No. 1C: Maintenance Painting for Power Tool Cleaned Surface Surface preparation Coating system

: Power tool cleaning to ISO 8501-1:2007, St 3 DFT

st

Surface Tolerant High Solid Epoxy

125

µ

nd

Surface Tolerant High Solid Epoxy

125

µ

rd

Aliphatic Polyurethane

50

µ

300

µ

1 coat 2 coat 3 coat Total


Carbon Steel Design Temperature <110°C Insulated in Atmospheric Zone

6.2.2.1 Coating System No. 2A: Initial Painting Surface preparation

: Blast cleaning to ISO 8501-1:2007, Sa 2.5

Coating system st 1 coat Inorganic Zinc Silicate / Epoxy Zinc Rich nd 2 coat High Solid Epoxy Total

DFT 75 150 225

µ µ µ

6.2.2.2 Coating System No. 2B: Maintenance Painting for Blast Cleaned Surface Surface preparation

: Blast cleaning ISO 8501-1:2007, Sa 2.5

Coating system st 1 coat Epoxy Zinc Rich nd 2 coat High Solid Epoxy Total

DFT 75 150 225

µ µ µ

6.2.2.3 Coating System No. 2C: Maintenance Painting for Power Tool Cleaned Surface Surface preparation

: Power tool cleaning to ISO 8501-1:2007, St 3

Coating system st 1 coat Surface Tolerant High Solid Epoxy nd 2 coat Surface Tolerant High Solid Epoxy Total

6.2.3

DFT 125 125 250

µ µ µ

Offshore Platform Decks (including primary and secondary structures)

6.2.3.1 Coating System No. 3A: Initial Painting and Maintenance Painting Surface preparation


Coating system st 1 coat Polyester Glass Flake nd 2 coat Polyester Glass Flake Antiskid Aluminium Oxide 20-30 Mesh (0.85 - 0.60 mm) Total

DFT 400 400

µ µ

800

µ

6.2.3.2 Coating System No. 3B: Initial Painting and Maintenance Painting (Alternative) Surface Preparation


Coating system st 1 coat Epoxy Glass Flake nd 2 coat Epoxy Glass Flake Antiskid Aluminium Oxide 20-30 Mesh (0.85 - 0.60mm) Total

DFT 400 400

µ µ

800

µ

Note: For maintenance painting, both Polyester Glassflake and Epoxy Glassflake can be applied in one coat application if antiskid is not required. The technical specification for Polyester Glassflake and Epoxy Glassflake are given in Appendix 2 and 3, respectively.


Splash Zone and Spray Zone

6.2.4.1 Coating System No. 4A: Initial Painting and Maintenance Painting Surface preparation


Coating system st 1 coat Polyester Glass Flake nd 2 coat Polyester Glass Flake Total

DFT 500 500 1,000

µ µ µ

6.2.4.2 Coating System No. 4B: Initial Painting and Maintenance Painting (Alternative) Surface Preparation


Coating system st 1 coat Epoxy Glass Flake nd 2 coat Epoxy Glass Flake Total

DFT 500 500 1,000

µ µ µ

Note: For major maintenance painting, one coat application of 1000 µ is allowed for Polyester Glass Flake and Epoxy Glass Flake. 6.2.5

Carbon Steel Design Temperature > 110°C (Insulated and Non-Insulated) in Atmospheric Zone

6.2.5.1 Coating System No. 5A: Initial Painting and Maintenance Painting i) Coating System No. 5A (1): Facilities with surface temperature 110 - 250°C Surface preparation


Coating system st 1 coat Inorganic Zinc Silicate nd 2 coat Modified Silicone Acrylics rd 3 coat Modified Silicone Acrylics Total ii)

DFT 75 30 30 135

µ µ µ µ

Coating System No. 5A (2): Facilities with surface temperature 250 - 450°C Surface preparation


Coating system st 1 coat Silicone Aluminium nd 2 coat Silicone Aluminium Total

DFT 25 25 50

µ µ µ

Note: ! Modified Silicone Acrylics and Silicone Aluminium shall be air-drying type. ! If the operating temperature is in different range/class than the design temperature, then the selection of the coating system shall be considered on a case by case basis. ! To ensure good adhesion to the metal surface, surface tolerant Aluminum paint shall be used.


6.2.5.2 Coating System No. 5B: Maintenance Painting Power Tool Cleaned Surface i)

Coating System No. 5B (1) : Facilities with surface temperature 110 - 250°C Surface preparation


Coating system st 1 coat Zinc Graphite nd 2 coat Modified Silicone Acrylics rd 3 coat Modified Silicone Acrylics Total ii)

DFT 40 30 30 100

µ µ µ µ

Coating System No. 5B (2): Facilities with surface temperature 250 - 450°C Surface preparation


Coating system st 1 coat Zinc Graphite nd 2 coat Silicone Aluminium rd 3 coat Silicone Aluminium Total

DFT 40 25 25 90

µ µ µ µ

Note: ! Applicable for isolated or spot touch up maintenance painting only. ! Modified Silicone Acrylics and Silicone Aluminium shall be air-drying type.

6.2.6

Galvanised Steel

6.2.6.1 Coating System No. 6A: Initial Painting Surface preparation

: Degrease as SSPC-SP1 and wash with fresh clean water, light abrade or sweep blast surface to provide anchor pattern of 25µ.

Coating system st 1 coat Surface Tolerant High Solid Epoxy nd 2 coat Aliphatic Polyurethane Total

DFT 125 50 175

µ µ µ

Note: Hot dip galvanising shall be carried out in accordance with the requirements of BS 729: "Hot 2 dipped galvanised coatings on iron and steel articles". A minimum of 610 gm/m (dft 86 m) of zinc shall be applied. Maintenance of galvanised steel shall be treated as carbon steel as per this section 6.2.


Stainless Steel

6.2.7.1 Coating System No. 7A: Initial Painting and Maintenance Painting i)

Coating System No. 7A (1) : Non insulated facilities operating < 110°C Surface preparation

: Sweep blast with dry, non-iron containing grit or roughen surface with emery paper to provide an anchor profile.

Coating system st 1 coat High Solid Epoxy (refer to Note) nd 2 coat Aliphatic Polyurethane Total ii)

DFT 125 50 175

µ µ µ

Coating System No. 7A (2) : Insulated facilities operating < 110°C Surface preparation

: Sweep blast with dry, non-iron containing grit or roughen surface with emery paper to provide an anchor profile

Coating system st 1 coat High Solid Epoxy (Refer to Note) Total

DFT 125 125

µ µ

(iii) Coating System No. 7A (3) : Insulated and non-insulated facilities operating 110 600°C Surface preparation Coating system st 1 coat nd 2 coat Total

: Sweep blast with dry, non-iron containing grit to create an anchor profile. DFT

Silicone Aluminium Silicone Aluminium

25 25 50

µ µ µ

Note: High solid epoxy should be non-inhibitive and non-metallic pigmented. 6.2.7.2 Painting Guideline for Stainless Steel Table below can be used as a guideline to select painting system for Stainless Steels. Temp Range

Martensitic/ Ferritic

Austenitic

Duplex

Remarks

110ºC to 600ºC

Coating System # 7A(3)

Coating System # 7A(3)

Coating System # 7A (3)

Insulated and non insulated

60ºC to 110ºC

Coating System # 7A (2) Coating System # 7A (1) Coating System # 7A (2) Coating System # 7A (1)

Coating System # 7A (2) Coating System # 7A (1) Coating System # 7A (2) No Painting

Coating System # 7A (2) No Painting

Insulated

Up to 60ºC

Coating System # 7A (2) No Painting

Non-insulated Insulated Non-insulated


Carbon Steel Storage Tank

6.2.8.1 Coating System No. 8A: Initial painting Selection of initial painting systems for carbon steel storage tanks shall be made based on specific requirements of the relevant sections 6.2.1 through to 6.2.5. 6.2.8.2 Coating System No. 8B: Initial and Maintenance Painting for Underside of Bottom Plate (ONLY if painting is required for corrosion protection to supplement Cathodic Protection) Surface preparation


Coating system st 1 coat Epoxy Zinc Rich nd 2 coat Coal Tar Epoxy Total

DFT 75 300 375

µ µ µ

6.2.8.3 Coating System No. 8C: Shell and Roof Plate, Stairways, Stair Treads, Gangways and Others External Parts Including Piping (non-galvanised) The maintenance painting scheme shall follow that for carbon steel design temperature at < 110°C. The recommended Tank identification system is given in Appendix 4. 6.2.9

Timber Decks

6.2.9.1 Coating System No. 9A: Initial and Maintenance Painting Surface preparation

: Light sanding to remove contaminant, sharp edges and old paints.

Coating system st 1 coat Aluminium Wood primer nd 2 coat Alkyd Semi-gloss finish rd 3 coat Alkyd Semi-gloss finish

DFT 50 50 50

µ µ µ

Antiskid aggregate Total

150

µ

6.2.9.2 Coating System No. 10: Markings Surface preparation

: Degrease and wash with clean fresh water. Abrade surface to provide another pattern.

Coating system Marking Aliphatic Polyurethane Total

DFT 50 50

µ µ

The recommended piping identification system and legend are given in Appendix 5 and 6, respectively.

PTS 30.48.00.31 September 2012 Page 35 of 78 6.2.10 Coating System No. 11: Living Quarters Pressurized Building, Control Room (Interior) Surface preparation


Coating System st

1 coat

DFT

Surface Tolerant Epoxy

Total

150

µ

150

µ

6.2.11 Coating System No. 12: Fire Barriers / Passive Fire Protection (PFP) System Approval of Passive Fire Protection (PFP) Systems shall be the discretion of Principal. Fire test report or certificate shall be submitted for validation. Fire Test Standards The minimum standard curve temperature of passive fire proofing materials for rapid rise fires follows either the following standards: ! !

UL1709 standard for rapid rise fire test OR BS 476 Parts 20 and 21 (High rise hydrocarbon type fire curve)

In addition to compliance with the above fireproofing standards, where specifically required only, manufacturers must submit the following tests: ! !

Gas flame impingement/Jet Fire High pressure water hose during fire conditions.

All hydrocarbon fire PFP coating system shall be capable of preventing the passage of smoke and flame for at least 120 minutes exposure to a hydrocarbon fire. A test report simulating this capability shall be provided. Lightweight epoxy-based thin film intumescent (TFI) coating shall be preferred over cementitious PFP coating system for weight control of offshore production facilities. Water-based intumescent coating system shall be used for interior application. Externally applied PFP coating system shall include a compatible top coat for weathering-resistant performance. 6.3

PAINTING AND COATING SYSTEM SCHEDULES FOR INTERNAL APPLICATION

6.3.1

Fuel Gas (Sweet and Sour)

6.3.1.1 Coating System No. 13A :

Initial painting, Maintenance Painting for Blast Cleaned surface and Power Tool Cleaned Surface.

Surface preparation

:

Blast cleaning to ISO 8501-1:2007, Sa 2.5, Power tool cleaning to ISO 8501-1:2007, St 3 for minor touch-u painting

Surface to be painted

:

All over

Service Temperature

:

Up to 60 ºC

Coating System

DFT

st

Amine Adduct Epoxy

125

µ

nd

Amine Adduct Epoxy

125

µ

250

µ

1 coat 2 coat Total


Crude / condensate (Sweet and Sour), Emulsion/Slop

6.3.2.1 Coating System No. 14A: Initial Painting, Maintenance Painting for Blast Cleaned Surface and Power Tool Cleaned Surface. i)

Coating System No. 14A (1) : Roof and Shell plate Surface preparation : Blast cleaning to ISO 8501-1:2007, Sa 2.5, Power tool cleaning to ISO 8501-1:2007, St 3 for minor touch-up painting Service Temperature : Up to 60 ºC Coating System

DFT

st

Amine Adduct Epoxy

125

µ

nd

Amine Adduct Epoxy

125

µ

250

µ

1 coat 2 coat Total

Note: Floating roof tank plates which are subjected to excessive abrasion and wear shall be uncoated. However, if the Principal considers otherwise, suitable coating systems may be specified. (ii)

Coating System No. 14A (2) : Bottom plate and vessels Surface preparation : Blast cleaning to ISO 8501-1:2007, Sa 2.5, Power tool cleaning to ISO 8501-1:2007, St 3 for minor touch-up painting Service Temperature : Up to 60 ºC Coating System

DFT

st

Amine Adduct Epoxy

100

µ

nd

Amine Adduct Epoxy

100

µ

rd

Amine Adduct Epoxy

100

µ

300

µ


(iii)

Coating System No. 14A (3) : Alternative system for bottom plate Surface preparation Service Temperature

: Blast cleaning to ISO 8501-1:2007, Sa 2.5, Power tool cleaning to ISO 8501-1:2007, St 3 for minor touch-up painting : Up to 60 ºC

Coating System

DFT

st

Amine Primer

50

µ

nd

Amine Glassflake

200

µ

rd

Amine Glassflake

200

µ

450

µ



Light Naptha, Heavy Naptha, Treated Naptha, Reformate, Jet A-1 Fuel, Lube Oil, Fuel Oil, Gasoline (unleaded), Gasoline (leaded)

6.3.3.1 Coating System No. 14A (3) : Initial Painting, Maintenance Painting for Blast Cleaned Surface and Power Tool Cleaned Surface Surface preparation Service Temperature

: Blast cleaning to ISO 8501-1:2007, Sa 2.5, Power tool cleaning to ISO ISO 8501-1:2007, St 3 for minor touch-up painting : Up to 60 ºC

Coating System

DFT

st

Amine Adduct Epoxy

125

µ

nd

Amine Adduct Epoxy

125

µ

250

µ

1 coat 2 coat Total

6.3.4

Diesel

6.3.4.1 Coating System No. 16A: Initial Painting, Maintenance Painting for Blast Cleaned Surface and Power Tool Cleaned Surface Surface preparation Surface to be painted Service Temperature

: Blast cleaning to ISO 8501-1:2007, Sa 2.5, Power tool cleaning to ISO 8501-1:2007, St 3 for minor touch-up painting : Roof and Shell plate : Up to 60 ºC

Coating System

DFT

st

Amine Adduct Epoxy

125

µ

nd

Amine Adduct Epoxy

125

µ

250

µ

1 coat 2 coat Total

Note: Floating roof tank plates which are subjected to excessive abrasion and wear shall be uncoated. However, if the Principal considers otherwise, suitable coating systems may be specified. 6.3.4.2 Coating System No. 16B: Initial Painting, Maintenance Painting for Blast Cleaned Surface and Power Tool Cleaned Surface Surface preparation Surface to be painted Service Temperature

: Blast cleaning to ISO 8501-1:2007, Sa 2.5, Power tool cleaning to ISO 8501-1:2007, St 3 for minor touch-up painting : Bottom plate and Vessels : Up to 60 ºC

Coating System

DFT

st

Amine Adduct Epoxy

100

µ

nd

Amine Adduct Epoxy

100

µ

rd

Amine Adduct Epoxy

100

µ

300

µ


PTS 30.48.00.31 September 2012 Page 38 of 78 6.3.4.3 Coating System No. 16C: Alternative System for Bottom Plate Surface preparation Surface to be painted Service Temperature

: Blast cleaning to ISO 8501-1:2007, Sa 2.5, : Bottom plate and Vessels : Up to 60 ºC

Coating System

DFT

st

Epoxy Primer

50

µ

nd

Epoxy Glassflake

200

µ

rd

Epoxy Glassflake

200

µ

450

µ


6.3.5

Potable (drinking / aerated / non-aerated) Water, Seawater (aerated / non-aerated), Produced Water, Brackish, Demineralised Water, Brine

6.3.5.1 Coating System No. 17A: Initial painting, Maintenance Painting for Blast Cleaned Surface and Power Tool Cleaned Surface. Surface preparation Service Temperature

: Blast cleaning to ISO 8501-1:2007, Sa 2.5, Power tool cleaning to ISO 8501-1:2007, St 3 for minor touch-up painting : Up to 60 ºC

Coating System

DFT

st

Amine Adduct Epoxy

125

µ

nd

Amine Adduct Epoxy

125

µ

250

µ

1 coat 2 coat Total

Note: Coating system applied for portable water system shall be accompanied with a health certificate.

6.3.6

Steam (condensate), Boiler Feed

6.3.6.1 Coating System No. 18A: Initial Painting, Maintenance Painting for Blast Cleaned Surface and Power Tool Cleaned Surface. Surface preparation Surface to be painted Service Temperature

: Blast cleaning to ISO 8501-1:2007, Sa 2.5, or Power tool cleaning to ISO 8501-1:2007, St 3 for minor touch-up painting : All over : Up to 100 ºC

Coating system st

1 coat nd 2 coat Total

DFT Phenolic Epoxy Phenolic Epoxy

150 150 300

µ µ µ


Utility Air

6.3.7.1 Coating System No. 19A: Initial Painting, Maintenance Painting for Blast Cleaned Surface and Power Tool Cleaned Surface. Surface preparation

: Blast cleaning to ISO 8501-1:2007, Sa 2.5, or Power tool cleaning to ISO 8501-1:2007, St 3 for minor touch-up painting Surface to be painted : All over Service Temperature : Up to 60 ºC Coating system st


DFT Amine Adduct Epoxy Amine Adduct Epoxy

125 125 250

µ µ µ

6.3.7.2 Coating System No. 19B: Alternative System Surface preparation Surface to be painted Service Temperature

: : :

Blast cleaning to ISO 8501-1:2007, Sa 2.5 All over Up to 60 ºC

Coating system st 1 coat Polyester Glassflake or Epoxy Glassflake

DFT 400

µ

Total

400

µ

6.3.7.3 Coating System No. 19C: Initial painting, Maintenance Painting for Blast Cleaned Surface and Power Tool Cleaned Surface. Surface preparation Surface to be painted Service Temperature

: Blast cleaning to ISO 8501-1:2007, Sa 2.5, or Power tool cleaning to ISO 8501-1:2007, St 3 for minor touch-up painting : All over : More than 60 ºC

Coating system st


DFT Phenolic Epoxy Phenolic Epoxy

125 125 250

µ µ µ

6.3.7.4 Coating System No. 19D: Alternative System Surface preparation Surface to be painted Service Temperature

: : :

Blast cleaning to ISO 8501-1:2007, Sa 2.5 All over More than 60 ºC

Coating system st 1 coat Vinyl Ester Glassflake Total

DFT 400 400

µ µ


Corrosion Inhibitors, Demulsifier, Oxygen Scavenger

6.3.8.1 Coating System No. 20A: Initial Painting, Maintenance Painting for Blast Cleaned Surface and Power Tool Cleaned Surface Surface preparation

:

Surface to be painted Service Temperature

: :

Blast cleaning to ISO 8501-1:2007, Sa 2.5, or Power tool cleaning to ISO 8501-1:2007, St 3 for minor touch-up painting All over Up to 60 ºC

Coating system st


6.3.9

Vinyl Ester Glassflake Vinyl Ester Glassflake

DFT 800-1500 800-1500 1600-3000

µ µ µ

Methanol and Percroethalyne

6.3.9.1 Coating System No. 21A: Initial painting, Maintenance Painting for Blast Cleaned Surface and Power Tool Cleaned Surface Surface preparation Surface to be painted Service Temperature

: Blast cleaning to ISO 8501-1:2007, Sa 2.5, or Power tool cleaning to ISO 8501-1:2007, St 3 for minor touch-up painting : All over : Up to 60 ºC

Coating system st


DFT Epoxy Phenolic Epoxy Phenolic

125 125 250

µ µ µ

6.3.9.2 Coating System No. 21B: Alternative System Surface preparation Surface to be painted Service Temperature pH Coating system st 1 coat Total

: Blast cleaning to ISO 8501-1:2007, Sa 2.5, or Power tool cleaning to ISO 8501-1:2007, St 3 for minor touch-up painting : All over : Up to 60 ºC : 6-9 DFT

Inorganic Zinc Silicate

75-100 75-100

µ µ

PTS 30.48.00.31 September 2012 Page 41 of 78 6.3.10 Triethylene Glycol / Methylethylene Glycol 6.3.10.1 Coating System No. 22A: Initial Painting, Maintenance Painting for Blast Cleaned Surface and Power Tool Cleaned Surface Surface preparation

:


: :


Coating system st


DFT Amine Adduct Epoxy Amine Adduct Epoxy

125 125 250

µ µ µ

6.3.10.2 Coating System No. 22B: Alternative System Surface preparation

:


: :


Coating system st


DFT Epoxy Phenolic Epoxy Phenolic

125 125 250

µ µ µ

6.3.10.3 Coating System No. 22C: Initial Painting, Maintenance Painting for Blast Cleaned Surface and Power Tool Cleaned Surface Surface preparation

:


: :

Blast cleaning to ISO 8501-1:2007, Sa 2.5, or Power tool cleaning to ISO 8501-1:2007, St 3 for minor touch-up painting All over More than 60 ºC

Coating system st


Vinyl Ester Glassflake Vinyl Ester Glassflake

DFT 400-500 400-500 800-1000

µ µ µ

6.3.11 Chemicals (Others) 6.3.11.1 Acids and Alkalis, Ammonia, Caustic Soda, Biocide, Chlorine, Descalers In the event that there are large variations in the description of chemical cargo; the Principal shall consult the Paint Manufacturers for the selection of the most appropriate coating system to be applied. Typical information to be furnished by the Principal shall include the following: ! Chemical action (concentration, pH, impurities or contaminants, chemical reactions) ! Temperature (maximum, minimum, and operating cycle e.g. steam out condition) ! Pressure (maximum, minimum, and operating cycle) ! Environmental conditions (outside, inside, climate, accessibility) ! Possibility of different cargo ! The tank internal (eg: attachments, etc.) shall be coated with the same respective coating system.


PAINT MATERIALS STORAGE, SHELF-LIFE AND HANDLING

6.4.1

Storage All containers containing paint materials shall be stored under cover giving protection from direct sunlight and rain at a temperature below 35°C. The storage condition should also allow for adequate ventilation to minimise paint container deterioration from humidity. Materials should be systematically stored after delivery so that a First-In-First-Out (FIFO) withdrawal procedure can be adopted.

6.4.2

Shelf-Life The shelf-life quoted on product data sheets is generally a conservative value which takes into account the variable storage conditions encountered; and it is probable that paints can be applied without any compromise on its performance after the shelf life period has elapsed. However, if the quoted shelf-life period has been exceeded, it is recommended that the usability of the product shall be checked by the Manufacturer and notified to the Principal. The procedure described in ASTM D 869 shall be used to evaluate degree of settling of paint. Paint which has liveried, gelled, or otherwise deteriorated during storage shall not be used.

6.4.3

Handling Many of the paints used in the oil and gas industry are heavy duty protective coatings supplied in 5 to 20 litres containers. Because of the weight of the containers, care must be taken in handling to avoid injury to the individual and damage to equipment. Palletised materials with mechanical handling should be used whenever possible. When handling, damage can occur to the container and in severe cases leaks or spills of the paint may result. Damage to any container should be avoided to maximise storage and shelf life of the paint.

6.5

COATING SYSTEM PRODUCT APPROVAL REQUIREMENT New coating products, upgrading of existing product or formulation changes of approved coating products shall be submitted for a full laboratory screening before the product can be considered as an approved product. Complete coating systems shall be tested and qualified in accordance with the procedures described in QP-CS1: Procedure for Qualification and Testing of Coating Systems. The PETRONAS Protective Coatings and Linings Technical Committee (PCLTC) recognizes a list of testing laboratories/bodies for conducting the various tests and evaluation of blast-cleaning abrasives and protective coating and lining system. The list includes but not limited to SIRIM, Universiti Kebangsaan Malaysia (UKM) and Det Norske Veritas (DNV) Singapore. The PCLTC has the right to accept or reject test results or reports produced by other third party testing bodies and laboratories.

6.5.1

Test Panels One (1) set of test panels shall be prepared for each generic coating system as per the various ASTM test requirements listed in the table in section 6.5.2 below; depending on the types of tests to be carried out. The test panels shall be prepared in the field, for example in a coastal fabrication yard, to simulate field application condition where adverse climatic conditions may prevail. Each test panel shall be surface cleaned and coated to the requirement as prescribed in this specification. All test panels should be kept indoors for a period of seven (7) days for curing before any testing.


Laboratory Testing The test panels shall be submitted to an approved third party testing agency for laboratory testing. Recommended laboratory test methods shall include, but not limited, to the following: Types of Laboratory Tests Type

Salt Spray (Scribed)

Test Method ASTM B117 ASTM D1654 (Proc. A)

Purpose To study the creep resistance of Flawed coatings under accelerated conditions of the corrosive environment.

Acceptance Criteria Blast Cleaned Surface 3,000 hours, coating defects as per ASTM D 1654 Proc. A, Rating 4-5 at scribe. Power Tool Cleaned Surface 3,000 hours, coating defects as per ASTM D 1654 Proc. A, Rating 3 at scribe.

Salt Spray (Unscribed)

To observe the performance of coatings subject to accelerated conditions of the corrosive environment.

4,500 hours, coating defects as per ASTM D 1654 Proc. B, area failed Rating No.9

ASTM D4541

To give a quantitative indication on the adhesion properties of the coating systems with DFT > 200 m.

500 psi (Splash Zone) 300 psi (Atmospheric Zone) To conduct after 7 days cured period from the final coat

ASTM D3359, Test Method A

To give a quantitative indication on the adhesion properties of the coating systems with DFT < 200 m.

For ASTM D3359 Method A, the acceptance criteria is 3A

Impact

ASTM D2794

To give a quantitative indication of the ability of paints to resist cracking due to impact loading.

18 J (Intrusion)

Abrasion

ASTM D4060

To assess quantitatively the abrasion resistance of the coatings.

150 mg/ 1000 cycles/ 1kg load using wheel CS10

Water Immersion

ASTM D 870

To assess the water resistance of coatings by partial or complete immersion of coated specimens in distilled or demineralised water at ambient or elevated temperatures.

6000 hours without any visible coating defects.

Cathodic Disbonding

ASTM G 8

To assess resistance of coating to Cathodic disbondment.

< 10 mm disbondment.

Adhesion

ASTM B117 ASTM D1654 (Proc. B)


Types of Laboratory Tests Type

Test Method

Purpose

Acceptance Criteria

ASTM G 26

To study the effects of weather on coatings.

2,000 hours without any coating defects (except a max. degree of chalking rate of 6)

HeatResistance

ASTM D 2485, To evaluate the heat-resistant Test Method B properties of coatings designed to protect steel surfaces exposed to elevated temperatures during their service life.

Gradual increase in temperature to the requirement as per specific requirement of section 6.2. Cool down the panel to room temperature before salt spray for 24hr. Result, without coating defect such as rust, blister & loss of adhesion

Cyclic Salt Fog/UV Exposure

ASTM D5894

4,200 hours, coating defects as per ASTM D1654 Proc. B, area failed Rating No. 9.

Accelerated Weathering

To observe the performance of coatings subject to accelerated conditions of the cyclic corrosion/UV exposure : ! Salt Spray duration 72 hours ! Drying in air duration 16 hours ! UV-A 340 nm duration 80 hours ! 25 cycles at 168 hours per cycle

Note : Users may select ASTM D5894 test method to replace ASTM B117, ASTM D1654 and ASTM G 26.

Polyurethane topcoated coating systems for testing shall be measured for "glossiness" and colour retention using Specular Excluded (SPEX) method at 60° angle (Specular Reflectance) depicted in ASTM D 523. The coating systems, depending on their functions set forth in section 6.2 and 6.3 shall pass the respective tests as shown in Appendix 7. The final acceptance and approval of the coating systems tested shall be carried out in accordance with the process depicted in Appendix 8. 6.5.3

Product QA/QC Report Paint Manufacturers shall submit QA/QC reports on the coating systems that passed the laboratory screening tests. The QA/QC reports must have the following information: ! ! ! ! !

Drying time Hold up property Glossiness Specific gravity Viscosity

Paint Manufacturers shall maintain that the properties of their coating systems selected for actual painting work will be the same as the ones that passed the laboratory screening tests. In this regard and if deemed necessary, paint manufacturers in consultation with the Principal, may be required to send their paint batches to the approved third party testing agency to verify conformance to the QA/QC report stated herein.

PTS 30.48.00.31 September 2012 Page 45 of 78 Whenever considered deemed necessary, Principal may carry out a non-conformance audit on the paint manufacturers. 6.5.4

Paint Quality Control Batch Certificate Paint manufacturers shall furnish their Paint Quality Control Batch certificates to ensure that the properties of the products supplied are consistent with the laboratory tested products. As a minimum, the following information shall be provided: i) ii) iii) iv) v) vi) vii)

viii)

Manufacturer's name Factory location Date of manufacture Batch number Product name Generic name Key composition/components description: ! Resin ! Pigments ! Curing Agent (generic name) ! Solvent (generic name) QC Test Results including Test Standard, Pass Criteria, Actual Results: ! Colour ! Viscosity ! Density/S.G. ! Fineness ! Drying ! Time ! Hiding ! Power ! Gloss

*All Quality Control test results shall be provided by paint manufacturer as and when requested by the Principal.


QUALITY CONTROL (QC)

7.1

INSPECTION Compliance to this specification shall be controlled through inspection of each phase of a painting programme. Inspection is required during all phases of surface preparation and coating application. The process map for the inspection activities is illustrated in Appendix 9.

7.2

PROJECT PRODUCTION TESTING The purpose of project production testing is to check and test the Contractor’s compliance and to demonstrate that the painting procedures, equipment and craftsmanship satisfy this specification on top of meeting paint manufacturer requirement. The production testing shall be conducted after the Contractor has selected the coating systems. The production testing shall not be used by Contractor to qualify coating systems. All observations, data and test result of the production trial shall be documented in pre-approved format, which shall include information such as painting contractor, type of cleaning and surface standards, generic coating materials, manufacturers and product brand names, batch number, blasting/painting environmental conditions, test results, etc. The following tests shall be conducted by Contractor and witnessed by Principal’s representative and Paint Vendors: !

Visual Inspection shall be carried out on each individual coat and completed coating system listing the appearance of the coating. The coating shall be free from run pinholes, cracking, blistering, sagging, crater, dry spray and over spray.

!

Surface profile height shall be spot checked and documented using an approved surface profile gauge (e.g. Elcometer 123)

!

Film thickness measurement for both wet thickness and dry film thickness shall be conducted during all coating application sequences (i.e. individual coats and specified total dry film thickness). WFT and DFT measurement shall comply to ASTM D4414 and SSPC-PA2, respectively.

!

Adhesion Test shall be performed on a flat surface in accordance with ASTM D4541 Standard test method for full-off strength of coating using hydraulic adhesion tester for coating total DFT above 200 microns. Adhesion test on final coat or complete coating system shall be conducted after curing for a minimum of seven (7) days. Degree of curing for Inorganic Zinc coatings shall be determined using the method described in ASTM D4752. The recommended minimum “pull-off” value for glassflake coating system is 500 psi and all other systems, shall be minimum 300 psi.

!

For coating DFT less than 200 microns (mainly reference to single pack coatings), power tool cleaned surface (maintenance system) galvanized steel, aluminium and stainless steel, the X-cut technique, and the use of pressure sensitive adhesive tapes to cut surface shall be used. The X-cut test shall be carried in accordance to ASTM D3359 Method A Standard test method for measuring adhesion by tape test.

All areas of damaged coatings due to the destructive tests shall be repaired immediately.


RESOURCE REQUIREMENT

8.1

PAINTING CONTRACTOR Painting contractors shall have the personnel, organisation, qualifications, procedures, knowledge and capability to produce surface preparation and coating application of the required quality for complex structures. The procedure for evaluating qualifications of painting contractors is described in SSPC-QP1. Functional areas to be evaluated shall include the following: ! Management procedures; o Company Policy o Organisation and Personnel o Administrative and Management Procedures

8.2

!

Technical Capabilities; o Personnel Qualifications o Technical Resources o Procedure o Equipment, Facilities and Experience

!

Quality Control o Personnel Qualifications o Inspection Procedures and Recording Systems

!

Safety o Safety Procedure and Record – Keeping Systems o Resource Materials

PAINTING INSPECTOR All painting inspection shall be carried out by certified personnel described in 8.2.1 below.

8.2.1

Qualifications/Experience

8.2.1.1 Painting Inspector The painting inspector shall be certified under either one (1) of the following certification institutes: ! ! !

Institute of Materials, Malaysia (IMM) Level II NACE International Certified Coating Inspector Level III Other reputable Institutes e.g. SSPC, FROSIO, ICorr, etc.

He shall have at least three (3) years of experience in painting inspection, and good working knowledge on all aspects of painting: procedures, specification, paint performance, and application as well as inspection. He shall be able to use paint inspection tools which are normally associated with the works. 8.2.1.2 Thermal Spray Coatings Inspector Thermal Spray Coatings Inspector shall be certified to Institute of Materials, Malaysia (IMM) Level III or equivalent. He shall have at least three (3) years of experience in thermal spray coating inspection, and a good working knowledge on all aspects of thermal spray application: procedures, specification, paint performance, and application as well as inspection. He shall be able to use thermal coating inspection tools which are normally associated with the works.


Responsibilities The Painting Inspector is held responsible for ensuring that the quality of all aspects of a painting programme is correct and according to this specification. The Inspector's duty is to ensure that the requirements of the coating specification are met. ASTM D3276-86 Standard Guide for Painting Inspectors (Metal Substrates) or SSPC Publication #91-12 Coating and Lining Inspection Manual, Section 2 shall be referred by the Inspector at all times as an information aid in carrying out his task efficiently. The Inspector's function is to enforce the specifications without exception even if he deems them to be inadequate and to consult the Principal's QA/QC Engineer of any deviations. Besides specification enforcement, the Painting Inspector shall be responsible for witnessing, verifying, and documenting the work at various inspection points: ! ! ! ! ! ! ! ! ! ! ! ! ! !

Pre-surface preparation inspection. Measurement of environmental conditions. Evaluation of compressor (Air cleanliness) and surface preparation equipment. Determination of surface preparation cleanliness and profile. Inspection of application equipment. Witnessing paint mixing. Inspecting paint / application. Determination of wet film thickness. Determination of dry film thickness. Evaluating cleanliness between coats. Pinhole and holiday testing. Adhesion testing. Evaluating the curing of applied paints. Any other coating related activities

8.3

BLASTING AND PAINTING SUPERVISOR

8.3.1

Qualifications/Experience Blasting and painting supervisor shall hold a valid IMM Blasting and painting supervisor certificate or equivalent. Blasting and painting supervisor shall have at least three (3) years of experience in Blasting and Painting and a good working knowledge in Blasting and Painting specification and procedures. The knowledge and skill shall cover the following: ! Corrosion ! PFP ! Cathodic Protection ! Dry Ice Application ! Hot-Dip Galvanising ! Volume of Solid (%) ! Thermal Spray ! Paint Defects ! Paint Technology ! Quality Control ! Paint and Properties ! Inspection ! Marine ! Safety ! Concrete ! Role of Supervisor ! Pipe Coatings ! Human Relations ! Powder Coatings


Responsibilities ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! !

The Blasting and Painting Supervisor is held responsible in all Blasting and Painting Equipment Set Up. Understand how protective coatings can effectively control corrosion. Ensuring the surface preparation to be carried out properly. Awareness in coating defects. Able to perform relevant calculation, cost and estimation. Awareness in Health, Safety and Environment. To ensure progress of Blasting and Painting works are according to schedule and/or planning. To ensure abrasives, paints, thinners, consumables are sufficient. To ensure paint materials are sufficient for prepared area. To reduce wastage. To ensure safety gear are sufficient and worn correctly. To maintain daily reports on work progress, materials consumption and materials stock. To report to superior for any problem that might arise. To ensure that a coating project meets the specifications of workmanship. Understand work schedule, ensure that all phases of the job are done in the manner outlined and approved by client. Should not leave the meeting without a crystal-clear understanding. Working smoothly with all the team members is one of the most important tasks. Painting works inspection is a necessary quality control function. Prime liability for safety. Prepare all required reports, and/or the reports appropriate for the project. Keeping track of and ordering materials.

8.4

COATINGS AND QUALITY CONTROL TECHNICIAN (QC)

8.4.1

Qualifications/Experience QC Technicians shall hold a valid IMM coatings QC Technician certificate or equivalent. The QC Technicians shall have at least two (2) years of experience in Blasting and Painting and a good working knowledge in the following: ! ! ! ! ! ! ! ! ! !

QA and QC Monitoring Environmental Conditions Reference Standards and Codes Scope of Work Safety Practices Pre-Cleaning Inspection Blast Cleaning Operations Coating Materials and Handling Practices Application Procedures Inspection (Tools, Methods and Sequence)

! ! ! ! ! ! ! ! ! ! ! !

Surface Preparation Degreasing Mechanical Cleaning Abrasive Blast Cleaning Surface Preparation Standards Surface Profile Application Repairs and Remedial Coating Work Documentation and Compiling Accurate Reports Material Traceability Recommendations


Responsibilities ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! !

Know where the coatings will be stored on site and ensure storage conditions are in accordance with specification and manufacturer’s latest instructions. Check containers for any sign of damage. Know how the coatings are to be mixed, thinned and agitated. Product name and number, colour and batch number. Understand the work schedule. Knowledge of applicable standards required for the preparation of surfaces to be coated. Ensure that the coating application is done as specified in a workmanlike manner, free from defects. Evaluate and revise current standard specification, special provisions and contract (i.e. contractor and Principal or third party inspection) to clearly define the responsibilities of QC and QA personnel. Required adequate QC coverage based on projected schedules or minimum QC coverage by crew, structure, location, or working hours. QC personnel shall meet minimum standards of training and experience, provide QC procedures and maintain documentation that will be used to verify the quality of final product. When specifying IMM or similar certifications, the contractor is required to provide evidence of QC personnel qualifications and training, necessary QC equipment, QC procedures and the type of documentation to be completed by the QC technician. Document required information in QC forms. Evaluate QA coverage based upon the contractor’s proposed work plan, number of crews, location and working hours. Recognize that the QC is the first step in the Total Quality Process and the importance of adequate employee training and experience and adherence to QC procedures and documentation. It is only through the establishment of clear qualification, responsibilities and documentation requirements for both QC and QA on a given project, that the full benefit of the Total Quality Management process can be realized. Benefits can include avoiding duplication of documentation and inspection, reduction of conflicts between the Contractor and Principal and the third party QA, real or perceived under or over inspection, and most importantly, long lasting protection of the structure or asset.

8.5

THERMAL SPRAY APPLICATOR

8.5.1 `

Qualifications / Experience Thermal Sprayer shall be qualified and certified by the Institute of Materials, Malaysia (IMM) under the following categories or equivalent: ! !

Thermal Sprayer Level 1 (Flame Spray or Arc Spray). Thermal Sprayer Level 2 (Flame Spray and Arc Spray).

Thermal Sprayers must also possess the IMM Blaster and Painter Certification (IMM certified Protective Coatings Technician Level 1 or Level 2) or equivalent. The Thermal Sprayer qualification and certification by IMM shall test the ability of the sprayer to apply the thermal spray coating material using the Flame Spray and/or Arc Spray technique to high quality standards in accordance to ISO-14918. Thermal Sprayer Level 1 shall be allowed to conduct work using only the technique he is qualified for (i.e. either Flame Spray or Arc Spray technique). Thermal Sprayer Level 2 shall be allowed to conduct work using both Flame Spray and Arc Spray techniques.


BLASTER/PAINTER

8.6.1

Qualifications / Experience Blaster/Painter shall be either a IMM certified Protective Coatings Technician Level 1 or Level 2 or equivalent, Akademi Binaan Malaysia/Construction Industry Development Board (ABM-CIDB) certified blasters and painters, qualified to do blasting and painting work as required by the Principals. He shall be competent and skilful with the following operations: !

!

Blasting; o Equipment Set Up (Type of Nozzle, Compressor Pressure, Type of Hose, After Cooler). o Abrasive (Type, Size). o Surface Quality Achieved. Painting; o Equipment (Application Method, Air Pressure, Tip Size) o Paint Used (Product used, Generic name, Mixing Ratio, Mixing Method, Thinner, Percent thinning, Expected Pot Life, Thickness required) He shall have a minimum of two (2) years of experience in blasting and/or painting.

8.6.2

Responsibilities Level 1: Technician shall be allowed to carry out either blasting or painting work depending on his category of certification. Level 2: Technician shall be allowed to carry out both blasting and painting works Performance of all blasting and painting works shall be under the supervision of the Painting Inspector.

8.6.3

General Requirements and Working conditions Both Level 1 and Level 2 Protective Coating Technicians should be capable of working effectively from scaffolding or temporary structures and at heights up to 300m above water.

8.7

PAINT SUPPLIER COATING ADVISOR

8.7.1

Qualifications / Experience A Coating Advisor shall possess as a minimum a Diploma in Chemistry or equivalent engineering qualification or a minimum five (5) years field experience in blasting and painting operation with intensive paint manufacturer internal training.

8.7.2

Responsibilities His responsibilities are the following: !

! !

Educate and demonstrate on correct application methods of new paint products to protective Coating Technician whenever deemed necessary. Provide technical advice during pre-job meeting. Clarify dispute on quality of paint materials delivered to work site. Advice HSE Officer on matters related to handling and disposal of paint materials.


INSPECTION EQUIPMENT The painting inspection equipment shall be provided by the Inspection agency and the Contractor. The appropriate instruments with valid calibration where applicable, to be used at various inspection points are listed but not limited to the following: Item No

Item Description

1

Sling Psychrometer

2

Surface Thermometer 0°C to 150°C

3

Psychrometric Tables

4

Hypodermic Needle Pressure Gauge

5

Blast Nozzle Aperture Gauge

6

Surface Profile Gauge

7

Surface Preparation Standards

8

Inspection Mirror

9

Illuminated Magnifier

10

Salinity Refractometer / Salt Contamination Meter

11

WFT Gauge

12

DFT Gauge for Ferrous or non-Ferrous

13

Low voltage Holiday Detector

14

High voltage Holiday Detector

15

Cutter for tape Adhesion Test

16

Hydraulic Adhesion Tester

17

Blotter Test Kit (ASTM 4285)

Purpose Weather Condition Check

Blasting Equipment Check

Surface Quality Check

Paint Thickness Check Holiday Detector Adhesion Check Air Cleanliness


HEALTH, SAFETY AND ENVIRONMENT (HSE)

9.1

SAFETY AND HEALTH REGULATIONS Principal shall have a stake in ensuring that contractors employed have the capability to comply with health and safety regulations, and that hazardous operations in the protective coatings industry are recognised such as: a. Materials ! Fire Hazards and Explosions ! Health Hazards b. Paint Application c. Surface Preparation d. Access and Ringing ! Ladders ! Fall Hazards ! Confined Spaces e. Equipment Grounding Contractor shall submit and has full responsibility for maintaining a proper and sufficient safety loss and prevention programme covering the work and covering the employees. Contractor Safety and Health Programme shall be designed to comply with PETRONAS Corporate Policy Statement on Health, Safety and Environment (Appendix 10), the Malaysian National Council for Occupational Safety and Health Act (OSHA), 1994 which states that it shall be the duty of every employer and every self-employed person to ensure, as far as practicable, the safety, health and welfare at work of all his employees. The purpose of an OSHA Compliance Programme is to make further provisions for securing that safety, health and welfare of persons at work, for protecting others against risks to safety or health in connection with the activities of persons at work. The components of an OSHA Compliance Programme shall include: 1) Policy statement establishing goals and commitment of management and the means for communicating these to all employees. 2) Delegation of responsibilities for implementing the programme. 3) Methods of identifying hazards and hazardous activities and for controlling them. 4) Commitment to on-going training and education of all supervisors and employees on all aspects of job safety and health. 5) Proper reporting and record keeping, and investigation of all incidents, injuries and illness. 6) Methods and procedures for complying with specific OSHA regulations. 7) Periodic review of programme with revisions made as necessary.

9.2

ENVIRONMENTAL REGULATIONS Painting and coating activities have a significant effect on the environment. Some examples of these activities and their specific effects are: a.

Abrasive Blast Cleaning Significant quantities of dust from the abrasive and the surface debris are made airborne and can contribute to air pollution. This dust is recognised as a fugitive emission that is often regulated. Control of dust generation shall be in compliance with the Environmental Quality (Clean Air) Regulations 1989.

b.

Paint Application In the process of spraying, a substantial portion of the liquid coating does not coach the substrate but is lost due to overspray. In addition, most coatings have appreciable quantities of volatile organic compounds (VOC) that can contribute to smug formation.

PTS 30.48.00.31 September 2012 Page 54 of 78 c.

Waste Production Both coating removal and coating application generate waste products, which must be proper disposed of. In many instances, the waste may be classified as hazardous by the Environmental Quality Act (EQA) 1974 because of heavy metal (e.g. lead) content of the residue, or the solvents of unused paint or thinner. The control of Scheduled Wastes shall be in compliance with the Environmental Quality Act 1974 (Act 127) Part IV A Section 34B. Scheduled wastes as identified in Environmental Quality (Schedule Wastes) Regulation, 1989 First Schedule (Regulation 2) Part I “Schedule Wastes from Non Specific Sources” and Part II “Schedule Wastes from Specific Sources” shall collected and disposed of at Prescribed Premises. These Prescribed Premises shall be in compliance with the Environmental Quality (Prescribed Premises) (Schedule Wastes Treatment and Disposal Facilities) Order, 1989 and Environmental Quality (Prescribed Premises) (Scheduled Wastes Treatment and Disposal Facilities) Regulations, 1989.

d.

Product Storage The storage of certain products is regulated by EQA 1974 because of the potential ecological damage that could result from a spill or leak from storage vessels.

e.

Leaching of Coatings Under certain circumstances, toxic or otherwise undesirable components of applied coating films may leach into the environment.

The above activities collectively can affect almost all the major environmental receptors i.e. air, soil, groundwater, surface water, potable water. Contractor Environmental Programme shall comply with the Malaysian Environmental Quality Act (EQA), 1974 relating to the prevention, abatement, control of pollution and enhancement of the environment. Contractors hired to remove hazardous paint shall be qualified in accordance with the procedures described in SSPC-QP 2(I). The qualification process shall evaluate four (4) functions: i) ii) iii) iv)

Management of Hazardous Paint Removal Technical Capabilities Qualification of Personnel Safety and Health


COLOUR SCHEMES

10.1

COLOUR SCHEME FOR ONSHORE/OFFSHORE INSTALLATION Colour scheme for Onshore/Offshore Installation is as per Appendix 11. Where applicable, colour schemes shall be in accordance with local statutory rules and regulations and customs specific to the Principal's requirements. If an intermediate coat has to be applied, it should be applied a shade lighter than the top coat in order to increase the inspectability.

10.2

COLOUR IDENTIFICATION FOR STORAGE TANK Colour identification should be painted on a square (1m x 1m)* at tank shell in position which is easily visible. The colour scheme shall be specific to the Principal's requirements. For easy reference, the product contents and the tank number should be worded above the colour identification square box. The size of the lettering and the location is described in Appendix 4.

10.3

IDENTIFICATION OF PIPING SYSTEM Identification may be accomplished by stencilling or the use of tape and/or markers. In any situations, the detail dimensions, number and location of identification markers shall be based on the particular piping system as specified in Appendix 5 and 6. For other systems which are not described in those Appendices, specification shall be determined by the Principal based on ANSI 13.1, Scheme for Identification of Piping System. All valves shall be painted WHITE except for firewater line which shall be painted RED

10.4

SAFETY COLOURS Where appropriate for safety reasons, the following colour scheme shall be adopted. Items

Colour Scheme

BS 4800

Dangerous obstructions

Black and OSHA Yellow (in alternate bands) Alert (OSHA) Orange OSHA Red OSHA Green OSHA Yellow OSHA Orange/White (in alternate bands)

00-E-53/

Dangerous or exposed parts of machinery Fire Equipment and services First Aid equipment Foam System Flare Stack/Communication Towers

/00-E-55


REFERENCES The standards referenced in this specification are listed in sections 11.1, 11.2, 11.3 and 11.4 and shall form part of this specification. The latest issue, revision, or amendments of the reference standards shall govern unless otherwise specified. In the event of any conflict between this specification and the requirements of any of the standards and/or publications referred, the requirements of this specification shall prevail.

11.1

NACE INTERNATIONAL STANDARDS AND PUBLICATIONS Standard/Publication No. NACE No. 2/SSPC-SP 10 NACE No. 3/SSPC-SP 6 NACE No. 5/SSPC-SP 12

NACE No. 8/SSPC-SP 14 NACE Publication 6G186 NACE RP 0181-94 NACE Publication 6A192

11.2

STEEL STRUCTURES PAINTING COUNCIL Standard/Publication No. SSPC-Guide to Vis 1-89 SSPC-SP 1

Description Visual Standard for Abrasive Blast Cleaned Steel Solvent Cleaning

SSPC-SP 3 SSPC-SP 11

Power Tool to Remove Loose Scale Power Tool Cleaning to Bare Metal

SSPC-SP 15 SSPC-AB 1 SSPC-PA 2 SSPC-PS Guide 8 SSPC-QP 1

Commercial Grade Power Tool Mineral and Slag Abrasives Measurement of Dry Paint Thickness with Magnetic Gauges Guide to Topcoating Zinc-Rich primers Standard Procedure For Evaluating The Qualifications of Painting Contractors (Field Application to Complex Standard Procedure For Evaluating The Qualifications of Painting Contractors To remove Hazardous Paint Zinc rich primer, Type I 'Inorganic ' and Type II 'Organic'

SSPC-QP 2(I) SSPC-Paint 20

11.3

Description Near-White Metal Blast Cleaning Commercial Blast Cleaning Surface Preparation and Cleaning of Steel and Other Hard Materials by High- and Ultrahigh-Pressure water Jetting Prior to Recoating Industrial Blast Clean (85% clean) Surface Preparation of Contaminated Steel Surfaces Liquid-Applied Internal Protective Coatings for Oil field Production Equipment Dehumidification Equipment in Lining Application

AMERICAN SOCIETY FOR TESTING & MATERIALS (ASTM) Standard No. Description Preparation of Surfaces For Painting ASTM D 4285 Standard Test Method For Indicating Oil or Water in Compressed Air ASTM D 4417 Standard Test Methods For Field Measurement of Surface Profile of Blast ASTM E 337 Standard Test Method For Measuring Humidity with a Psychrometer (the Measurement of Wet- and Dry-Bulb Temperature)

PTS 30.48.00.31 September 2012 Page 57 of 78 Standard No. Description Physical Properties - Liquid Paints ASTM D 869 Standard Test Method For Evaluating Degree of Settling of Paint Physical Properties - Cured Films ASTM D 3359 Standard Test Methods For Measuring Adhesion by Tape Test ASTM D 4541 Standard Test Method For Pull-Off Strength of Coatings Using Portable ASTM D 4752 Standard Test Method For Measuring MEK Resistance of Ethyl Silicate Thickness Measurement ASTM D 4414 Standard Practice for Measurement of Wet Film Thickness by Notch Gauges Visual Examination and Appearance ASTM D 610 Test Method For Evaluating Degree of Rusting on Painted Steel Surfaces ASTM D 4214 Standard Test Methods For Evaluating Degree of Chalking of Exterior Paint General Topics ASTM D 523 Standard Test Method for Specular Gloss ASTM D 870 Standard Practice for Testing Water Resistance of Coatings Using Water Immersion ASTM D 2485 Standard Test Methods for Evaluating Coatings For High Temperature ASTM D 3276 Standard Guide For Painting Inspectors (Metal Substrates) ASTM D 5064 Standard Guide for Conducting a Patch Test to Assess Coating ASTM D 5162 Standard Practice For Discontinuity (Holiday) Testing of Non-conductive ASTM G 8 Standard Test Methods for Cathodic Disbonding of Pipeline Coatings

11.4

INTERNATIONAL STANDARDS Standard Description /Publication No. ISO 8501-1: 2007 Preparation of steel substrates before application of paints and related products - Visual assessment of surface cleanliness - Part 1 : Rust grades and preparation grades of uncoated steel substrates and steel substrates after overall removal of previous coatings. ISO 8502-1: 2002 Preparation of steel substrates before application of paints and related products - Tests for the assessment of surface cleanliness - Part 1 : Field test for soluble iron corrosion products ISO 8502-3: 1992 Preparation of steel substrates before application of paint and related products - Test for the assessment of surface cleanliness - Part 3 : Assessment of dust on steel surfaces prepared for painting (pressuresensitive tape method) ISO 8504-2:2000

Preparation of steel substrates before application of paint and related products - Surface preparation methods - Part 2: Abrasive blast-cleaning

ISO 8504-3:1993

Preparation of steel substrates before application of paint and related products - Surface preparation methods - Part 3: Hand and power tool cleaning


AMERICAN NATIONAL STANDARD INSTITUTE Standard /Publication No. ANSI 13.1

11.6

11.7

Description Scheme For Identification of Piping System

SHELL STANDARD Standard/ Publication No.

Description

DEP 70.48.11.30

Protective Coatings for Offshore Facilities

DEP 30.48.00.31-Gen

Protective Coatings for Onshore Facilities

OTHERS Standard/ Publication No.

Description

CSP-23

PETRONAS Carigali Standard Procedure for Coating System for Bolts and Nuts


APPENDICES

APPENDIX 1

GUIDELINE ON MAINTENANCE PAINTING CRITERIA AND EXPECTED COATING PERFORMANCE

APPENDIX 2

GLASS FLAKE POLYESTER GENERIC SPECIFICATION

APPENDIX 3

GLASS FLAKE EPOXY GENERIC SPECIFICATION

APPENDIX 4

STORAGE TANK IDENTIFICATION SYSTEM

APPENDIX 5

PIPING IDENTIFICATION SYSTEM

APPENDIX 6

PIPING COLOUR IDENTIFICATION LEGEND

APPENDIX 7

COATING SYSTEMS TESTING REQUIREMENTS

APPENDIX 8

COATING SYSTEM APPROVAL PROCESS FLOW

APPENDIX 9

FLOWCHART FOR INSPECTION OF BLASTING AND PAINTING ACTIVITIES

APPENDIX 10 COLOUR SCHEMES FOR ONSHORE/OFFSHORE INSTALLATION AND EQUIPMENT APPENDIX 11 SPECIFICATIONS FOR BOLTS AND NUTS COATING

PTS 30.48.00.31 September 2012 Page 60 of 78 APPENDIX 1: GUIDELINE ON MAINTENANCE PAINTING CRITERIA AND EXPECTED COATING PERFORMANCE A) MAINTENANCE PAINTING CRITERIA The objective of this guide is to assist the Owner in ensuring a high standard in code of practices to assure high coating performance, whether in new construction or maintenance painting. A contractual arrangement may be necessary whereby the Contractor (or paint manufacturer) are required to supply and apply the paints. Following completion of a new construction or major maintenance painting, a touch up painting shall be carried out. Touch up painting or spot repairs shall be carried out before or at the expiry of the "Ideal/Optimum" service life of the coating systems; while complete repainting shall be carried out at or after the expiry of the "Practical" service life of the coating systems, as illustrated in the graph below.

Concept of "Ideal/Optimum" and "Practical' Service Life of Coating System

Degree of Rusting (%)

10

5

0 0

5

10

15

20

Service Life (yrs) "Ideal/Optimum" Service Life

"Practical" Service Life

The maintenance criteria recommended is stipulated in the table below.

Paint Coating Failure Types Rusting

Category of Painting Assessment No Maintenance Spot Repair Standard required for 2 Only ASTM years or longer D 610

Spot Repair Plus Topcoat

Complete Repaint

Rust Grade 10 Rust Grade 9- 6 Rust Grade 5- 4 Rust Grade 3 -0 (< 0.01% rusting) (< 1% rusting) (1 - 10% rusting) (> 10% rusting)

PTS 30.48.00.31 September 2012 Page 61 of 78 B) EXPECTED COATING PERFORMANCE A facility coated with a reasonable coating system and applied with good workmanship and regular maintenance carried out is expected to perform for certain duration of time. The table below serves as a recommendation and a guide for the Principal to determine total recoating interval, dependent on his intended maintenance frequency and quality of maintenance based on the coating system proposed as per Section 6.2. Classification

Rate of Rusting (ASTM D 610) (% per yr.)

Spot Repairs Interval (yrs)

Type I Type II Type III

0.5 1 2

maximum 2 Maximum 1 maximum 0.5

Spot Repairs Plus Topcoating Interval (yrs) 2 - 15 1 - 10 0.5 - 5

Total Repainting Interval (yrs)

minimum 15 minimum 10 minimum 5

Note: For Type III classification, lower quality coating system than specified in Section 6.2 may be used, especially for facilities of lesser importance or marginal field projects. However, the Principal may consider to carry out total recoating in lesser period than the above guideline based on other options as listed below: 1. 2. 3.

Making full use of the resources meant for other maintenance e.g. scaffolding. Coincide with a major shutdown or revamp project. Other critical issues.

PTS 30.48.00.31 September 2012 Page 62 of 78 APPENDIX 2: GLASSFLAKE POLYESTER GENERIC SPECIFICATION This specification establishes the minimum requirements of a glassflake filled polyester coating. This is recommended to be applied for both topsides and splash zone. 1. Type of Polyester The polyester resin shall be either Bisphenol A or Isophtalic. 2. Wax Content A wax-free coating is preferred. Where wax layers are unavoidable, the wax content shall be as low as possible. The maximum content shall be 0.1% (wt). 3. Glass Flakes The glassflakes used shall be of the chemical resistance type (Type C). The minimum glassflake content shall be 20% by weight. However, the percentage of glass loading can be variable without compromising the system performance with respect to water resistance during immersion and its acceptance shall be based on the results of a successful qualification test. The maximum thickness of the glassflake shall be 5 ± 2 microns. The glassflake particles shall be of 20 microns to 400 microns in any one direction of the planer surface. A maximum of 4% may be allowed outside the above range. Extenders such as silica flour, mica or talc shall not be used. The glassflake is an added product to give a low permeability. Therefore, the maximum permeability should be 0.015 perm cm (0.0006 perm inches) measured in accordance with ASTM D1653. 4. Application Properties The product shall be capable of being applied in one single coat through wet to wet technique by airless spray up to a thickness of 800 microns at a temperature of up to 35 °C without "curtains" or "sags" and in one spray application. 5. Volume Solids The product shall have a volume solid of 95% minimum. 6. Pigment Content The pigment content shall be maximum 3.5% by weight of the resin component. If required, the manufacturer may add UV stabiliser provided the above maximum is adhered to. 7. Shelf Life / Pot Life The shelf life of the base product shall be 6 months minimum at a temperature of 35°C when not stored in direct sunlight. The MEK peroxide shall be stored at a temperature of maximum 30 °C. The pot life shall be 30 minutes minimum at a temperature of 23 °C.

PTS 30.48.00.31 September 2012 Page 63 of 78 8. Drying Time The final product shall be dry to touch within one hour and dry to walk on within three hours at a temperature of 35 °C. 9. Hardness The Barcol hardness shall be within the range of 35 - 45 as measured in accordance with ASTM D2583. 10. Abrasion Resistance The maximum loss in weight shall be below 150 mg when using a Taber Abrasion Tester with a CS-10 wheel, a 1 kg load applied for 1000 cycles. 11. Other Properties A good flexibility of the product is required for the coating to be able to withstand mechanical damage. The required properties shall be Minimum Requirement - Tensile strength (test speed 50 mm/min) 30 N/mm² - Elongation 0.9 % The coefficient of thermal expansion shall be in the same order as that of steel i.e. -6 between 10-90 x 10 /° C. 12. Salt Spray Test The coating shall be able to withstand a salt spray test according to ASTM B117 for 10,000 hours without showing a coating failure. 13. Immersion The coating shall be able to withstand immersion in sea water and distilled water according to ASTM D870-92, test for 6,000 hours at ambient temperature without showing a coating failure such as blistering, loss of adhesion, softening, or embrittlement. 14. Cathodic Disbondment Test The coating shall pass a cathodic disbondment resistant test (<10 mm disbondment) in accordance with ASTM G8 at a potential of -1450 mV (against Ag/Ag Cl) at 30° C. 15. Safety The Manufacturer shall provide the Principal and the relevant applicator with a valid Materials Safety Data Sheets (MSDS).

PTS 30.48.00.31 September 2012 Page 64 of 78 APPENDIX 3:

GLASSFLAKE EPOXY GENERIC SPECIFICATION This specification establishes the minimum requirements of an epoxy glassflake filled coatings recommended for application on both topsides and splash zone. The required dry film thickness shall be 800 microns. 1.

Type Of Epoxy The epoxy resin will be based on liquid epoxy.

2.

Glass Flake The glassflake used shall be of the chemical resistance type 'C' glass. The minimum content shall be 10% by weight. The minimum thickness of the glass flake shall be 5±2 microns with an average length of 400 microns in any direction of the planner surface. However, t h e percentage of glass loading can be variable without a compromise on system performance with respect to water resistance during immersion; and its acceptance shall be based on the results of a successful qualification test. The glassflake is an added product to give a low permeability. Therefore, the maximum permeability should be 0.015 perm cm (0.0006 perm inches) measured in accordance with ASTM D1653.

3.

Spray Application The product is high in viscosity and it is necessary to ensure all equipment is in good working order before attempting to apply. Pump should have a minimum ratio of 45:1. Filters should be removed to avoid filtering out glass flake. It also advisable to check that adequate air volume is present, otherwise a consistent spray fan will not be obtained.

4.

Volume Solids The product should have a minimum volume solids of 90%.

5.

Shelf Life/Pot Life The shelf life of this product shall be 6 months minimum at a temperature of 35°C when not stored in direct sunlight. The pot life shall be 30 minutes at a temperature of 23°C.

6.

Drying Times The product shall hard dry within 4 to 10 hours at temperature range of 25° to 40° C.

7.

Hardness The Barcol hardness shall be within the range of 40 - 50 as measured in accordance with ASTM D2583. (Model GYZJ 935)

8.

Abrasion Resistance The maximum loss in weight shall be below 150 mg when using a Taber Abrasion Tester with a CS-10 wheel, a 1 kg load applied for 1000 cycles.


9.

Other Properties Other properties required to achieve good mechanical properties are as follows :Tensile Strength (ASTM D2370) Elongation (ASTM D2370)

-

10 M Pa (1450 psi.) 2%

The coefficient of thermal expansion shall be in the same order as that of steel i.e. -6 between 10-90 x 10 /° C. 10. Salt Spray Test The coating shall be able to withstand a salt spray test according to ASTM B117 for 10,000 hours without showing a coating failure. 11. Immersion The coating shall be able to withstand immersion in sea water and distilled water according to ASTM D870-92 test for 6,000 hours at ambient temperature without showing a coating failure such as blistering, loss of adhesion, softening, or embrittlement. 12. Cathodic Disbondment Test The coating shall pass a cathodic disbondment resistant test (<10 mm disbondment) in accordance with ASTM G8 at a potential of -1450 mV (against Ag/Ag Cl) at 30° C. 13. Safety The Manufacturer shall provide the Owner and the relevant applicator with a valid Materials Safety Data Sheets (MSDS).

PTS 30.48.00.31 September 2012 Page 66 of 78 APPENDIX 4; STORAGE TANK IDENTIFICATION SYSTEM

t

TK - 123

*

X X

Y

LOCATION OF ITEM NUMBER AND SIZE OF LETTERING FOR STORAGE TANK H = Tank Height Y= 3/5 H L = 2/3 H

t = 1/12 H X = 1 M (Max) Lettering Location

: :

Black Fixed at field

Colour of the square is as described in section 10.2.

PTS 30.48.00.31 September 2012 Page 67 of 78 APPENDIX 5 - PIPING IDENTIFICATION SYSTEM

TYPE

IDENTIFICATION LEGEND

PIPE O.D.

A 1

0.75 - 1.25

2

1.50 - 2.00

3

2.50 - 6.00

4

8.00 - 10.00

5

Over 10.00

FLOW DIRECTION ARROW (Inches)

B

C

D

0. 5

0.7 5

8.0 0

0.7 5

0.7 5

1.0 0

8.0 0

1.0 0

1.2 5

2.2 5

12.0 0

2.2 5

2.2 5

4.0 0

24.0 0

4.0 0

E 4.00 5.00 8.00 12.00 16.00

PIPING IDENTIFICATION SYSTEM

CONDENSATE

A

B

C

D

BLACK OSHA YELLOW

E

IDENTIFICATION OF PIPING SYSTEM (ANSI A 13.1)

PTS 30.48.00.31 September 2012 Page 68 of 78 APPENDIX 6

PIPING COLOUR IDENTIFICATION LEGEND PROCESS LINE Gas Liquid Process DRAIN & RELIEF Drain, Hot Oil Drain, Pressurised Drain, Gravity

Gas Liquid Process

Black/OSHA Yellow Black/OSHA Yellow Black/OSHA Yellow

00-E-53 00-E-53 00-E-53

Hot oil drain Pressurised, drain Hazard, drain

Black/OSHA Yellow Black/OSHA Yellow beige Black/OSHA Yellow

00-E-53 00-E-53 00-E-53

Black/OSHA Yellow Black/OSHA Yellow Black/OSHA Yellow OSHA Blue/White OSHA Blue/White

00-E-53 00-E-53 00-E-53 00-E-55 00-E-55

Black/OSHA Yellow Black/OSHA Yellow OSHA Green/White

00-E-53 00-E-53 00-E-55

OSHA Green/White OSHA Red/white

00-E-55 00-E-55

OSHA Green/White

00-E-55

OSHA Green/White

00-E-55

OSHA Green/White

00-E-55

Condensate Drain Cond. Drain Flare, High Press. HP flare Flare, Low Press. LP flare Vent Vent Vent, Atmospheric Atmosphere vent STEAM & CONDENSATE Condensate Condensate Steam Steam Boiler Feed Water Boiler H2O UTILITY WATER Cooling Water Cooling H2O Firewater/ Fire Fire H2O Extinguishing Potable Water/ Potable H2O Service Water Ballast Water Service H2O Sea Water Washdown Chilled Water Chilled H2O


PIPING COLOUR IDENTIFICATION LEGEND UTILITY & GENERAL Air, Instrument Inst. Air Air, Utility Utility Air Gas, Instrument Inst. Gas Gas, Utility Utility Gas Hydraulic Hydraulic UTILITY GAS & FUEL Blanket Gas Blanket Gas Diesel Fuel Diesel Fuel Aviation Fuel Aviation Fuel Fuel Gas Fuel Gas Nitrogen Nitrogen UTILITY OIL Lube Oil Lube Oil Seal Oil Seal Oil Hot Oil Hot Oil CAUSTIC & CHEMICAL Chemical Chemical Glycol Glycol Caustic Caustic Chlorine Chlorine GENERAL Treated Water Treated H2O Black Water Black H2O Grey Water Grey H2O Hot Water Hot H2O OTHERS To be determined by principal

OSHA Blue/White OSHA Blue/White Black/OSHA Yellow Black/OSHA Yellow Black/OSHA Yellow

00-E-55 00-E-55 00-E-53 00-E-53 00-E-53

Black/OSHA Yellow Black/OSHA Yellow Black/OSHA Yellow Black/OSHA Yellow OSHA Blue/White

00-E-53 00-E-53 00-E-53 00-E-53 00-E-55

Black/OSHA Yellow Black/OSHA Yellow Black/OSHA Yellow

00-E-53 00-E-53 00-E-53

Black/OSHA Yellow Black/OSHA Yellow Black/OSHA Yellow Black/OSHA Yellow

00-E-53 00-E-53 00-E-53 00-E-53

OSHA Green/White OSHA Green/White OSHA Green/White Black/OSHA Yellow

00-E-55 00-E-55 00-E-55 00-E-53

PTS 30.48.00.31 September 2012 Page 70 of 78 APPENDIX 7: Coating Systems Testing Requirements Coating System No

Salt Spray


Adhesion

Impact

Abrasion Water Immersion

Cathodic Disbonding


Heat Resistance

External Coating Systems 1A 1B 1C 2A 2B 2C 3A 3B 4A 4B 5A (1) 5A (2) 5B (1) 5B (2) 6A 7A (1) 7A (2) 7A (3) 8B 11

Note: !

Cyclic Salt Fog/UV Exposure test may be carried out in addition to the Salt Spray and Accelerated Weathering tests whenever considered necessary.

!

Adhesion test shall be carried out using the hydraulic adhesion/tensile tester.

!

Abrasion test is mandatory for coating systems which will be exposed to abrasion, wear and tear


Coating System No

Salt Spray


Adhesion

Impact

Abrasion

Water Immersion

Cathodic Disbonding


Heat Resistance

Internal Coating Systems 13A 14A (1) 14A (2) 14A (3) 15A 16A 16B 16C 17A 18A 19A 19B 19C 19D 20A 21A 21B 22A 22B 22C

Note: !

Adhesion test shall be carried out using the hydraulic adhesion/tensile tester.

!

Abrasion test is mandatory for coating systems which will be exposed to abrasion, wear and tear

APPENDIX 8: COATING SYSTEM APPROVAL PROCESS FLOW

age 2

APPENDIX 9: FLOW CHART FOR INSPECTION OF BLASTING AND PAINTING ACTIVITIES

age 3

APPENDIX 10 - COLOUR SCHEME FOR ONSHORE/OFFSHORE INSTALLATION & EQUIPMENT No.

STRUCTURES /ITEMS

COLOUR

BS 4800 CODE

1.

Splash Zone/Spider Deck Offshore structural members steel below castellation point (shim connection splash zone substructures), spider deck and boat landing

Yellow

10 E 53

2.

Cellar Deck up to Main Deck incl. Bridge Structure Structural members, from cellar deck up to the main deck, castellation point outwards, beams, girders, underside of drip pan, pipe support & cable tray and Bridge structures

Yellow

10 E 53

3.

Risers

Yellow

10 E 53

4.

Footway & stairway supports

Yellow

10 E 53

5.

Grating panel (maintenance only)

Yellow

10 E 53

6.

Handrails

Alert Orange

-

7.

Pressure Vessels, Columns, Heat Exchangers

White

00 E 55

8.

Wellheads

White

00 E 55

9.

Pipeworks except valvesbodies, manifolds and firewater lines *refer to Appendix 6 for Piping Colour Identification

White

00 E 55

White

00 E 55

10. Storage Tank 11. Chemical Tank 12. Instrument Control Panel, Instrument & Lighting stand 13. Module (including Living Quarters) ! Interior Walls and Ceiling ! Exterior Walls ! Production Shed & Equipment Store 14. Helideck a) Structure and underside helideck, footway and Stairway supports, ladders, instrument and lighting stand and cable tray

White With Black stripe White

00 E 55 00 E 53 00 E 55

White White White

00 E 55 00 E 55 00 E 55

White

00 E 55

Holy Green

14-C-39

15. Deck Top of Living Quarters

Forest Green

12 E 53

16. Firewater lines

OSHA Red

-

17. Process/Utility piping, temp > 80 ºC

Aluminium

-

b) Helideck landing

18. Conductor pipes

Yellow

10 E 53

19. Inside drip pan including pipeworks

Black

00 E 53

20. Chequer plates

Yellow

10 E 53

21. Jib crane and gantry crane booms and monorail beams

Alternate Black & Yellow

00 E 53

22. Pumps, motors, Equipment

Mid green

14 E 53

generators

and

other moving

age 4

APPENDIX 11: SPECIFICATION FOR BOLTS AND NUTS COATING

1. PURPOSE The purpose of this specification is to provide general guidelines for coating system of carbon steel and low alloy steel stud bolts and nuts operating below 200°C. The procedure shall be used by all PETRONAS Design Consultants, Purchasers, Fabricators, Hook Up and Commissioning (HUC) Contractors, Skid Package Vendors and Manufacturers in designing, purchasing, manufacturing, storage, handling and installing the stud bolts and nuts for all PETRONAS facilities. 2. SCOPE This specification outlines the requirement for bolt and nut coating for onshore and offshore oil and gas facilities including subsea applications. The guideline is established based on experience at offshore facilities.

3. PROCEDURE 3.1 General Description This section detailed out the requirement for coating system of stud bolts and nuts for systems operating at temperature below 200°C as per Table 1 which consists of: • Basecoat (First Coat) - provides the corrosion resistance • PTFE Based Topcoat (Second Coat) - reduce friction when tightening and loosening the bolting components which is not meant for primary corrosion protection. Coating system st 1 coat nd

2 coat

Zinc Nickel Plating or Ceramic Metal Coating Poly Tetra Fluoro Ethylene (PTFE) Based Coating Table 1: Coating System for Stud Bolts and Nuts

DFT 10-18

µ

25-35 20-35

µ

For systems operating at temperature above 200°C, only basecoat is required unless otherwise specified. 3.2 Base Metal The specified coating systems are intended for use on carbon and low alloy steels or equivalent: • Stud bolts of grades ASTM A193/ A193M and ASTM A 320/ A 320M • Nuts of grade ASTM A194/ A 194M • Washer of grade ASTM F 436/ F 436M • U-bolts of grade A 307/ A 307M 3.3 Surface Preparation Mechanical cleaning and/or chemical treatments shall be used to produce a satisfactory surface for subsequent plating/ deposition and finish coating, i.e. free from soils, environmental matter, drawing compounds, oil grease, discoloration oxides, scale and other foreign matter. Materials used for cleaning shall have no damaging effects on the base metal.

age 5

Surface preparation for zinc nickel plating includes the following: • Overtap Nuts • Degreasing and/or water rinsing • Acid Pickling and/or water rinsing • Abrasive blasting and water rinsing Surface preparation for cermet basecoat includes the following: • Overtap nuts • Bake out • Degreasing • Abrasive blasting Both specified surface preparation for zinc nickel plating and cermet basecoat shall comply with standards in Table 2. Surface Preparation Zinc Nickel Plating Cermet

Standards ASTM B322 and ASTM B183 ASTM B322, ASTM D 4285 and SSPC SP 5 Table 2: Surface Preparation

3.4 Coating System The coating system for stud bolts and nuts shall be as per Table 1. Equivalent or better coating system may be considered subjected to the qualification test and PCSB approval. The detailed requirements on the basecoat shall be as per Table 3:

Basecoat Zinc Nickel Plating

Details •

• • •

Cermet

Zinc Nickel alloyed coating deposited from an alkaline, cyanide free, electrolyte shall have a composition of the coating to be in the range of 12-18% Nickel balance being Zinc. The bolting materials coated with Zinc Nickel alloyed coating shall be phosphate treated in accordance with ASTM D 2092, Method A (12-18 µm) The phosphate treatment is to ensure basecoat is adherent to topcoat. The general plating process shall be as per below: o Zinc Nickel Plating o Visual Inspection o Rinsing o Phosphate conversion treatment1 o Rinsing and drying o Inspection and testing

Note: Chromate (instead of phosphate) conversion treatment is required for stud bolts and nuts with only Zinc Nickel plating. • Ceramic metal coating shall consist of one or more individual layer of product combining pigments that include aluminium and/or metal oxide pigments in an inorganic binder. • The general coating process shall be as per below: o Conventional spray o Baking (oven cured) o Inspection and testing o Burnishing with clean alumina or soft mineral abrasives o Conductivity test (upon recommendation by paint manufacturer) Table 3: Base Coat

age 6

The detailed requirements on the topcoat shall be as per Table 4: Topcoat Details PTFE Based • A PTFE based coating shall be applied as secondary coating corrosion barrier Coating and to reduce torque-up friction during installation. • The general coating process shall be as per below: o Conventional spray o Baking (oven cured) o Inspection and testing Table 4: Top Coat

3.5 Quality Assurance Basecoat and final coat inspection and testing shall be performed as per Table 6 and Table 7 prior to conducting salt spray qualification performance test. Salt spray qualification performance test as per Table 5 shall be performed on the stud bolts and nuts by independent laboratory as per ASTM B117 for either following purposes: a) To qualify new stud bolts and nuts coating applicator; b) To assess the performance and qualify the new coating systems; c) To verify the questionable coating quality and performance of the supplies. Minimum Test Duration 5000 hours

Acceptance Criteria

• The coated specimen shall not be degraded to a condition inferior to Rust Grade 5 (≤ 3% rust) per ASTM D 610 • Nuts must be capable of being easily loosened Table 5: Salt Spray Qualification Performance Test

3.6 Quality Control Basecoat and final coat inspection and testing shall be performed as per Table 6 and Table 7) Inspection/ Testing

Test Method

Frequency

Visual Examination

n/a

ASTM B602 Level I, highest quality level

DFT

ASTM B 499

Adhesion Test Conductivity Test

ASTM D 6677

ASTM B602 Level I, highest quality level 1 piece per lot

Curing Test – Rub Test

Acceptance Criteria ZnNi

Cermet

Surface: uniform and free from defects e.g. mud cracking, pits, cracks, blisters, exfoliation or growths. As per Table 1 in Section 5.1

As per coating ASTM B602 Level n/a manufacturer I, highest quality recommendation level As per coating ASTM B602 Level n/a manufacturer I, highest quality recommendation level Table 6: Basecoat Quality Control

Rating not less than 8 As per coating manufacturer recommendation As per coating manufacturer recommendation

age 7

Inspection/ Testing

Acceptance Criteria (ZnNi/ Cermet + PTFE Based Coating) Free of surface defects e.g. blisters, pits, pimples, cracks, etc. As per Table 1

Test Method

Frequency

Visual Examination

n/a


DFT (flat end of the stud bolt and nut) DFT (externally threaded stud bolt) Adhesion Test Curing Test – Rub Test

ASTM B 499


ASTM B 487

1 piece per lot

ASTM D 6677

1 piece per lot

Rating not less than 8

As per coating manufacturer recommendation ASTM D 3363


As per coating manufacturer recommendation

1 piece per lot

Minimum 4H

Hardness Test – Pencil Hardness

Table 7: Final Coat Quality Control 3.7 Marking, Packaging and Handling The coated stud bolts and nuts shall be visibly die-stamped with manufacturer’s company logo/ trademark and Grade. The externally threaded stud bolts are to be assembled with matching pairs of coated nuts. The stud bolts and nuts shall be properly packed in bubble pack or nylon netting. Proper handling of the coated stud bolts and nuts shall be done to avoid coating damage. 3.8 Plating and Coating Repair Any rejected stud bolts and nuts plating/ coating during manufacturing shall be reworked instead of spot repair. The rework at threaded areas shall be controlled within the tolerance specified by UNC qualified by microscopic evaluation or profile projector. Plating and coating failure during or after installation shall be rectified as per coating applicator’s recommendations. 4.0 SPECIAL REQUIREMENTS 4.1 Material Receiving Inspection The materials receiving inspection shall be witnessed by assigned painting/ coating inspector with the issuance of Inspection Release Note before shipment after final inspection as per Table 7 at manufacturer’s site. Documentation review is as per Appendix 11, Section 5.0 during shipment at site.

age 8

4.2 Colour Coding Finish colour shall be as per Table 8 unless otherwise specified. Services High Temperature Low Temperature

Grades Bolts ASTM A193-B7/ B7M and Nuts ASTM A194-2H/ 2HM Bolts ASTM A320-L7/ L7M and Nuts ASTM A194-7M

Colour Blue Green

5.0 DOCUMENTATION 5.1 General This procedure shall be kept by QA/QC manager and shall be made available to the assigned inspector for reference. 5.2 Test Certificates All bolts and nuts supplied shall be accompanied with complete test certificates for all testing specified. Each test certificate shall be signed by an authorized company officer with the name legibly displayed. Certificates shall be issued with following details: a) Bolts and nuts material certificate b) Batch number c) Date d) Number, type and size e) Testing results Test reports shall be submitted for each batch of bolts and nuts delivered to COMPANY and shall consist of following details as a minimum: a) Visual examination test results b) Dry film thickness test results (basecoat and topcoat) c) Curing test results d) Adhesion test results e) Pre-coating data including heat treatment report f) Coating material certificates

Petronas Technical Standard (Pts 30.48.0031 Sept2012)

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