Procedure for Painting of Tanks

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Procedure for Painting of Tanks at Site

PROCEDURE FOR ABRASIVE BLASTING AND PAINTING OF TANKS AT SITE

Rev

Date

Cause of Revision

0

23-Nov-2015

First Submission

Prepared by

Reviewed by

Authorized by

___________________ ____________________________ ___________________ ___________________ ___________________ __________________ _____________________ ______________________ _________________ _________ _ Page 1 of 18

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TABLE OF CONTENTS

1

GENERAL

3

2

DEFINITIONS

3

3

REFERENCE DOCUMENTS

3

4

SCOPE OF WORK

4

5

RESPONSIBILITIES

5

6

TOOLS AND EQUIPMENTS

7

7

MATERIALS

8

8

WORK PROCEDURE

9

9

QUALITY CONTROL MEASURES

12

10

INSPECTION & TESTING

14

11

STORAGE

16

12

WASTE DISPOSAL

17

13

SAFETY

17

14

ANNEXURE – 1 TECHNICAL DATA SHEET OF PAINT

18

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1. GENERAL

This procedure provides information concerning the materials, equipment, tools and method of application to ensure compliance with project specification, contract requirements, regulatory requirements, drawings and quality control for Surface Preparation, Supply & application of Paint on external of tanks for Al Taweelah Alumina refinery.

2. DEFINITIONS

COMPANY

– means

CONSULTANT

– means

CONTRACTOR

– means

SUB-CONTRACTOR

– means specialized agency for painting works

MANUFACTURES/SUPPLIER – means party which manufactures and supplies materials like garnet and paint.

3. REFERENCE DOCUMENTS

The following reference documents form a part of this method statement.



General Specification for Painting.



Manufacturers technical data sheets, recommendations, and instructions.



Project Specific EHS Plan Procedure –



Construction Environmental Control Plan -



Abu Dhabi Codes of Practice: a) CoP 48 – Spary Painting

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b) CoP 49- Compressed Gas Cylinders c) CoP 50 – Abrasive Blasting and Protective coating

4. SCOPE OF WORK

The paint shall be applied on the external surface of the tanks where insulation will be installed to prevent corrosion. The painting of structural supports is not included in this procedure.

Details of tanks to be painted as per the contract is listed in the Table-1.

Table -1

5. RESPONSIBILITIES

5.1 Project Manager Shall be responsible for controlling all activities in accordance with project schedule. 5.2 Site Engineer/ Supervisor / Foreman

1. Shall make sure the personnel for execution of the job are well aware of the procedure. 2. Shall ensure all the personnel are capable to operate the equipments (like Compressors, Blasting & Painting units, etc.) for which they are deployed. 3. Shall ensure only approved coating and blasting materials are used. 4. Shall ensure that only calibrated equipment (Compressor, blasting/painting units, etc.), blasting and paint material are received at site. Calibration shall be done by third party. 5. Shall ensure the coating materials are stored at site as per the manufacturer technical data sheet/MSDS. 6. Shall check and ensure that the weather conditions are acceptable as per contract specification requirements. ________________________________________________________________________________________________ Page 4 of 18

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7. Shall check and ensure surface cleanliness, profiles, salt contamination, WFT, DFT, visual conditions are as per the approved procedure 8. Shall ensure the time lapse between abrasive blasting and coating and curing time between each coat. 9. Shall ensure and monitor the good working condition of blasting and painting equipments. These equipments needs to be cleaned before and after each shift. 10. Shall keep the MSDS at work and paint storage area 11. Shall ensure all the coating activities are carried out as per project specification. 12. Shall ensure all the personnel’s involving coating operations are wearing PPE an d all Safety equipments / tools are available. 13. Shall inspect and ensure safety requirements are implemented. 14. Shall ensure all the activities are recorded and signed off by the authorized personnel.

5.3 Quality Control Engineer

1. QA & QC Inspector shall ensure that all work are executed as per project specification, project quality plan and procedures. 2. Shall ensure all the measuring and testing equipments are available and duly calibrated and risk analysis carried out before induction in to service. 3. Shall ensure the approved procedure is followed as per Project specification. 4. Shall monitor the environmental condition as per Project specification 5. Shall inspect blasted and painted surfaces (cleanliness, surface profile, salt contamination, WFT, DFT, painted surface finish) 6. Shall prepare the daily painting inspection reports. 7. Shall ensure that all tests are undertaken and, in the case of witness tests and inspections that the Company’s representative is present 8. Shall ensure only approved and accepted blasting and coating materials are used. 9. Issuing final acceptance for coating and releasing the items to Contractor for further process

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5.4 ESH Officer

1.

Shall verify the works are carried out in accordance with the Project and Abu Dhabi HSE regulations and site requirements.

2.

Shall ensure only authorized personnel are permitted to enter into work place and it is prohibited without an authorized permit to work (PTW).

3.

Shall verify the availability of material safety data sheet at site and store room and implement all the provisions stipulated in the data sheet.

4.

Shall verify that all personnel are wearing PPE and fire extinguishers are available at site / store room.

5.

Shall verify that the hoses and equipment are in good and safe working condition.

6.

Shall ensure that dead man switch is attached to the hose.

5.5 Blaster

1.

Shall ensure the blasting equipments and hoses are in good working condition on daily basis before starting the works.

2.

Shall ensure that all blasting accessories are in working condition before starting the works on daily basis

3.

Shall ensure that specified surface finish and profile are achieved.

4.

Shall ensure blasting air is free from moisture, oil and dust

5.

Shall have a control over exclusion zone around activity

6.

Shall ensure all correct respiratory protective equipment and coveralls are used to complete the job. Respiratory protective equipment is to be stored in a hygienic manner

7.

Shall take care not to blast towards any personnel

5.6 Painters

1. Shall ensure by daily pre-work check that all tools and equipments are in good working condition. All tools and equipments are to be cleaned at the end of each shift ________________________________________________________________________________________________ Page 6 of 18

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2. Shall ensure proper mixing of paint components 3. Shall clean and maintain the painting tools and equipments 4. Shall ensure correct nozzle size as per the paint manufacturer recommendation used. 5. Shall ensure correct WFT / DFT achieved 6. Shall ensure the painted surface is free from any visual defects. 7. Shall have a control over exclusion zone around activity

5.7 Scaffolders

5.8 Helpers

1. Shall verify all the equipments are in a ready condition to use and ensure the quality of air, control pressure, condition of coupling, hoses, etc. and free from any leakages. 2. Shall ensure all the helps whatever necessary for the execution of this project

6. TOOLS AND EQUIPMENTS

Blasting & Painting shall be carried out using following equipments, whichever is suitable.



Air Compressor 850cfm or 750cfm.

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Blast Pots 200Ltrs Capacity.

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Air after Coolers.

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Air Receiver Tank.

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Blasting equipment with dead man switch

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Pneumatic Hand Held mixer for mixing Paints.

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Airless Spray Pump with hoses and tip sizes as per recommendation of the paint manufacturer in their data sheet.

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Painting Inspection Equipments (like profile gauge, DFT meter, Testex Tape)



Hygrometer & Dew Point Calculator

7. MATERIALS

7.1 Abrasives

The abrasive used for blasting carbon steel shall be garnet 30/60 for surface preparation. Batch Certificates of abrasive will be documented for each abrasive batch received at site. MSDS shall be approved by BPJV ES&H prior to site use.

7.2 Paint Materials

1. All paints and paint materials used must be obtained from Manufactures approved by BPJV. 2. All paint materials shall be factory tinted, sealed, and labeled. Thinners and solvents shall be identified in the paint Manufacturers data sheets. 3. The paint container must need the batch number, date of manufacture, the shelf-life expiry date and the Manufacturers name or trade mark. All paint materials shall be used on a first-in, first-out basis. 4. MSDS shall be approved by BPJV ES&H prior to delivery to site.

7.3 Coating System and Materials

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8. WORK PROCEDURE All required permits /approvals need to be obtained from BPJV prior to start of work

8.1 Pre Blasting Activities

1.

Painting shall be done after the completion of erection works for each tank.

2.

Erect necessary scaffolding around the tank

3.

Erect necessary screens (green net) around the work area to prevent contamination and to prevent the spreading of garnet and paint.

4.

Before abrasive blast cleaning, all area which does not require painting shall be suitably protected by wrapping, taping, or other means.

5.

Remove all weld burrs, weld spatters and flux, protrusions and other foreign matters by

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grinding. 6.

Dust, dirt and debris shall be removed from the substrate by high pressure water washing. Where necessary, stubborn deposits shall be removed by scrubbing with stiff plastic brushes.

7.

Surface contaminants such as oil, grease, hydrocarbons etc. shall be removed by water based cleaner. Cleaner concentration shall be according to manufacturer’s recommendations.

8.2 Surface Preparation/Abrasive Blasting Operation 1.

The compressed air supply used for blast cleaning shall be free from water and oil.

2.

When the surface is dry, blast clean the surface to blasting standard as per specification and requirement.

3.

Weld spatters, laminations or other surface irregularities if found shall be ground out and reblast cleaned.

4.

Inspect the surface for surface cleanliness and surface profile.

5.

Blast cleaning shall be done from top to bottom of tank

6.

Blast cleaning shall only be conducted when the steel surface temperatures are minimum 3 degree Celsius above the dew point.

7.

Prior to commencing of any blasting operation previously coated surfaces shall be adequately protected to avoid damage of coated surfaces and surface irregularities shall be removed.

8.

Abrasive used shall be Garnet.

9.

After surface preparation is accomplished, visually check in day light, the surface is free of metal defects, dust & debris or any remaining traces of abrasives.

8.3 Painting Activities 1.

Use the correct paint system specified for the materials. Apply the type and colour of paint as required by the system number.

2.

Do not paint the surfaces that will undergo welding or bolts and area next to field welds.

3.

Painting shall not take place during bad weather conditions specified in quality control measures.

4.

Immediately after blast cleaning or within 4 hours from commencement of blast cleaning and

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after QC approval, the first coat shall be applied as per manufacturer's recommendations 5.

Paint shall be applied by Spraying/Brushing/Roller

according to the manufacturers’

recommendation and site condition. 6.

Clean the spray pump, hoses etc. using cleaners before painting. Hose and containers shall be thoroughly cleaned before addition of new materials.

7.

Thinning, mixing and handling, of paint materials shall be in accordance with the paint data sheet.

8.

Thoroughly mix paints in their shipping containers using mechanical agitators.

9.

Paint shall be applied from top to bottom

10.

Each paint coat shall be applied in a manner that will produce an even, continuous film of uniform thickness.

11.

Edges, corners, joints, welds and other surface irregularities shall receive special attention to ensure that they receive adequate thickness of paint.

12.

No coating shall be applied until the preceding layer has dried thoroughly. The over coating intervals as recommended by manufacturer must be followed.

8.4 Repair / Field Touch up Procedure

1.

The repair procedure for each system shall be as recommended by paint manufacturer.

2.

Visually Inspect surface areas for contamination such as oil, grease, dust / dirt etc.

3.

Mechanically clean the area using wire brush or spot blast as per paint manufacturer recommendation.

4.

Visually examine to ensure all surfaces are cleaned up to standard.

5.

Paints shall be applied by brush, roller or spray pump in accordance with paint specification and paint manufactures instruction.

6. Apply primer as per specification where ever required. 7.

Apply finish coat for the entire surface.

8.

Make sure to keep the minimum and the maximum recoating interval.

9.

If the surface being prepared lies adjacent to a coated surface which is not to be repaired, the surface preparation shall overlap the coated surface by at least 25mm.

10.

Areas with inadequate coating thickness shall be thoroughly cleaned and additional compatible

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coats applied until they meet the specification. These additional coats shall blend in with the final coating on adjoining areas. Color match shall be achieved.

9. QUALITY CONTROL MEASURES 9.1. Surface Preparation

1. Obtain all batch certificates for abrasive and paint materials. 2. For blasting, abrasives shall be Garnet 30/60. 3. Compressed air shall be clean, dry, oil free, and supplied at a temperature of less than 110 0C. 4. Moisture and oil traps shall be used in compressed air lines for blast cleaning and airless spray equipments. 5. Compressed air pressure shall not be less than 90psi unless for sweep blast cleaning where lower pressures to 40 psi can be used. 6. Abrasive for blast cleaning shall be sharp, angular, clean, dry and free of oil or contaminants. The particle size shall be capable of producing the specified surface profile. The degree of cleanliness and depth of the profile shall be recorded. 7. Blast cleaned surfaces shall be primed as shortly as possible, maximum 4 hours if weather is stable. 8. Blast cleaned surface must meet the requirements of the surface preparation standard specified for a particular painting system. 9. Surface preparation shall be inspected before prime coat is applied to ensure all traces of dust and foreign matter have been removed by brushing, blowing with clean compressed air. 10. Weld spatters, laminations or other surface irregularities if found shall be ground out and reblast cleaned. 11. The surface profile shall be inspected prior to the application of the prime coat. 12. The blast profile for dry abrasive blast cleaning must be above 50 microns as measured from peak to the trough or as per specified in manufacturers product data sheet, but shall not exceed 75 microns. Re-blasting of carbon steel to remove old coatings will generally result in lower surface profile.

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9.2. Paint Application

1.

Unless otherwise recommended by Manufacturer, coating shall not be applied when: 

The ambient temperature is less than 10 0 C



The relative humidity is more than 80% .



The surface temperature is less than 3 0C above the dew point.



The metal surface temperature is higher than that recommended by the manufacturer for application.



Where there is a deposition of moisture in the form of rain, condensation, frost, etc. on the surface.

2.

The paint container must contain the batch number, date of manufacture, the shelf-life expiry date and the manufacturers name or trade mark.

3.

Store the paint material in a pre-assigned area at the temperature range specified in the material data sheet and site requirements.

4.

Stainless steel, nonferrous materials etc. which do not require painting shall be effectively masked to protect from overspray and drips of paint.

5.

Thinning, mixing and handling, of paint materials shall be in accordance with the paint data sheet.

6.

For paint materials, manufacturers pot-life and induction time requirements shall be followed.

7.

All paint materials shall be used on a first-in, first-out basis.

8.

All containers shall remain closed in factory sealed containers until required for use.

9.

Hose and containers shall be thoroughly cleaned before addition of new materials.

10.

Before priming verify that elapsed time from blasting has not exceeded specified time between blasting and painting.

11.

The spray gun shall be held no closer than 200mm or more than 600mm from the surface to be coated. Each pass shall overlap the previous one by 50%. When large surface areas are being coated, spray application shall be made in two directions so that the passes are at right angles to each other.

12.

The spray equipment, nozzles and sizes of tips for the spray guns shall meet the paint manufacturer’s recommendation for a specific paint material.

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13.

Prior to the application of each coat, all weld joints, corners etc. stripe coated by a brush to ensure that these areas have the minimum film thickness specified for each coat.

14.

Extra coats of paint shall be applied on areas where shape and/or plane of application results in thinly applied coating; e.g. at edges, welds, corners, etc. To compensate for these effects, a stripe coat of paint shall be brush applied before applying the finish coat.

15.

All coatings shall be uniformly applied without runs, sags, solvent blisters, dry spray or other blemishes.

16.

No coating shall be applied until the preceding layer has dried thoroughly. The over coating intervals as recommended by manufacturer must be followed.

17.

Coatings that have been left to cure past the manufacturers recommended re-coat interval must be abraded to roughen the surface to allow adhesion of the new coating. The manufacturers re-coat instructions should be followed.

18.

Inter coat contamination shall be minimized by maintaining proper cleanliness and by applying intermediate and finish coats within the time period recommended by the Manufacturer. If contaminants are present, they shall be removed before applying succeeding coats.

19.

Document and submit daily progress report, daily weather report, and daily inspection report.

10. INSPECTION AND TESTING

The following inspections should be conducted during blasting and painting activities.

10.1 Pre Blasting Inspections

1.

All paint materials and abrasive delivered to site shall be accompanied with the batch certificates.

2.

The Technical data sheets and material data sheets must be readily available at site.

3.

Verify that the paint material is stored in a pre-assigned area at the temperature range specified in the material data sheet.

4.

Verify that surfaces not to be coated are masked off or otherwise protected.

5.

Verify that the surfaces are free of oil, grease etc.

6.

The solvent used for cleaning must be recommended by paint manufacturer.

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7.

Scaffolding is in good condition and ready for use. Scaffolding needs to be inspected and signed daily

8.

Blast containment media are in good condition and there are no escape route for blast media to enter atmosphere.

10.2 Surface Preparation Inspections

1.

Inspections shall be carried out to verify that weather conditions are within the specified limits for blasting and painting, and shall be recorded at every 2 hours interval, more frequently during adverse weather conditions.

2.

Verify the pressure and cleanliness of compressed air used for blasting using blotting paper.

3.

Blasting of the steel surfaces – Visual inspection to ascertain the degree of cleaning as per SSPCVis-1.

4.

The profile of blasted surfaces shall be checked by Profile gauge and Tape.

5.

Inspect the surface for corrosion pitting, metal loss etc.

6.

Ensure that the correct grade of Tape is used to record the profile. Tape shall be added to the daily QC report as permanent record.

7.

Substrate shall be checked for soluble salt contamination using an approved salt contamination meter. The maximum allowable level of contamination shall be 50mg/m 2. Surfaces that do not meet this criterion shall be reprocessed.

8.

Surface preparation shall be inspected before prime coat is applied to ensure all traces of dust and foreign matter have been removed by brushing, blowing with clean compressed air.

10.3 Paint Application Inspections

1.

Record batch numbers of the paint materials for each painting activity.

2.

Verify that the shelf life of the paint material has not been exceeded before application.

3.

Verify method of application is as recommended by paint manufacturer.

4.

Verify the mixing of the paint material.

5.

Verify that the substrate, ambient and material temperatures are within the range specified in the

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material data sheet. 6.

Verify the humidity and dew points are within the specified limits.

7.

Verify the method of application, time interval between coats, number of coats applied and the minimum cure time of paint materials are according to material data sheet.

8.

Verify that pot life of mixed materials has not been exceeded.

9.

Verify by spot checking the wet film thickness (WFT) during the course of the paint application to ensure that the film thickness is maintained.

10.

Verify the proper curing of the coating.

11.

The required dry film thickness of each coat shall be in accordance with the requirements stated in the Shaheen project specification.

12.

All inspection instruments should have a valid Calibration certificates

13.

Verify the gauges are properly calibrated and the readings obtained are recorded.

14.

The DFT inspection for the paints on the various items shall be as per paint system tables as per SSPC PA2 and should be attached in the inspection report.

15.

Each coat of a system and the complete system shall be visually inspected for the surface imperfections.

16. The adhesion of the primer to the substrate and the intercoat adhesion of the subsequent coats after curing must be tested for adhesion qualification test by the application of either a cross-cut test or a pull-off test on test panels. The test panels shall be coated at the same time and under same conditions as the production work. 17.

Approved Inspection and Test plan (ITP), and Daily Inspection reports must be prepared and kept up to date.

10.4 Inspection Instruments

1. All Inspection Instruments should have a Valid Calibration certificates. 2. Instruments should be calibrated before using.

11. STORAGE OF PAINTS ________________________________________________________________________________________________ Page 16 of 18

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Storage of paints shall be as per MSDS from manufacturer for the specified paint

12. WASTE DISPOSAL 1.

All empty paints, thinner drums shall be safely stored in a designated place at the site approved by the client. Necessary sign board, warning and barricading shall be provided at this designated waste storage area.

2.

Ensure no flammable thinners, paints are present in the designated area that may catch fire. The waste storage area shall be away from direct sunlight and sources of heat.

3.

Used Abrasives shall be collected in Jumbo bags and shall be taken back by subcontractor.

4.

All waste shall be disposed as per the requirements stipulated by the regulatory authorities.

13. HSE Ensure the following points 1.

Strictly Adhered Project HS&E Requirement.

2.

Ensure work permits to be obtained before start of Job.

3.

Daily /weekly information to be issued for information to other party.

4.

Blasting area to be fenced to avoid unauthorized entry.

5.

Blasting area to be surrounded by a boundary of Green Netting/Tarpaulin.

6.

The nearby facilities should be covered if required to avoid impact from blasting.

7.

All persons to be equipped special with PPEs in addition to general requirement.

8.

Trained and competent persons are allow to do Blasting and painting job.

9.

Blasting hose nozzle and clamps to be checked on regular basis and ensure the daily checklist signed by operator.

10.

No persons except blaster and his helper are allowed around the Blast cleaning area.

11.

All electrically operated machines to be properly earthed and inspected by competent person.

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12.

Stacking of paint drums should do in a well-ventilated place and designated area.

13.

Availability of fire extinguisher to be ensured.

14.

Hot works are not allowed in the vicinity of the painting area.

15.

Identification of hazards. Ensure that all concerned are aware of all the hazards and control methods.

16.

Working area safety barricading must be required to avoid incidents & accidents.

17.

Proper Inspection of all Equipment’s prior t o use to avoid equipment failure.

14. Annexure 1 – Technical Data Sheet of Paint

Please refer attachment

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Procedure for Painting of Tanks

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