PTS 15.20.03

PETRONAS TECHNICAL STANDARD

Protective Coatings and Linings

PTS 15.20.03 February 2016

© 2016 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. PETRONAS Technical Standards are Company’s internal standards and meant for authorized users only.

PTS 15.20.03 PROTECTIVE COATINGS AND LININGS

February 2016 Page 2 of 111

FOREWORD

PETRONAS Technical Standards (PTS) has been developed based on the accumulated knowledge, experience and best practises of the PETRONAS group supplementing National and International standards where appropriate. The key objective of P TS is to ensure standard technical practice across the PETRONAS group. Compliance to PTS is compulsory for PETRONAS-operated facilities and Joint Ventures (JVs) where PETRONAS has more than fifty percent (50%) shareholding and/or operational control, and includes all phases of work activities. Contractors/ Manufacturers/ Suppliers who use PTS are solely responsible in ensuring the quality of work, goods and services meet the required design and engineering standards. In the case where specific requirements are not covered in the PTS, it is the responsibility of the Contractors/ Manufacturers/ Suppliers to propose other proven or internationally established standards or practices of the same level of quality and integrity as reflected in the PTS. In issuing and making the PTS available, PETRONAS is not making any warranty on the accuracy or completeness of the information contained in PTS. The Contractors/ Manufacturers/ Suppliers shall ensure accuracy and completeness of the PTS used for the i ntended design and engineering requirement and shall inform the Owner for any conflicting requirement with other international codes and technical standards before start of any work. PETRONAS is the sole copyright holder of PTS. No part of this document may be reproduced, stored, in a retrieval system or transmitted in any form or by any means (electronic, mechanical, recording or otherwise) or be disclosed by users to any company or person whomsoever, without the prior written consent of PETRONAS. The PTS shall be used exclusively for the authorised purpose. The users shall arrange for PTS to be kept in safe custody and shall ensure its secrecy is maintained and provide pro vide satisfactory information to PETRONAS that this requirement is met.



FOREWORD

PETRONAS Technical Standards (PTS) has been developed based on the accumulated knowledge, experience and best practises of the PETRONAS group supplementing National and International standards where appropriate. The key objective of P TS is to ensure standard technical practice across the PETRONAS group. Compliance to PTS is compulsory for PETRONAS-operated facilities and Joint Ventures (JVs) where PETRONAS has more than fifty percent (50%) shareholding and/or operational control, and includes all phases of work activities. Contractors/ Manufacturers/ Suppliers who use PTS are solely responsible in ensuring the quality of work, goods and services meet the required design and engineering standards. In the case where specific requirements are not covered in the PTS, it is the responsibility of the Contractors/ Manufacturers/ Suppliers to propose other proven or internationally established standards or practices of the same level of quality and integrity as reflected in the PTS. In issuing and making the PTS available, PETRONAS is not making any warranty on the accuracy or completeness of the information contained in PTS. The Contractors/ Manufacturers/ Suppliers shall ensure accuracy and completeness of the PTS used for the i ntended design and engineering requirement and shall inform the Owner for any conflicting requirement with other international codes and technical standards before start of any work. PETRONAS is the sole copyright holder of PTS. No part of this document may be reproduced, stored, in a retrieval system or transmitted in any form or by any means (electronic, mechanical, recording or otherwise) or be disclosed by users to any company or person whomsoever, without the prior written consent of PETRONAS. The PTS shall be used exclusively for the authorised purpose. The users shall arrange for PTS to be kept in safe custody and shall ensure its secrecy is maintained and provide pro vide satisfactory information to PETRONAS that this requirement is met.



ANNOUNCEMENT

Please be informed that the entire PTS inventory is currently undergoing transformation exercise from 2013 – 2015 which includes revision to numbering system, format and content. As part of this c hange, the PTS numbering system has been revised to 6-digit numbers and drawings, forms and requisition to 7-digit numbers. All newly revised PTS will adopt this new numbering system, and where required make reference to other PTS in its revised numbering to ensure consistency. Users are requested to refer PTS 00.01.01 (Index to PTS) for mapping between old and revised PTS numbers for clarity. For further inquiries, contact PTS administrator at [email protected]



Table of Contents 1.0

INTRODUCTION .......................................................................................................... 7 SCOPE .................................................................................................................................. 7 GLOSSARY OF TERM ............................................................................................................ 7 1.3

2.0

SUMMARY OF CHANGES ................................................................................................... 11

WARRANTY .............................................................................................................. 12 GENERAL ............................................................................................................................12

3.0

COATING AND COATING SYSTEMS ............................................................................ 14 COATING SYSTEMS SELECTION.......................................................................................... 14 NEW CONSTRUCTION COATING SPECIFICATIONS ............................................................. 15 MAINTENANCE COATING SPECIFICATIONS ....................................................................... 21 COATING SYSTEM PRODUCT APPROVAL REQUIREMENT.................................................. 25 PRODUCT QA/QC REPORT ................................................................................................. 25 COATING QUALITY CONTROL BATCH CERTIFICATE ........................................................... 25

4.0

COATING CONTRACTORS RESPONSIBILITIES .............................................................. 27 GENERAL ............................................................................................................................27 HSE..................................................................................................................................... 27 HAZARDOUS COATING COMPONENTS.............................................................................. 28 PERSONNEL........................................................................................................................ 28 PROTECTION OF EQUIPMENT AND STRUCTURAL MEMBERS ........................................... 28 BLASTING AND SPRAYING EQUIPMENT............................................................................. 29 ACCESS............................................................................................................................... 29 HANDLING OF COATED PARTS/COMPONENTS ................................................................. 29 STORAGE PROTECTION ...................................................................................................... 30 SHELF-LIFE.......................................................................................................................... 30

5.0

SURFACE PREPARATION ........................................................................................... 31 SURFACE PROFILE .............................................................................................................. 31 GRADES OF SURFACE FINISH ............................................................................................. 32 SURFACE PREPARATION BY HAND AND POWER TOOL CLEANING.................................... 32 SURFACE PREPARATION METHOD- STAINLESS STEEL, GALVANIZED STEEL, NICKEL ALLOY AND NON-FERROUS ALLOY ............................................................................................................ 33

6.0

APPLICATION ........................................................................................................... 34 PRE-APPLICATION PROCEDURES ....................................................................................... 34



APPLICATION CONDITION.................................................................................................. 35 APPLICATION METHODS .................................................................................................... 36 REPAIRS AND TOUCH UP COATING ................................................................................... 38

7.0

QUALITY CONTROL (QC) ........................................................................................... 40 GENERAL ............................................................................................................................40 QUALITY REQUIREMENTS .................................................................................................. 40 INSPECTION AND TESTING................................................................................................. 41 PROCEDURE AND REPORT ................................................................................................. 41

8.0

RESOURCE REQUIREMENT ........................................................................................ 43 COATING CONTRACTOR .................................................................................................... 43 INSPECTION EQUIPMENT .................................................................................................. 46

9.0

HEALTH, SAFETY AND ENVIRONMENT (HSE).............................................................. 47 SAFETY AND HEALTH REGULATIONS ................................................................................. 47 ENVIRONMENTAL REGULATIONS ...................................................................................... 48

10.0

COLOUR SCHEMES .................................................................................................... 49 STRUCTURAL COLOUR SCHEMES....................................................................................... 49 PIPING COLOUR SCHEMES AND IDENTIFICATION SYSTEM ............................................... 49 EQUIPMENT COLOUR SCHEME.......................................................................................... 49 PIPELINE/RISER IDENTIFICATION SYSTEM ......................................................................... 49 SAFETY COLOUR SCHEME .................................................................................................. 50

11.0

BIBLIOGRAPHY ......................................................................................................... 51

APPENDIX 1: COATING SYSTEM PRODUCT APPROVAL REQUIREMENT .................................. 57 APPENDIX 2: COATING FINGERPRINT CERTIFICATE FOR 2 -COMPONENT INTERMEDIATE MATERIALS OF POLYMERIC COATINGS ............................................................. 59 APPENDIX 3: APPROVED VENDOR COATINGS LIST ................................................................ 62 APPENDIX 4: GLASS FLAKE POLYESTER GENERIC SPECIFICATION ........................................... 77 APPENDIX 6: STORAGE TANK IDENTIFICATION SYSTEM ........................................................ 81 APPENDIX 7: PIPING IDENTIFICATION SYSTEM ..................................................................... 82 APPENDIX 8: PIPING COLOUR IDENTIFICATION LEGEND ....................................................... 83 APPENDIX 9: COLOUR SCHEME FOR ONSHORE/OFFSHORE INSTALLATION AND EQUIPMENT 85 APPENDIX 10: ESCAPE ROUTE .............................................................................................. 90 APPENDIX 11: INSPECTION AND TESTING REQUIREMENTS ................................................... 91 APPENDIX 12: RISK MATRIX ................................................................................................. 93



APPENDIX 13: TYPICAL COATING QUALITY INSPECTION AND TEST PLAN CHECKLIST ............. 94 APPENDIX 14: COATING DAILY INSPECTION REPORT TEMPLATE ........................................... 96 APPENDIX 15: ITEMS TO BE EXCLUDED FROM PTS 15.20.03 .................................................. 97 APPENDIX 16: MAINTENANCE COATING .............................................................................. 99 APPENDIX 17: SURFACE PREPARATION BY BLAST CLEANING .............................................. 101 APPENDIX 18: RECOMMENDED ORGANISATION CHART FOR COATING WORK EXECUTION . 109 APPENDIX 19: REGULATIONS ON ABRASIVES, COATING PRODUCTS, WASTE PRODUCTION, PRODUCT STORAGE AND LEACHING OF COATINGS ...................................... 110



1.0

INTRODUCTION

This PTS provides the minimum technical requirement for surface preparations, application procedures, selection of coating and coating systems, enhanced quality control measures, personnel qualifications and updated colour schemes to be used on metallic substrates requiring corrosion protection for new construction and maintenance. SCOPE

1.1.1

The PTS covers both external and internal coating for onshore and offshore facilities on metallic substrates for domestic and international projects. It shall also include initial and maintenance coating.

1.1.2

This standard is only applicable to the following listed environments: i.

Atmospheric (Insulated and Non-Insulated)

ii.

High Temperature

iii.

Immersed

iv.

Splash Zone

v.

Spray Zone

vi.

Sweating

1.1.3

Services which are not covered under this PTS and required to be coated shall be referred to the Owner to advise the appropriate coating system.

1.1.4

Specialised equipment supplied by vendors such as valves, pumps, compressors, etc. shall be coated in accordance to specific coating systems as dictated by the environment in Section 3.0 of this PTS.

1.1.5

Other items excluded from this PTS as listed in Appendix 15. GLOSSARY OF TERM

1.2.1

General Definition of Terms & Abbreviations Refer to PTS Requirements, General Definition of Terms, Abbreviations & Reading Guide PTS 00.01.03 for General Definition of Terms & Abbreviations.

1.2.2

Specific Definition of Terms No

Term

Definition

1

Chalking

The appearance of a loosely adherent fine powder on the surface of a coating coating, arising from the degradation of one or more of its constituents.



No

Term

Definition

2

Coat

One layer of a coating applied to a substrate in a single, continuous application to form a uniform film when dry.

3

Coating System

The complete number and types of coats applied to a substrate in a predetermined order. The system includes surface preparation, procedures and materials, coating materials, sealants, application method, and environmental controls including special procedures e.g. stripe coat application.

4

Cracking

The splitting of a dry coating film that reaches the substrate, usually as the result of ageing a nd stresses in the coating system.

5

Epoxy

Type of resin formed by the reaction of aliphatic or aromatic polyols (e.g. bisphenol) with epichlorohydrin and characterised by the presence of reactive oxirane end groups.

6

Equipment

The equipment to be coated 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.

7

Fingerprint

Method of identifying a coating material through laboratory analyses of coating density, solids content, pigment content, etc. (Infrared Spectroscopy is often used).

8

Flaking

The detachment of pieces of the coating film itself either from its substrate or from coating previously applied. Flaking is usually preceded by cracking or blistering.

9

Grit

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



No

Term

Definition

10

Holiday

A discontinuity in a protective coating that exposes unprotected surface to the environment.

11

Inorganic Zinc-Rich Coating

Coating containing a metallic zinc pigment (typically 75% or more in the dry film) in an inorganic vehicle.

12

Organic Zinc-Rich Coating

Coating containing a metallic zinc pigment (typically 75% or more in the dry film) in an organic resin.

13

Coating

A pigmented coating material in liquid or paste or powder form, which when applied to a substrate, forms an opaque film having protective, decorative or other specific properties.

14

Pot Life

The elapsed time within which a coating can be effectively applied after all components of the coating have been thoroughly mixed.

15

Pre-fabrication Primer

A thin and fast drying coating that is applied to a blast cleaned steel to provide temporary protection during fabrication while still allowing welding and cutting. This is also known as shop primer.

16

Primer

A coating material intended to be applied as a first coat on an uncoated surface. The coating is specifically formulated to adhere to and to protect the surface as well as to produce a suitable surface for subsequent coats.

17

Shelf Life

The maximum length of time packaged materials e.g. coating materials can be stored at specific conditions and remain in usable condition.

18

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.



No

Term

Definition

19

Stripe Coat

A coat applied only to edges or to welds on steel structures before a full coat is applied to the entire surface. The stripe coat is intended to give those areas sufficient film build to resist corrosion.

20

Surface Profile

The irregular peak and valley profile on the surface of bare metal that results from abrasive blast cleaning or power tool cleaning.

21

Zinc-Rich Primer

A general term used for inorganic zinc-rich coatings and organic zinc-rich coatings used as a primer.

Table 1: Specific Definition of Terms 1.2.3

Specific Abbreviations

No

Abbreviation

Description

1

CDBM

Corrosion Design Basis Memorandum

2

CORAL 2.0

Cost Reduction Alliance

3

CSDS

Chemical Safety Data Sheets

4

DFT

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

5

GRP

Glass fibre Reinforced Plastic

6

ITP

Inspection Test Plan

7

JHA

Job Hazard Analysis

8

JSA

Job Safety Analysis

9

LCC

Life Cycle Costing



1.3

No

Abbreviation

Description

10

MCI

Materials, Corrosion and Inspection

11

MEL

Maximum Exposure Limit

12

MOC

Management Of Change

13

MSDS

Material Safety Data Sheets

14

OEL

Occupational Hazardous Limit

15

PPE

Personal Protective Equipment

16

QA

Quality Assurance

17

QC

Quality Control

18

QP

Quality Plan

19

TDFT

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

20

TPI

Third Party Inspector

21

PSC

Production Sharing Contractors

22

WFT

Wet Film Thickness; the thickness of the uncured or wet coating or coating film. Table 2: Specific Abbreviations

SUMMARY OF CHANGES

This PTS 15.20.03 replaces PTS 30.48.00.31 (October, 2012) and PTS 70.48.10.10 (November, 2012).


PROTECTIVE COATINGS AND LININGS

Page 12 of 111

2.0

WARRANTY GENERAL

2.1.1

Contractors, undertaking coating works in accordance with this PTS, shall guarantee the quality of their coating work. Prior to start of coating works, warranty period shall be agreed with the Owner.

2.1.2

A minimum warranty period of seven (7) years for all coatings and ten (10) years for TSA inclusive of maintenance coatings. This requirement shall be incorporated in the coatings contract document. For shorter design life the warranty period can be reduced to meet project requirement based on owner’s agreement.

2.1.3

The severity of corrosion shall not exceed a Ri 3 scale based on ISO 4628-3 Assignment of Degree of Rusting during the warranty period.

2.1.4

The warranty shall be based on the reference area within the structure or facility involved. Reference area shall be selected at a location with typical corrosive stresses for the structure. Surface preparation, coating application and the quality of work at the selected reference area shall be agreed and witnessed by the Owner, the Contractor’s representative together with TPI. Clear documentation and marking on the structure showing the reference area shall be made available for the reference of the Owner, Contractor and TPI. Refer Table 3 for further details on reference area.

Up to 2,000

2

Recommended minimum total area of reference areas, m2 10

2,001 to 5,000

4

24

5,001 to 25,000

6

60

25,001 to 50,000

8

80

Above 50,001

8

160

Size of Coated Area, m2

Recommended minimum number of reference areas

Table 3: Recommended reference area selection



2.1.5

Surfaces that have deteriorated beyond the acceptable level of breakdown within the warranty period shall be repaired by the Contractor at Contractor’s cost. The Contractor shall also bear the cost for materials, equipment, labour, transportation and sto rage necessary for the repair.

2.1.6

Initial acceptance of any new coating work by the Owner 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.

2.1.7

A final inspection shall be carried by TPI to be agreed between the Contractor and the Owner before expiry of the coating work warranty period.

2.1.8

In case of a dispute on the condition and quality of the coating work that has been applied, an independent consultant shall be engaged to conduct a review inspection. Both the Owner and the Contractor shall accept the inspection findings by this independent consultant.

2.1.9

Owner may engage a consultant as their representative in the event that requires detailed coating failure investigation, services which shall include al l the required laboratory and failure analysis.

2.1.10 In the event where dispute arises to assign responsibility of defect between the Contractor and the coating manufacturer, an independent consultant shall be appointed by the coating manufacturer and Contractor to arbitrate the issue. The Owner shall at no times be liable to this process. 2.1.11 The degree of compensation coverage shall be on a diminishing value of 10% coverage starting from 100% until the end of first year, 90% till the end of the second year and so on until the end of the warranty period.



3.0

COATING AND COATING SYSTEMS COATING SYSTEMS SELECTION

3.1.1

General i.

This section addresses the selection of coating system for external and internal application. Selection of coating systems and products which are not listed shall require approval from the Owner.

ii.

Prior to execution of coating works, the items below shall be qualified to the requirements of this PTS: a) Coating Systems (Appendix 1) b) Abrasive materials (Appendix 11)

3.1.2

3.1.3

iii.

Recycled abrasive must comply with tests mentioned in Appendix 11

iv.

Maintenance and touch-up coating systems shall be compatible with the New Construction coating systems. Coating system compatibility shall be tested using patch test methods described in ASTM D5064.

Primer i.

Sacrificial-type primer such as organic or inorganic Zinc-rich primer shall contain a high percentage of zinc dust of greater than 80% by mass in the non-volatile portion of the primer. The zinc dust shall comply with the requirements specified in ASTM D520 (Type II or III) or ISO-3549. The zinc-rich primers shall be overcoated with chemically resistant coatings to avoid direct exposure acid and strong alkalis such as in marine environment. Cleaning using freshwater or power scrubbing shall be required to remove contaminants prior to overcoating. Damaged inorganic zinc-rich primers shall be repaired with an organic zinc-rich coating.

ii.

Organic inhibitive primer contains inhibiting pigments that produce alkaline conditions to protect the base metal against corrosion when exposed to moisture. Overcoats are required to ensure the effectiveness of this inhibitive primer due to the reactive pigments content.

Intermediate Coats and Topcoats Intermediate coats and topcoats function as barrier to restrict the permeation of water vapor, oxygen and active chemical ions. The application of topcoat is to provide added abrasion, impact, UV light and solvent resistance. Topcoat also adds aesthetic value to the surface. Generic characteristics of intermediate coats and topcoats include the following: i.

Chemically Cured Thermoset Coatings. These materials are usually epoxies, epoxy phenolics, polyesters, or vinyl esters.

ii.

Polyurethanes or Polysiloxanes. These materials are used exclusively as a topcoat in the atmospheric zone to provide UV resistance. In general, polysiloxane provides better UV resistance than polyurethane.



3.1.4

3.1.5

Organic and Inorganic Zinc-Filled Coatings i.

The metallic zinc content in the zinc dust shall be a minimum of 94%.

ii.

Zinc content by percentage weight for Inorganic Zinc Silicate and Organic Zinc Epoxy should comply with SSPC-Coating 20 (Zinc rich primer, Type I 'Inorganic ' and Type II 'Organic') requirement or equivalent.

iii.

Organic Zinc Epoxy is preferred due to the ease of application. Although Inorganic Zinc Silicate provides better corrosion in aggressive environments, its limitations such as tendency to crack in access of 75 microns thickness and requirement for humid environments for curing makes it undesirable.

iv.

If shop primer for temporary protection is applied, then it must be 100% full blasted to the requirement stated in section 5.0 prior to the application of the full coating system.

v.

For primed surface, a secondary surface preparation shall be performed. All zinc salt formation shall be sweep blasted. All other possible contaminants shall be sand down and solvent cleaned before top coating. For damaged areas, welding joints and rusty area, spot blast to Sa 2.5 followed by one coat of epoxy zinc rich or power tool cleaned to St 3 and followed by Surface Tolerant epoxy, subject to Owner approval.

Selection and Application of Top Coats i.

For areas to be applied with polyester glassflake, all shop primer shall be removed completely to Sa 2.5.

ii.

The minimum volume solids for high solid epoxy shall be 75%. As an alternative, surface tolerant high solid epoxy coating may be applied.

NEW CONSTRUCTION COATING SPECIFICATIONS

3.2.1

For new construction, single coating manufacturer responsibility shall be maintained by using primers, intermediate coats and topcoats from the same Manufacturer.

3.2.2

For some systems, there are options available and the application of LCC shall be considered during development of CDBM.

3.2.3

Unless otherwise stated by Manufacturer, the surface preparation for new construction shall be blast cleaned to ISO 8501-1, Sa 2.5.

3.2.4

The list of approved coating products can be found under Appendix 3. This list will be updated during the next PTS review. New coating products shall be tested to comply with the new DFT requirements specified in this PTS and shall be certified by PETRONAS approved testing laboratories. PRSB shall be the main body for any testing work or owner’s approved testing bodies. Any deviations from the approved systems in Table 3-1 or Table 3-3, though not advisable, requires MOC with approval from the highest Technical Authority.



Page 16 of 111

Service(j)

System Coat ID

N1-1(a)

1 2 3

Paint and Coating Specifications

Zn Rich Primer Epoxy Polyurethane Total

N1 Carbon Steel Atmospheric zone -50°C to 120°C With/Without Insulation

N1-2

1

Epoxy Primer Epoxy Polyurethane Total

N1-3

1 2 3

Thermal Spray Aluminium Thinned Sealer (Epoxy) Sealer (Epoxy) Total

N2 Carbon Steel Atmospheric zone -70°C With Insulation

N2-1(b)

1 2 3

High Solid Epoxy Phenolic High Solid Epoxy Phenolic High Solid Epoxy Phenolic Total

N3-1

1 2 3 4

Zinc Rich Primer High Solids Epoxy Antiskid Epoxy Polyurethane Total

N3 Offshore Platform Decks (Including Primary and Secondary Structures)

N3-2

1 2 3 4

Epoxy Primer High Solids Epoxy Antiskid Epoxy Polyurethane Total

N3-3

1 2 3


N3-4

N4-1 N4 Offshore Platform Decks (Decks and Floors -Heavy Duty and Helidecks)

1

Antiskid High Build Epoxy

1 2 3 4

Zinc Rich Primer High Solids Epoxy Antiskid Epoxy Polyurethane safety marking Total

N4-2

1 2 3 4


Min DFT ( m)

Target DFT ( m)

50-75 125-175 50-75

75 125 75

225-325

275

125-175 125-175 50-75

125 125 75

300-425

325

250-375

250

‡

‡

‡

‡

250-375

250

100 100 100

100 100 100

300

300

50-75 125-175 125-175 50-75

75 125 125 75

350-500

400

125-175 125-175 125-175 50-75

125 125 125 75

350-500

450

250-375

250

‡

‡

‡

‡

250-375

250

Vendor Specification

Vendor Specification

50-75 200-300 200-300 50-75

75 250 250 75

500-750

650

125-175 125-175 125-175 50-75

125 125 125 75

425-600

450



Page 17 of 111

Service(j)

System Coat ID

N4-3

1 2 3



N4-4

1


N5-1

1 2

Glass Flake Epoxy (c) Glass Flake Epoxy Total

N5 Carbon Steel Splash zone and spray zone <60°C

N5-2

N7 Carbon Steel Splash zone and spray zone between 100°C and 130°C


N5-3 N6 Carbon Steel Splash zone and spray zone between 70°C to 100°C

1 2 3

N6-1

N7-1

N8-1

N8-2

N9-1

N10-1

‡

‡

‡

250-375

250

ᵠ

ᵠ

450-550 450-550

500 500

900-1100

1000

250-375

250

‡

‡

‡

‡ (d)

200-250

250

25 25

1 2 3

Primer Bonding Agent Polychloroprene Rubber(e)

25-50 25-50 6-13 mm

25 25

1 2 3

Primer Bonding Agent EPDM Rubber(f)

25-50 25-50 6-13 mm

25 25

1 2 3

High Solids Epoxy Stripe Coat High Solids Epoxy 75-125

125

250-375

250

‡

‡

‡

‡

75-125

125

50-75 25-50

75 50

75-125

125

250-375

250

‡

‡

‡

‡

75-125

125

100-125 100-125

125 125

75-125

125

1 2 3

Thermal Spray Aluminium Thinned Sealer (Epoxy) Sealer (Epoxy)

1 2

Inorganic Zn Rich Primer Silicone Acrylic

1 2 3


N10 Carbon Steel Atmospheric Zone, surface

250

‡

25-50 25-50 6-13 mm

Total

N9-2

250-375

Primer Bonding Agent Polychloroprene Rubber

Total

N9 Carbon Steel Atmospheric Zone, surface temperature at 110°C to 150°C, Without Insulation

Target DFT ( m)

1 2 3

Total

N8 Carbon Steel Exterior Submerged zone <60°C

Min DFT ( m)

1 2

Epoxy Phenolic Epoxy Phenolic Total

Ɨ

Ɨ

Ɨ



Page 18 of 111

Service(j)

System Coat ID

temperature at 110°C to 150°C, With Insulation N10-2

1 2 3



N11 Carbon Steel Atmospheric Zone, surface temperature at 150°C to 450°C, With/Without Insulation

N11-1

1 2 3


N11-2

1 2 3

Inorganic Zinc Rich Primer Silicone(g) Silicone Total

N12 Galvanised Steel Atmospheric Zone, surface temperature at -50°C to 150°C N13 Stainless Steel Atmospheric zone -50°C to 120°C With/Without Insulation N14 Stainless Steel Atmospheric zone 120°C to 150°C With/Without Insulation N15 Stainless Steel Atmospheric zone 150°C to 450°C With/Without Insulation

N12-1

1 2

Total

N13-1

1 2

N17 Timber Decks

Epoxy(h) Polyurethane Total

N14-1

1 2


N15-1

1 2

Epoxy Polyurethane Total

N15-2

1 1

N16 Carbon Steel Storage Tank Underside (External)

Epoxy Polyurethane

N16-1

N17-1

2 3

1 2 3

Thermal Spray Aluminium Inorganic Zinc Rich Epoxy (compatible with Cathodic Protection) Coal Tar-free, High Build Epoxy Coal Tar-free, High Build Epoxy Total Aluminium Wood Primer Alkyd Semi-gloss finish Alkyd Semi-gloss finish Total

N18 Markings

N18-1

1

Aliphatic Polyurethane

Min DFT ( m)

Target DFT ( m)

250-375

250

‡

‡

‡

‡

75-125

125

250-375

250

‡

‡

‡

‡

75-125

125

50-75 25-50 25-50

75 50 50

100-175

175

150-200 50-75

150 75

200-275

225

150-200 50-75

200 75

200-275

275

100-125 100-125

125 125

200-250

250

150-200 50-75

200 75

200-275

275

50-100

75

50-100

100

200 200

200 200

400

400

50 50 50

50 50 50

150

150

50

50



Page 19 of 111

Service(j)

N19 Living Quarters, Pressurised Building, Interior Control Room (Interior) N20 Fuel Gas (Sweet & Sour)

System Coat ID

N22 Carbon Steel Storage Tank (Internal) Light/Heavy/Treated Naphtha, Reformate, Jet A-1 Fuel, Fuel Oil, Gasoline (leaded & unleaded) and Diesel

Surface Tolerant Epoxy

150

150

N20-1

1 2

Amine Adduct Epoxy Amine Adduct Epoxy

125 125

125 125

250

250

125 125

125 125

250

250

100 100 100

100 100 100

300

300

50 200 200

50 200 200

450

450

125 125

125 125

250

250

125 125

125 125

250

250

125-175

125

125-175

125

125-175

125

375-525

375

150 150

150 150

300

300

Total

1 2

Total

N21-2 Bottom Plate & Vessels

1 2 3

N21-3 Bottom Plate Alterna tive

1 2 3

N22-1


Amine Adduct Epoxy Amine Adduct Epoxy Amine Adduct Epoxy Total

Amine Primer Amine Glass Flake Amine Glass Flake Total

1 2


Total

1 2

Amine Adduct Epoxy Amine Adduct Epoxy Total

N23-2 Ballast Water Tank

1 2 3 4 5

High Solids Epoxy Stripe Coat High Solids Epoxy Stripe Coat High Solids Epoxy Total

N24 Steam Condensate and Boiler Feed Water

Target DFT ( m)

1

N23-1 N23 Potable Water (i) (Drinking/Aerated/NonAerated), Seawater, Produced/Brackish Water, Demineralised Water and Brine

Min DFT ( m)

N19-1

N21-1 Roof and Shell Plate N21 Carbon Steel Storage Tank (Internal) Crude/Condensate (Sweet & Sour), Emulsion/Slop


N24-1

1 2




Page 20 of 111

Service(j)

System Coat ID

N25-1

N25 Utility Air

1 2

Min DFT ( m)

Target DFT ( m)

125 125

125 125

Total

250

250



N25-2

1

Polyester Glass Flake or Epoxy Glass Flake

400

400

N25-3

1

Vinyl Ester Glass Flake

400

400

N25-4

1 2

Epoxy Phenolic Epoxy Phenolic

125 125

125 125

250

250

800-1500 800-1500

1500 1500

1600-3000

3000

125 125

125 125

250

250

75-100

100

125 125

125 125

250

250

125 125

125 125

250

250

800-1500 800-1500

1500 1500

1600-3000

3000

Total

N26 Corrosion Inhibitors, Demulsifier, Oxygen Scavenger

N27 Methanol and Perchloroethylene (PERC)

N28 Triethylene Glycol and Methylethylene Glycol

N26-1

1 2

Vinyl Ester Glass Flake Vinyl Ester Glass Flake Total

N27-1

1 2


N27-2

1

N28-1

1 2

Inorganic Zinc Silicate Amine Adduct Epoxy Amine Adduct Epoxy Total

N28-2

1 2


N28-3

1 2

Vinyl Ester Glass Flake Vinyl Ester Glass Flake Total

Table 3-1: New Construction Coating Systems Notes: ID Legend: N XX – Y N XX Y ‡

Do not add to total DFT

Ɨ

End user specification

ᵠ

Vendor specification

;

e.g.

N28-2

“N” for new coating Sytem number i.e. System 28 System option i.e. 2nd option in System 28

(a) Structural steel and piping can be coated in the shop with the first two coats. The third coat can be applied at site after erection. A mist coat will be required following the application of primer as per M anufacturer’s specifications



(b) Applicable for surface of cold insulated steel pipe operated down to -70°C under wet insulation Coating may also be carried out in 2 coats (150 microns each) (c) The average surface profile shall be 75 microns (d) Allow thinned sealer to dry >30 minutes before application of next sealer coat. (e) For service temperature >70 0C, polychloroprene rubber shall only use carbon black pigment, which gives better thermal resistance. (f) Ethylene Propylene Diene Elastomer (g) High Temperature Silicone coating should not be applied more than 40 microns thick which could lead to blistering. Alum colour can withstand temperature more than 200°C. (h) Never use zinc based coating on stainless steel which can cause Liquid Metal Embrittlement during fire. (i) Coating system applied for potable water system shall be accompanied with a health certificate. (j) The temperature described in Table 3-1: New Construction Coating System shall be of design temperature. (k) For Service N13, the stainless steel surface described is for Austenitic type stainless steel. 22%Cr and 25%Cr stainless steels shall be painted in accordance to System N13 for operating temperatures ≥50°C and ≥80°C respectively.

MAINTENANCE COATING SPECIFICATIONS

Unless otherwise stated by the Manufacturer, the surface preparation for maintenance works shall be Power Tool Cleaning to ISO 8501-1, St 3, as a minimum. Where maintenance coating systems are not listed, the new construction specifications shall be followed. 3.3.1

Types of Maintenance Depending on the condition of the coating, one or more of the following three (3) types of maintenance coating shall be applied. i.

Touch-up or Spot Repair If the coating film, apart from local rust areas, is sound and adequate (Ri=3), the areas that are corroded, approximately 100 cm2 in size, shall be spot cleaned and touched up using a single pack system to full film thickness with Owner approval. All corrosion products shall be removed and the interface between the sound coat and cleaned areas shall be properly prepared.

ii.

Maintenance or Renovation For renovation (Ri=4), spot repairs shall be carried out to the existing coating and a full topcoat shall be applied. The existing coating system shall be sound and adequate while the new topcoat shall enhance the corrosion protection.

iii.

Refurbishment or Total Recoating

Refurbishment requires total removal of the existing coating system (Ri≥5). Surface preparation and application of a new coating system shall be carried out in accordance with Section 3.0 of this PTS.



Page 22 of 111

Table 3-2 contains recommendations for appropriate type of maintenance coating based on the surface condition. Maintenance coating should not be necessary for coated surfaces where less than 1% of the surface area is corroded (Ri ≤ 3).

Coating surface condition

Rust scale (ISO 46283) Ri 0

Maintenance

Minimum recommended surface pretreatment (ISO 8501) -

Contaminated, Preventive No Corrosion Cleaning 1% of Surface Area Ri 3 Spot Repair Corroded <10% of Surface Area Ri 4 Renovation Corroded >10% of Surface Area Ri 5 Refurbishment Corroded Table 3-2: Typical Maintenance Practices

Service

System ID

M1-1

Coat

1 2 3


Inorganic Zn Rich Primer Surface Tolerant Epoxy Polyurethane Total

M1 Carbon Steel Atmospheric zone -50°C to 120°C With/Without Insulation

M1-2

1

Epoxy Primer Surface Tolerant Epoxy Polyurethane Total

M1-3

1 2 3

Moisture Cured Urethane Primer Moisture Cured Urethane Primer Moisture Cured Urethane Primer Total

M2 Carbon Steel Atmospheric Zone, surface temperature at 110°C to 150°C, With/Without Insulation

M2-1

1 2


M2-2

1 2

Silicone Based High Build Coating Silicone Based High Build Coating Total

M3 Offshore Platform Decks (Including Primary and Secondary Structures)

M3-1

1 2 3 4


St2 St3 or Sa2 Sa2.5

Min DFT ( m)

Target DFT ( m)

50-75 125-175 50-75

75 125 75

225-325

275

125-175 125-175 50-75

125 125 75

300-425

325

75-125 75-125 75-125

100 100 100

225-375

300

100-125 100-125

125 125

200-250

250

100-200 100-200

150 150

200-400

300

125-175 125-175 125-175 50-75

125 125 125 75

425-600

450



Page 23 of 111

Service

M4 Offshore Platform Decks (Decks and Floors -Heavy Duty and Helidecks)

M5 Carbon Steel Splash zone and spray zone <60°C

System ID

Coat

M3-2

1


M4-1

1 2 3

Epoxy Primer Antiskid Epoxy(b) Polyurethane safety marking


Total

Min DFT ( m)

Target DFT ( m)

ᵠ

ᵠ

200-250 200-250 50-75

250 250 75

450-575

575

ᵠ

ᵠ

M4-2

1


M5-1

1

Glass Flake Epoxy(d)

450-550

500

M5-2

1 2

Epoxy Primer(d) Glass Flake Epoxy

125-175 200-500

125 375

325-675

500

300-2000

ᵠ

ᵠ

ᵠ

Total

1

Surface Tolerant Epoxy

M5-4

1

Underwater Curable Epoxy Primer + 2 half fibreglass composite outer sheaths

M6 Carbon Steel Exterior Submerged zone <60°C

M6-1

1

Underwater Curable Epoxy

500-1000

ᵠ

M7 Carbon Steel Water condensing surface

M7-1

1

Underwater Curable Epoxy

375-750

500

High Solids Epoxy Stripe Coat High Solids Epoxy

200-250

200

M8-1

1 2 3

200-250

200

400-500

400

50-100

75

25-50 25-50

50 50

50-100

100

100-200 100-200

150 150

200-400

300

150-200 50-75

150 75

200-275

225

150-200 50-75

200 75

M8 Carbon Steel Ballast Water Tank

M5-3

Total

M9 Carbon Steel Atmospheric Zone, surface temperature at 150°C to 450°C, With/Without Insulation

M9-1

1

Thermal Spray Aluminium

M9-2

1 2

Silicone Silicone Total

M9-3

M10 Galvanised Steel Atmospheric Zone, surface temperature at -50°C to 150°C

N10-1

M11 Stainless Steel Atmospheric zone

M11-1

1 2

1 2

Silicone Based High Build Coating Silicone Based High Build Coating


1 2

Epoxy(h) Polyurethane



Page 24 of 111

Service

-50°C to 120°C With/Without Insulation M12 Stainless Steel Atmospheric zone 120°C to 150°C With/Without Insulation M13 Stainless Steel Atmospheric zone 150°C to 450°C With/Without Insulation

M14 Timber Decks

System ID

Coat

Paint and Coating Specifications Total

M12-1

1 2


M13-1

1 2


M13-2

M14-1

1

Thermal Spray Aluminium Total

1 2 3

Aluminium Wood Primer Alkyd Semi-gloss finish Alkyd Semi-gloss finish Total

Min DFT ( m)

Target DFT ( m)

200-275

275

100-125 100-125

125 125

200-250

250

150-200 50-75

200 75

200-275

275

50-100

75

400

400

50 50 50

50 50 50

150

150

Table 3-3: Maintenance Coating Systems Notes: ID Legend: M XX – Y M XX Y

ᵠ

;

e.g.

M13-2

“M” for maintenance coating Sytem number i.e. System 13 System option i.e. 2nd option in System 13

Vendor specification

(a) Applicable for surface of cold insulated steel pipe operated down to -70°C under wet insulation Coating may also be carried out in 2 coats (150 microns each). (b) Antiskid grits should be mixed with the liquid coating prior to application to obtain good wetting of the grits. Fine grits should be used with the application of antiskid epoxy. (c) DFT of the applied coating shall be calculated prior to the addition of antiskid grits. (d) The average surface profile shall be 75 microns minimum. (e) For service temperature >70 0C, polychloroprene rubber shall only use carbon black pigment, which gives better thermal resistance. (f) Ethylene Propylene Diene Elastomer. (g) Average surface profile shall be 75 micron minimum. (h) Temperatures described in Table 3-3: Maintenance Coating Systems are operating temperature whereby evident operating experiences have been established and such that operating limits shall not exceed the range described. In case of operating conditions shall be as per design limit, then Table 3-1: New Construction Coating Systems shall be referred. (i) For Service M11, the stainless steel surface described is for Austenitic type stainless steel. 22%Cr and 25%Cr stainless steels shall be painted in accordance to System N13 for operating temperatures ≥50°C and ≥80°C respectively.



COATING SYSTEM PRODUCT APPROVAL REQUIREMENT

3.4.1

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.

3.4.2

Details of the testing required are explained under Appendix 1.

3.4.3

For qualifications of coating system other than those already qualified and/or specified in Appendix 3, Contractor shall engage with Owner on the test method and requirements. PRODUCT QA/QC REPORT

3.5.1

Coating Manufacturers shall submit QA/QC reports on the coating products that passed the laboratory screening tests. The QA/QC reports must have the following information: i.

Coating Product Name

ii.

Manufacturer

iii.

Batch number

iv.

Manufacturing date

v.

Testing date

vi.

Drying time

vii.

Hold up property

viii.

Glossiness

ix.

Specific gravity

x.

Viscosity

xi.

Coatings Fingerprint Certificate

3.5.2

Coating Manufacturers shall ensure that the properties of their coating systems selected for actual coating work will be the same as the ones that passed the laboratory screening tests. Owner may collect ad-hoc coating samples for verification an approved independent testing agency to verify conformance to the QA/QC report stated herein.

3.5.3

Whenever deemed necessary, Owner may carry out a non-conformance audit on the coating manufacturers. COATING QUALITY CONTROL BATCH CERTIFICATE

3.6.1

Coating Manufacturers shall furnish their Coating Quality Control Batch certificates to ensure that the properties of the products supplied are consistent with the laboratory tested products. The Coatings Fingerprint Certificate shall be produced per batch per coating manufactured and data stored in digital format. This data shall be submitted to the Owner’s MCI representative from the project team during delivery of coating products.



Example of the Coatings Fingerprint Certificate can be found under Appendix 2.

Note that coating fingerprinting will only be enforced for coating projects involving ≥ 5000 m2 of total surface to be coated. 3.6.2

Owner retains the right to conduct random coatings fingerprinting test at any given point during the course of the project as it deems fit. This shall be referenced against fingerprinting results submitted by the Manufacturers.

3.6.3

As a minimum, the following information shall be provided: i.

Manufacturer's name

ii.

Factory location

iii.

Date of manufacture

iv.

Batch number

v.

Product name

vi.

Generic name

vii.

Key composition/components description: a) Resin b) Pigments c) Curing Agent (generic name) d) Solvent (generic name)

viii.

QC Test Results including Test Standard, Pass Criteria, Actual Results: a) Colour b) Viscosity c) Density/S.G. d) Fineness e) Drying f)

Time

g) Hiding h) Power i) 3.6.4

Gloss

All QC test results shall be provided by coating manufacturer as and when requested by the Owner.



4.0

COATING CONTRACTORS RESPONSIBILITIES GENERAL

4.1.1

The Contractor, in addition to his responsibilities under the general conditions of the contract shall be 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.

4.1.2

The Contractor shall be fully responsible for all QA and QC activities. The Contractor shall submit for any major coating work an appropriate work planning and a QP for implementing this PTS for review and approval by the Owner. Copies of this PTS, work planning and the QP shall be made available to the Contractor’s representative at site. The representative shall confirm his understanding on the contents of the PTS, work planning and the QP.

4.1.3

The Contractor shall conduct a pre-job meeting to ensure that job and quality requirements are fully understood. Attendees shall be a representative of the Owner, Contractor Coating Advisor, the Coating Inspector and the Coating Manufacturer’s representative.

4.1.4

The Contractor shall conduct a site coating selection via panel test. This is to be executed before any major projects or major maintenance work. The Contractor shall shortlist a minimum of 3 coating manufacturers for this exercise. The Contractor Coating Advisor shall witness and accept the panel test results together with Owner.

4.1.5

The unmixed actual coating used for panel testing shall be marked, retained and properly sealed in a minimum 2” diameter by 2” height stainless steel container for traceability and to avoid product contamination. Owner may conduct fingerprinting test as deemed necessary.

4.1.6

The accepted test panels and retained unmixed coating samples shall be properly labeled and stored. The coating samples, test panels and QA/QC documents shall be included as handover items in the project handover checklist. MCI representative from Owner shall acknowledge receipt of items in the handover documents.

4.1.7

Coating manufacturer shall be consulted if the Contractor is not familiar with the coating materials to be applied.

4.1.8

The Contractor shall display his capability to Owner in achieving the requirements as specified in the contract. HSE

4.2.1

The Contractor shall be responsible for all aspects of HSE. Environmental regulations and rules shall be met.

4.2.2

Safe working is of the greatest importance particularly during coating works in confined spaces such as tanks and vessels. Site safety regulations shall be adhered to.



4.2.3

All personnel shall be provided with approved PPE suitable to the working environment as well as weather e.g. protective clothing, safety glasses, safety shoes, hard hats, goggles, respirators, earplugs, fresh-air-fed hood and any other necessary safety equipment. PPE made of fabrics such as coveralls and gloves that do not provide chemical resistant protection shall not be used to avoid dermal exposure to hazardous material during coating application. As a minimum, leather gloves are required when handling abrasive blasting equipment and airless spray gun. All safety equipment shall be maintained in good working condition adequate for all work requirements.

4.2.4

Adequate warning signs shall be prominently displayed on each access way to all areas where abrasive blasting and coating is in progress.

4.2.5

Handling and disposal of hazardous waste resulting from the Contractor's coating activities shall be in accordance with regulations and specific contract requirements. However, the Owner’s regulations on chemical management or banned materials shall be strictly adhered to.

4.2.6

Schedule waste disposal shall be under the Contractor’s scope. HAZARDOUS COATING COMPONENTS

4.3.1

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 Owner’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.

4.3.2

Reference to Occupational Safety and Health (Use and Standards of Exposure of Chemicals Hazardous to Health) Regulations shall be made in the event of any hazardous components are expected to be present for the identification of OEL/MEL. Coatings shall contain maximum 0.1% Monomeric Isocyanate at the time of coating. If the CSDS/MSDS of the coating does not specify the content of the isocyanate groups, Owner shall have the right to request for laboratory assessment of the monomeric isocyanate content in the coating. Refer to ASTM D2572 or ISO 14896/3 for the testing procedures. PERSONNEL

4.4.1

Refer to Section 8.0: Resource Requirement. PROTECTION OF EQUIPMENT AND STRUCTURAL MEMBERS

4.5.1

The Contractor shall protect all equipment, structures and any other areas from mechanical damage, environmental damage, blockage or obstruction, damage caused by over blasting, coating droppings and splashes or overspray.



BLASTING AND SPRAYING EQUIPMENT

4.6.1

The Contractor shall demonstrate that blasting and spraying equipment to be used are in good condition and well maintained. Blasting and coating equipment shall fully comply with any local and/or regional regulation. Wherever applicable, valid Certificate of Fitness for blasting and spraying equipment from local authority shall be made available for reference by Owner.

4.6.2

The blasting and spraying equipment shall be capable of achieving the quantity and quality requirements as prescribed in the contract.

4.6.3

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 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.

4.6.4

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. ACCESS

4.7.1

Access for coating work shall be constructed to provide safe and adequate access for surface preparation, coating and inspection of all surfaces.

4.7.2

Scaffolding shall be constructed in accordance with local regulations and the requirements of the Owner.

4.7.3

Where abseiling is required, the Contractor shall consult the Owner to conduct JHA prior to execution and approval shall be at the discretion of the Owner. HANDLING OF COATED PARTS/COMPONENTS

4.8.1

To minimise the risk of damage, no lifting, transportation, erection or fabrication operations shall be done before the coating has been fully dried and/or cured. Welding shall not be carried out on the external surfaces of internally coated tanks o r vessels.

4.8.2

Where transportation is required, canvas or nylon slings shall be used for lifting and wooden blocks applied for securing the structure. If weather change is expected during transportation, plastic wrapping may be applied based on the risk of coating deterioration of the structure.

4.8.3

Any damages to the coating from premature curing due to Contractor’s act of welding, erection, fabrication or lifting activities shall be repaired by the Contractor as per original specification.



STORAGE PROTECTION

4.9.1

The Contractor shall ensure the coating cans are stored in compliance to Manufacturer’s recommendations, particularly in regards to storage temperature. As a general rule, all containers containing coating materials shall be stored under cover giving protection from direct sunlight and rain at a temperature below 35°C. The storage condition shall also allow for adequate ventilation to minimize coating container deterioration from humidity. Materials shall be systematically stored after delivery so that a First-In-First-Out (FIFO) withdrawal procedure can be adopted.

4.9.2

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

4.9.3

Coating cans shall be stored away from any source of ignition.

4.9.4

The Owner has the right to audit and inspect the storage area while the materials are still kept or stored.

4.9.5

Prior to removal of the material from storage area, a joint inspection by Owner and Contractor shall be done to verify the condition of the material. Acceptance shall be as per agreed QA/QC requirement. SHELF-LIFE

4.10.1 The Contractor shall ensure that in the event that the quoted shelf-life period has been exceeded, the usability of the product shall be confirmed by the Manufacturer and notified to the Owner. The procedure described in ASTM D869 shall be used to evaluate the degree of settling of coating. A coatings fingerprint is also required to be conducted to ensure product quality is in accordance with Appendix 2. This needs to be accepted in conjunction with other tests. 4.10.2 Coating which has deteriorated during storage shall not be used and disposed of accordingly.



5.0

SURFACE PREPARATION SURFACE PROFILE

5.1.1

Roughness or anchor pattern measurement shall be carried out by the Contractor using instruments and procedures approved by the Owner. Where anchor patterns are not specified in the coating manufacturer’s technical data sheet, Table 5-1 below shall be used as a guide for determining the anchor pattern. Dry film thickness Anchor pattern 125-200 microns (5-8 mills) 25-50 microns (1 -2 mills) 200-500 microns (9-20 mills) 50-76 microns (2-3 mills) > 500 microns (>20 mills) 75-125 microns (3-5 mills) Table 5-1: Relationship between coating thickness and anchor pattern

5.1.2

Abrasives used in blast cleaning steels shall generally be in accordance with ISO 8504-2 and Table 5-2. In the event of other type of abrasive media not described in ISO 8504-2 and Table 5-2 is to be used, prior written approval from Owner shall be obtained. Type of abrasive

Metallic Non-metallic Natural Mineral Non-metallic Synthetic Mineral or Industrial by-product

Generic Name

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

Characteristics

Standard

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

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

Aluminium silicate

ISO 11126-4

Crystalline corundum

ISO 11126-7

Calcium silicate

ISO 11126-6

ISO 11126-10

Table 5-2: Abrasive specifications

5.1.3

Aluminium oxide or other abrasives (free from any chloride or iron/steel contamination) shall be used for blasting stainless steel.



Page 32 of 111

GRADES OF SURFACE FINISH

5.2.1

Acceptable surface finish grades are summarized in Table 5-3. 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

SP7

Sa 1

No. 4

Power-tool cleaning (to bare metal)

SP11

-

-

Commercial grade power tool

SP15

-

-

Power-tool cleaning

SP3

St 2 or 3

-

Hand-tool cleaning

SP2

St 2

-

Solvent cleaning

SP1

-

-

Pickling to white metal

SP8

High and ultrahigh pressure water jetting

SP12

-

No. 5

Water jet cleaning

SP12

-

No. 5

Clean to bare substrate water jetting

SP12- WJ-1

No.5 WJ-1

Very thorough water jetting

SP12- WJ-2

No.5 WJ-2

Thorough water jetting

SP12- WJ-3

No.5 WJ-3

Light water jetting

SP12- WJ-4

No.5 WJ-4

Wet abrasive blasting

TR2 Table 5-3: Surface Finish Grades

-

6G198

SURFACE PREPARATION BY HAND AND POWER TOOL CLEANING

5.3.1

The most technically effective surface preparation method is blast-cleaning. Manual preparation shall only be used when blast-cleaning is either not feasible or not strictly required, e.g. for rust scale Ri3.

5.3.2

Manual cleaning shall be performed using hand wire brushes or mechanically operated tools (grinders, bristle blaster, chippers or wire brushes) in accordance with ISO 8504-3. The surface shall be left roughly abraded and a burnished surface shall be avoided.

5.3.3

If the surface being prepared lies adjacent to a coated surface which is not to be refurbished, the power tool cleaning shall overlap the coated surface by at least 50 mm.

5.3.4

The following two preparation grades (in accordance with ISO 8501-1) are recognised for hand or power tool cleaning: i.

St 2 : Thorough hand and power tool cleaning

ii.

St 3 : Very thorough hand and power tool cleaning

NOTE: Preparation grade St 1 is considered an unsuitable surface for coating.



SURFACE PREPARATION METHOD- STAINLESS STEEL, GALVANIZED STEEL, NICKEL ALLOY AND NON-FERROUS ALLOY

Acceptable surface preparation methods can be varied for this specification dependent on the size and the access to the item being coated.

Vessels, cabinets, large bore pipe and valves shall be “Brush –off blast cleaned” to standard NACE No. 4/SSPC SP 7. Small bore piping, valves and instruments may be prepared by hand tool cleaning by “sanding” to achieve an abraded surface profile to enable adequate coating adhesion. 5.4.1

Pre-Blasting Operations All adjacent coated carbon steel, GRP piping, sight glasses, gauges and instruments to be adequately protected to avoid either direct (over blast) damage or indirect damage by dust accumulation / contamination (equipment / instrumentation)

5.4.2

5.4.3

Abrasive “Brush-off” blasting method i.

The surface to be blasted shall be washed down with Owner approved biodegradable alkali based detergent or degreaser applied as per the manufacturer’s instructions in such a manner to remove all surface contamination that would be detrimental to the coating.

ii.

The surface shall then be washed with potable water (chloride content to be below 20ppm) at high pressure (e.g. 200 psi) to remove the contaminated detergent or degreaser before it dries on the surface.

iii.

The surface shall then be “Brush –off blast cleaned” to standard NACE No. 4/SSPC SP 7 to give a dense surface profile of no more than 25 μm. The purpose of the blast cleaning in this instance is to give the primer a suitably “roughened “ surface to enable good adhesion while also removing any minor corrosion products. Fine size abrasives with low nozzle pressure (approx. 50-60 psi) shall be used for this blasting method.

iv.

Significant areas of corrosion pitting or metal loss that are exposed during blasting operations shall be referred to Owner for inspection prior to any further coating of these areas.

Hand Preparation Methods i.

The surface to be prepared shall be washed down with an Owner approved biodegradable alkali based detergent or degreaser applied as per the manufacturer’s instructions in such a manner to remove all surface contamination that would be detrimental to the coating.

ii.

The surface shall then be washed with potable water (chloride content to be below 20 ppm) at high pressure (e.g. 200 psi) to remove the contaminated detergent or degreaser before it dries on the surface.

iii.

While the surface is still wet using abrasive paper (rating 100 – 120) vigorously ‘rub’ the surface to achieve a 100% abraded surface suitable for the primer to adhere to.

iv.

Surface shall be kept wet during the operation (using potable water) and rinsed afterwards to ensure the sanding residue does not dry on the surface to be primed.



6.0

APPLICATION PRE-APPLICATION PROCEDURES

6.1.1

6.1.2

Coating Materials Storage and Handling i.

Coating materials shall be furnished in the manufacturer’s original, unopened container and clearly labeled to enable identification of the contents. Each container shall have full identification, information including manufacturer’s name, product identification, batch number and colour.

ii.

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. Safety requirements shall also be specified in the MSDS.

iii.

Manufacturer’s specified shelf life for coating components shall be followed.

iv.

Thinners or cleaners shall comply with the coating manufacturer’s recommendation, or if independently purchased, shall be of compositions approved by the coating manufacturer.

v.

Solvent can closures shall be kept tight at all times to prevent the entrance of humid air, which can lead to condensation.

Coating Material Mixing and Thinning i.

All coating materials shall be thoroughly mixed in accordance with the Manufacturer’s instruction.

ii.

Mixing of different brands or generic types of coating material is not permitted unless respective manufacturer’s consent has been received which shall not nullify the overall warranty by the Contractor.

iii.

Hand mixing of coatings shall only be permitted for containers up to 5 liters. All larger containers shall be mixed by mechanical agitators and brought to a uniform consistency. Where pigment separation readily occurs, provision shall be made for continuous mixing during application. If the pigment settles, it shall be redispersed with a power mixer to form a uniform mixture.

iv.

Two-pack coatings shall be mixed in strict compliance with Manufacturer's instructions including any necessary induction period. Partial mixing is strictly not allowed. The pot life of such coatings shall be specifically noted. Any mixed coating, which has exceeded its pot life, shall be discarded irrespective of its apparent condition.

v.

Sticks or similar tool shall not be used for mixing to avoid contamination.

vi.

Coating applied by brush shall not be thinned down without the approval of the Owner Site Representative. In such cases, thinners recommended by the coating manufacturer shall only be used.

vii.

Hardeners, catalyst and thinners shall be strictly used in accordance with the coating manufacturer's instructions. Any modification to coating materials at site is prohibited. This includes but not limited to pigmentation, adding solvents, tints etc.



APPLICATION CONDITION

6.2.1

Coating shall be applied to dry, clean, prepared surface under conditions recommended in the manufacturer’s product data sheet. The Contractor shall comply with the QP for work execution. Where deviation may exist, it is the responsibility of the Contractor to highlight the deviations and obtain the necessary approval from Owner Site Representative.

6.2.2

Coating shall not be applied when any of the following conditions exist: i.

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

ii.

The surface temperature is below 5°C as it could adversely affect the curing of coatings. Refer to product data sheet for systems that can be applied at temperatures below 5°C.

iii.

The relative humidity (RH) is greater than 85%, except for moisture-cured urethane coating systems which may be used at higher than 85% RH.

iv.

The metal surface temperature is above 50°C or higher than that recommended by the Manufacturer for application.

v.

Surface preparation has not been completed or oil, grease and dust are present on the substrate to be coated.

vi.

Poor weather conditions example rain, heavy fog or blowing sand.

vii.

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.

viii.

Where the available light is less than 500 lux.

ix.

6.2.3

6.2.4

Coating may be suspended at the discretion of the Owner Site Representative due to wind speed, wave height, or when adverse weather conditions are likely to develop before coating could be carried out, or for other reasons deemed inappropriate to proceed.

It is important to ensure residual salt contamination particularly from chloride ion is kept to as minimal as possible. Contractor to agree with Owner on random residual salt test that shall be conducted for these conditions: i.

Prior to primer application

ii.

Subsequent coating layer application after a long interval e.g. after 1 day curing of previous coating application.

The assessment of soluble chloride ion content shall be carried out in accordance with ISO 85026 and 8502-9 or any approved commercial field test kit by the Owner. The soluble chloride ion limit shall be 20mg/m2, except for maintenance coating works for other than stainless steels in atmospheric zone where 50mg/m2 is acceptable. The test shall be carried out once per 200m 2 area with a minimum of three times per shift.



6.2.5

If the soluble chloride ion content is high and obtaining a clean surface is too costly, the allowable soluble chloride ion content shall be agreed by the Contractor and Owner.

6.2.6

Other restrictions on coating applications include:

6.2.7

i.

Applied coatings for offshore and onshore near marine environment shall not be left without overcoating for a period more than 3 days or the maximum over coating time recommended by the Manufacturer whichever is shorter. If this is exceeded, high pressure (e.g. 200 psi) fresh water washing shall be conducted prior to the application of the subsequent coats and validated with soluble chloride ion test.

ii.

Applied coatings for onshore away from marine environment shall not be left without overcoating for a period of more than 14 days or the maximum over coating time recommended by the Manufacturer whichever is shorter. If this is exceeded, high pressure (e.g. 200 psi) fresh water washing shall be conducted prior to the application of the subsequent coats and validated with soluble chloride ion test.

iii.

Zinc or aluminium in the form of coating pigments or metal spray shall never be allowed to come into contact with stainless steel, nickel-based alloys or copper-based alloys.

iv.

Any coatings or coatings used on stainless steel, nickel based alloys and copper based alloys shall be chloride free and also free of low melting point metals such as zinc, aluminum, tin and lead.

v.

On structural steel areas subject to be assembled by high tension bolts, contact surface shall be primed only with Inorganic Zinc Silicate. Intermediate and final coat shall not be applied.

Compatibility with Existing Coating System: i.

For spot repair and renovation the selected coating systems shall be the same as or compatible with existing coating systems.

ii.

Epoxies and polyurethanes may only be applied on top of alkyd coatings in exceptional cases and only after a thorough investigation has been conducted into the softening and adhesion of the proposed coating system. In such cases the coating manufacturer shall be consulted.

iii.

Silicate-based coatings shall not be applied on top of organic coatings or organic shopprimers as there is insufficient intercoat adhesion.

iv.

Some hot-surface-applied maintenance coatings may be used for application o n hightemperature surfaces if their performance has been demonstrated. The temperature measurements shall be made a minimum of three times per shift during the progress of the work.

APPLICATION METHODS

6.3.1

General Requirements i.

The completed coating shall be uniform and free from defects such as runs, sags, pinholes, fish eyes, bubbles, orange peel, grit or dust inclusions, or other deleterious anomalies, and be of good visual appearance. The topcoat shall completely hide the



color of the underlying coat. ii.

Particular care shall be taken to ensure that sharp edges, welds, irregular shaped structures, crevices, corners, weld lines, bolt heads, nuts, small brackets and inaccessible areas are adequately coated to the full film thickness. To achieve this, sharp edges and welds shall be precoated (stripe coated) by brush application immediately prior to application of each coat of coating.

iii.

Edges of existing coating shall be feathered towards the substrate prior to overcoating to ensure good adhesion.

iv.

Inaccessible surfaces 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 coating system. Contact surface of bolted connections shall be primed.

v.

Contrasting colour shall be used for each coat of coating so as to ensure different coats are applied to meet the required dry film thickness.

vi.

Zinc silicate primers shall be sealed with a tie coat as soon as practical after complete curing has taken place to avoid salt or chemical contamination.

vii.

A holding or temporary protective primer may be used to facilitate shop or site handling procedures. Such primers shall in no way replace the function o r part of the film thickness of the priming coat originally quoted in the applicable coating specification.

viii.

Other considerations: a) Coating of small bore pipework (3" NPS) and smaller shall be applied by brush or pipe roller. b) Externally marine exposed non-galvanised bolts and nuts which cannot be over coated due to operational requirements shall be encased in a corrosion resistant lubricant based on the approval of Owner. c) Valve stems and threaded stems shall be applied with suitable corrosion resistant lubricant, subject to approval of Owner.

ix.

Type of application is as per Table 6-1 below.

Type of Application Airless Spray

Conventional Air Spray

Recommended Usage

For large areas application

Not Applicable

Description

Coatings are sprayed at higher pressure without compressed air. Twice as fast, provides higher film build, higher transfer efficiency and more economical. Versatile use but often leads to overspray and uneconomical costing.

Notes

Spray patterns have to be observed as clogging may occur and different spray patterns may require different nozzle. Not Applicable



Type of Application Brush Application

Roller

Recommended Usage

When spraying is not possible

Description

Good for complex shaped substrate that cannot be spray coated.

When spraying is not Not Applicable possible and primer has been roller coated as well Table 6-1: Types of Application

Notes

Correct application and technique may avoid overcoating i.e. too thick or thin Not Applicable

REPAIRS AND TOUCH UP COATING

6.4.1

6.4.2

General Requirements i.

Procedure for repair and/or touch up coating for each generic coating system shall be submitted by contractor for Owner approval.

ii.

Before application of any subsequent coating material, all damages from previous coats shall be repaired. All loose coating 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 coating. Surface preparation shall refer to Maintenance Coating requirements of this PTS.

iii.

If the surface being prepared lies adjacent to a sound coated surface, the surface preparation shall overlap the coated surface by at least 50mm. The remainder of existing coated surface shall be properly protected with shields or screens to prevent any possible damage to the coating.

iv.

Inorganic Zinc primer shall not overlap adjacent intermediate and finish co ats. Areas with inadequate coating thickness shall be thoroughly cleaned and if necessary, abraded, and additional compatible coats are applied until the specified thickness is met. These additional coats shall blend in with the final coating on adjoining areas.

Damaged Coating Not Exposing Substrate Surface Surface to be overcoated 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 to the Maintenance Coating requirements of this PTS.

6.4.3

Damaged Coating Exposing Substrate Surface The damaged area shall be cleaned to the original or maintenance coating system specified for that item. The full coating system to be 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.



6.4.4

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 Owner approval. In such cases, subject to operating temperature limitations, one or two packs of recoatable zinc primer may be used in lieu of zinc silicate primer subject to Owner approval.

6.4.5

Repair of Fully Cured Epoxy Coating In case of repair to damage 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 as describe in ASTM D5064.

6.4.6

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.

6.4.7

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 of non-metallic type.



7.0

QUALITY CONTROL (QC) GENERAL

7.1.1

Compliance to this PTS shall be controlled through inspection and testing during all phases of surface preparation and coating application.

7.1.2

Owner shall have the right to inspect and assess the coating work at all stages of preparation and application and to reject any or all tools, instrument, materials, equipment, personnel or work which does not conform to this PTS.

7.1.3

All QC requirements and acceptance criteria shall be stated in Project Specification and incorporating the requirement of this PTS, the Owner and coating manufacturer.

7.1.4

All and any coating activity greater than 2000 m 2 shall be supervised by a certified Owner appointed Coating Inspector, and under no circumstances will the Contractor’s Coating Inspector substitute this QA/QC role. All exceptions or deviations to this rule will be reviewed under an approved MOC for approval by Owner. QUALITY REQUIREMENTS

7.2.1

The Contractor shall be fully responsible for ensuring that all surface preparation, coating and wrapping work meets the relevant Owner QC standards, in addition to being carried out in a timely and professional manner.

7.2.2

The Contractor and his Sub-Contractors shall operate a Q uality Management System meeting the requirements of the relevant parts of ISO 9001.

7.2.3

Prior to placement of the contract, the Contractor and Sub-Contractors shall demonstrate the compliance of their Quality Management System with Owner requirements by submitting their QA Manual for review and approval. The QA Manual, as a minimum, shall contain: i.

The company profile and Quality Policy Statement.

ii.

The management structure organogram and details of individual managerial responsibilities.

iii.

Detailed list of all the activities carried out by the company with their interactions, preferably accompanied by a Flowchart.

iv.

The QC Plans for each activity from material purchasing and handling through to final inspection, testing and document control, including the treatment of nonconformances and corrective actions.

v.

Document Control System for the review and update of procedures and the retention of quality control records related to each contract.

vi.

Employee training and education system and records.

vii.

Auditing methods procedures, including incident or accident investigation.

viii.

Safety and environmental policy and assessment of each activity.



7.2.4

The Contractor and Sub-Contractors shall be subject to audit by Owner prior to placement of the contract and during the execution of the contract, as deemed necessary.

7.2.5

All personnel involved in the preparation, coating work and any Sub-Contractor proposed for this work shall be formally approved by the Owner, before the work begins.

7.2.6

Prior to commencement of the work, a formal minuted Pre-start Meeting shall be held between the Owner, Contract Administrator, relevant Contractor management and supervisory staff and Coating Inspectors. The full scope of the work required under the contract shall be discussed. All issues relating to the clarity or consistency of the surface preparation and/or coating requirements detailed within the tender documents and on relevant drawings shall be formally raised and clarified at this meeting. This will enable the quality requirements for the work to be mutually agreed. INSPECTION AND TESTING

7.3.1

Prior to commencement of the work, the Contractor shall submit his ITP (sample in Appendix 13) to Owner for review and approval. This shall detail the individual preparation, coating activities involved and the inspection and test methods that will be used to ensure that they are c arried out to an acceptable standard. The ITP will generally be in table form and will indicate the type and level of inspection and testing that is required at each stage of the work. It shall also contain references to verifying documents, acceptance criteria and personnel responsible for each activity.

7.3.2

The Contractor shall maintain a comprehensive recording and reporting system on all aspects of surface preparation, coating application and QC inspection and testing. This shall as a minimum meet all the requirements of this PTS. A final report shall be submitted to Owner, summarizing all the work performed and the inspection and test results for approval. PROCEDURE AND REPORT

7.4.1

Prior to commencement of coating activities, Contractor shall submit surface preparation coating application procedure which includes inspections and tests to be conducted for approval by Owner.

7.4.2

All observations, data and test result of the surface preparation and coating application activities shall be documented by Contractor in pre-approved format. These reports shall include: i.

Names of the Contractor and the responsible personnel including blaster, Painter, and coating and lining applicator.

ii.

Date, time and duration when coating activities were carried out, including surface preparation, coating application, inspection and testing activities.

iii.

Equipment, materials, abrasive media and techniques used for surface preparation and coating application.

iv.

Type and calibration validity of instruments and tools used.



v.

Environmental conditions including relative humidity, dew point temperature and surface temperature.

vi.

Condition of structure to be coated before and after surface preparation.

vii.

Information on coating systems and coating material being applied including manufacturer, type, batch number and shelf life.

viii.

Mixing tools and techniques prior to application.

ix.

7.4.3

Type and results of inspection and testing performed and compliance to standard and specification.

All report shall be reviewed and approved by Owner.



8.0

RESOURCE REQUIREMENT COATING CONTRACTOR

8.1.1

Coating contractors shall have the personnel, organisation, qualifications, procedures, knowledge and capability to produce surface preparation and coating application of the required quality. The procedure for evaluating qualifications of coating contractors is described in SSPC-QP1.

8.1.2

Functional areas to be evaluated shall include the following:

Roles Coating Inspector

i.

Management Procedures: Company policy and management procedures

ii.

Technical Capabilities: Personnel qualifications, technical resources, procedures, equipment, facilities and experience

iii.

Quality Control: Personnel qualifications, inspection procedures and recording systems

iv.

Safety: Safety procedure, record systems and resource materials

Responsibilities To ensure the coating quality is in accordance with the specification. The inspector may be required, as a minimum, to review, validate, witness, verify and document the work at various inspection points as per the ITP as per Appendix 13.

Note that this Coating Inspector is only responsible for his area of work. Overall coating project responsibility lies with the coating advisor Note that this role does not absolve the Coating Contractor of their overall QA/QC responsibilities. The Coating Inspector is in charge of areas ≥ 5000m 2 area to be coated in a single project.

Coating Advisor

To ensure the overall project coating quality is in accordance with the specification. The role of the advisor is to oversee all of the coating inspector’s activities. This role is an ad-hoc position by appointment given to a qualified Owner. Note that this role does not absolve the Coating Contractor of their overall

Qualifications Certified with either one of below as a minimum. Institute of Materials  Malaysia (IMM) Coating Inspector Level II NACE International  Certified Coating Inspector Level I SSPC PCI Level I  FROSIO Level II 

Notes IMM Coatings Fingerprint Quality Controller Level 1 certification is an advantage

Abseiling certification may be required

And minimum 3 years working experience in coating inspection with good working knowledge on all aspects of coating such as procedures, specification, coating performance, application and able to use coating inspection tools.

Certified with either one of below as a minimum. Institute of Materials Malaysia (IMM) Coating Inspector Level II NACE International Certified Coating Inspector Level II SSPC PCI Level II FROSIO Level III





 

IMM Coatings Fingerprint Quality Controller Level 1 certification is an advantage



Roles

Responsibilities QA/QC responsibilities.

The Coating Advisor is typically in charge of areas ≥ 10,000m 2 area to be coated in a single project.

Roles Blasting and Coating Supervisor



















Lead Blaster



Responsibilities The Blaster and Coating Supervisor assumes the overall execution of any coating activity Shall participate in developing JSA and JHA. Shall develop job plans and ensure adequate QC coverage based on projected schedules or minimum QC coverage by crew, structure, location, or working hours. Able to troubleshoot any application issues and help raise MOC. Ensure understanding of work scope, requirements of work and safety compliance among team members. Ensure surface preparation and coating application is done properly by adherence and compliance to procedures, technique, environment, equipment setups and limitations etc. to avoid defects. Ensure timely and quality job completion with most economical approach avoiding wastage. Keep track and act upon daily progress, material consumption and ordering of stock. Ensure equipment and material are stored according to manufacturer recommendations. Shall be able to carry out the company accepted

Qualifications

Notes

And minimum 5 years working experience in coating inspection with good working knowledge on all aspects of coating such as procedures, specification, coating performance, application and able to use coating and coating inspection tools.

Qualifications Shall be certified with either one of below as a minimum. Institute of Materials  Malaysia (IMM) Blasting and Coating Supervisor Institute of Materials  Malaysia (IMM) Coating Inspector Level II SSPC C7 Abrasive  Blasting Program, C12 Spray Application Program, or SSPC Coating Applicator Specialist Level I

And minimum 7 years working experience in coating inspection with good working knowledge in specification and procedures. Knowledge shall include: Corrosion Coating and Properties Marine environment for coating Volume of solid Coating defects Quality control Inspection Safety Role of Supervisor Human relations

  

      

Shall be certified with either one of below as a

Notes Not Applicable



Roles and Painter









i. 

 

ii. 



Responsibilities surface preparation and application of coatings safely and to the minimum required quality of this PTS. Shall be able to work independent of any direct supervision. Shall supervise up to a maximum of ten (10) blasters and P ainters. Shall be able to understand and apply PTW, JSA, JHA; read and apply manufacturers data sheet, MSDS and coating system sheets, coating specifications Shall be competent and skilful with the following operations (as a minimum): Blasting;

Qualifications minimum. Institute of Materials  Malaysia (IMM) Certified Lead Blaster and Painter Akademi Binaan  Malaysia/CIDB Certified Blasters and Painters SSPC Abarasive  Blasting Program (C7) and Spray Application Program (C12), or SSPC Coating Applicator Specialist Level I

Notes

And minimum 5 years working experience in blasting and coating.

Equipment Set Up (Type of Nozzle, Compressor Pressure, Type of Hose, After Cooler). Abrasive (Type, Size). Surface Quality Achieved. Coating; Equipment (Application Method, Air Pressure, Tip Size) Specialist Coatings and Linings Applications (Product used, Generic name, Mixing Ratio, Mixing Method, Thinner, Percent thinning, Expected Pot Life, Thickness required)

Lead Blaster or Painter should be capable of working effectively from scaffolding or temporary structures and at heights up to 300m above water.

Blaster and Painter







i.

Shall be able to carry out the company accepted surface preparation and application of coatings safely and to the minimum required quality of this PTS. Shall be working under the supervision of a lead blaster and Painter. Shall be competent and skilful with the following operations (as a minimum): Blasting; 

Equipment Set Up (Type of Nozzle, Compressor Pressure, Type of Hose, After Cooler).

Shall be certified with either one of below as a minimum. Institute of Materials Malaysia (IMM) Certified Blaster and Painter Akademi Binaan Malaysia/CIDB Certified Blasters and Painters SSPC Abarasive Blasting Program (C7) and Spray Application Program (C12)







Abseiling certification may be required



Page 46 of 111 Roles

ii.

Responsibilities Abrasive (Type, Size).  Surface Quality Achieved.  Coating; 



Qualifications And minimum 1 years working experience in blasting and coating.

Notes

Equipment (Application Method, Air Pressure, Tip Size) Coating Used (Product used, Generic name, Mixing Ratio, Mixing Method, Thinner, Percent thinning, Expected Pot Life, Thickness required)

Blaster or Painter should be capable of working effectively from scaffolding or temporary structures and at heights up to 300m above water.

Table 8-1: Resource Requirements

INSPECTION EQUIPMENT

8.2.1

The coating 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, but not limited to the following:

Item No

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 Salinity Refractometer / Salt Contamination Meter

10

Purpose

Item Description

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 D4285)

Weather Condition Check

Blasting Equipment Check

Surface Quality Check

Coating Thickness Check Holiday Detector Adhesion Check Air Cleanliness

Table 8-2: Recommended inspection equipment



9.0

HEALTH, SAFETY AND ENVIRONMENT (HSE) SAFETY AND HEALTH REGULATIONS

9.1.1

For international projects, all coating activities shall comply with the HSE requirements of the host country.

9.1.2

Coating activities shall be in compliance to Factories and Machinery (Mineral Dust) Regulations, 1989 or equivalent, permissible exposure limit, exposure monitoring, methods of compliance, personal protective equipment, housekeeping, medical examinations, changing rooms and lockers, employee information and training, record keeping and warning signs.

9.1.3

If existing coating contains metallic lead, the removal of lead base coating shall comply with Factories and Machinery (Lead) Regulations, 1984 or equivalent.

9.1.4

Coating products and abrasives shall be in compliance with Occupational Safety and Health (classification, labelling and safety data sheet of hazardous chemicals) regulations 2013 on packaging, labelling, safety data sheet, inventory of hazardous chemicals and confidential business information. Site blasting area shall have approval from the Local Authority of the host country (e.g. DOSH).

9.1.5

Owner 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 recognized such as: i.

Materials a) Fire Hazards and Explosions b) Health Hazards

ii.

Coating Application

iii.

Surface Preparation

iv.

Access and Ringing a) Ladders b) Fall Hazards c) Confined Spaces

v.

Equipment Grounding



9.1.6

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.

9.1.7

Contractor HSE 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.

9.1.8

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 personnel at work.

9.1.9

The components of an OSHA Compliance Programme shall include: i.

Policy statement establishing goals and commitment of management and the means for communicating these to all employees.

ii.

Delegation of responsibilities for implementing the programme.

iii.

Methods of identifying hazards and hazardous activities and for controlling them.

iv.

Commitment to on-going training and education of all supervisors and employees on all aspects of job safety and health.

v.

Proper reporting and record keeping, and investigation of all incidents, injuries and illness.

vi.

Methods and procedures for complying with specific OSHA regulations.

vii.

Periodic review of programme with revisions made as necessary.

ENVIRONMENTAL REGULATIONS

9.2.1

Under the Environmental Quality (Scheduled Wastes) Regulations 2005, every waste generator shall ensure that the scheduled waste generated is properly treated, stored and disposed of.

9.2.2

Every waste generator shall ensure that the scheduled waste that is subjected to movement or transfer be packaged, labelled and transported in accordance with the guidelines prescribed by the director-general of the Department of Environment.

9.2.3

Scheduled waste shall be stored in containers which are compatible with the waste and durable to prevent spillage or leakage.

9.2.4

All handling of waste materials including but not limited to spent abrasives, coatings, thinners, solvents and cleaners shall be performed in safe and legal manner and shall comply with all applicable regulations and laws.

9.2.5

For regulations on abrasives, coating products, waste production, product storage and leaching of coatings, refer to Appendix 19.



10.0

COLOUR SCHEMES STRUCTURAL COLOUR SCHEMES

10.1.1 The colour scheme for structures shall be as per Appendix 9. PIPING COLOUR SCHEMES AND IDENTIFICATION SYSTEM

10.2.1 The colour scheme for piping shall be as per Appendix 8. The piping identification system shall be as per Appendix 7. 10.2.2 For insulated and non-insulated piping identification, the product contained shall be marked by a legend specifying product name in full or abbreviated form. Arrows shall be used to indicate direction of flow. In cases where the piping changes direction or where pipe passes through walls or floors, arrows shall be placed in positions which are easily visible. As a minimum, arrows shall be placed at each location where the direction of the flow changes or prior to penetration of wall or floor. 10.2.3 Pipe marking may be done by either coating or using tape or markers. The application of tapes for pipe identification shall be limited to 60°C for non-insulated pipe and no temperature limit for insulated pipe. The detailed dimension, location and number of markings shall be based on particular piping system as specified in Appendix 8. 10.2.4 For systems not described in Appendix 8, the facilities owner shall determine the marking as appropriate based on ANSI A13.1- “Scheme for Identification of Piping System” . 10.2.5 Each line shall be labelled in English with its service and to/from designation (such as "Crude to L.P Separator Train 1"). The labelling shall be as short as possible, but concise. The labelling shall be applied only at the starting and termination of a line. EQUIPMENT COLOUR SCHEME

10.3.1 The colour scheme for equipment shall be as per Appendix 9. The storage tank identification system which includes product content and the tank number shall be as described in Appendix 6. PIPELINE/RISER IDENTIFICATION SYSTEM

10.4.1 Each pipeline/riser shall be marked in accordance with piping identification system as per Appendix 7. The pipeline marking shall be easily visible.



10.4.2 The marking location shall be determined by the Owner. As a minimum, the marking should be at beginning and end of pipeline. For offshore pipeline, the marking can be made at the launcher to riser section and at the receiver section. For onshore above ground pipeline, the marking can be made at the pipeline section before and after the pipeline is being buried. SAFETY COLOUR SCHEME

10.5.1 The colour scheme and marking for escape route shall be as per Appendix 10.



11.0

BIBLIOGRAPHY

In this PTS, reference is made to the following Standards/Publications. Unless specifically designated by date, the latest edition of each publication shall be used, together with any supplements/revisions thereto:

PETRONAS TECHNICAL STANDARDS

Index to PTS

PTS 00.01.01

Requirements, General Definition of Terms, Abbreviations & Reading

PTS 00.01.03

Guide Control Valves : Selection, Sizing and Specifications

PTS 14.10.04

Offshore Temporary Refuges

PTS 11.20.01

MALAYSIAN REGULATIONS

Environment Quality Act (EQA)

1974

Environmental Quality (Prescribed Premises)(Schedule Wastes

1989

Treatment and Disposal Facilities) Order Environmental Quality (Prescribed Premises)(Schedule Wastes

1989

Treatment and Disposal Facilities) Regulations Factories and Machinery (Mineral Dust) Regulations

1989

Factories and Machinery (Lead) Regulations

1984

Occupational Safety and Health (Use of Standards of Exposure of

2000

Chemicals Hazardous to Health) Regulations Occupational Safety and Health (Classification, Labelling and Safety

2013

Data Sheet of Hazardous Chemicals) Regulations Environmental Quality (Scheduled Wastes) Regulations Malaysian National Council for Occupational Safety and Health Act (OSHA) 1994

2005



INTERNATIONAL STANDARDS

Schedule of Coating for Building Purposes

BS 4800

Framework for Colour Co-ordination For Building Purposes

BS 5252

RAL Colour Chart Standards for Offshore Helicopter Landing Areas Technical Safety Assignment of Degree of Rusting

RAL CAP 437 NORSOK S-001 ISO 4628-3

Zinc Dust Pigments for Coatings

ISO 3549

Coatings and Varnishes – Pull-Off Test for Adhesion

ISO 4624

Preparation of Steel Substrates before Application of Coatings and

ISO 8501

Related Products – Visual Assessment of Surface Cleanliness Preparation of Steel Substrates before Application of Coatings and

ISO 8502

Related Products – Tests for the Assessment of surface Cleanliness Preparation of Steel Substrates before Application of Coatings and

ISO 8503

Related Products – Surface Roughness Characteristics of Blast-Cleaned Steel Substrates Preparation of Steel Substrates before Application of Coatings and

ISO 8504

Related Products – Surface Preparation Methods Plastics – Polyurethane Raw Materials – Determination of Isocyanate

ISO 14896

Content Preparation of Steel Substrates before Application of Coatings and

ISO 11124

Related Products – Specifications for Metallic Blast-Cleaning Abrasives Preparation of Steel Substrates before Application of Coatings and

ISO 11125

Related Products – Test Methods for Metallic Blast-Cleaning Abrasives Preparation of Steel Substrates before Application of Coatings and

ISO 11126

Related Products – Specifications for Non-Metallic Blast Cleaning Abrasives Preparation of Steel Substrates before Application of Coatings and Related Products – Test Methods for Non-Metallic Blast Cleaning Abrasives

ISO 11127



Coatings and Varnishes – Corrosion Protection of Steel Structures by

ISO 19840

Protective Coating Systems – Measurement of, and Acceptance Criteria for, the Thickness of Dry Films on Rough Surfaces Quality Management Systems – Requirements

ISO 9001

Coatings and Varnishes – Determination of Flow Time by Use of Flow

ISO 2431

Cups Coatings and Varnishes – Determination of Viscosity Using Rotary

ISO 2884

Viscometers Coatings and Varnishes – Determination of Density

ISO 2811

Coatings, Varnishes and Plastics – Determination of Non-Volatile-

ISO 3251

Matter Content Coatings and Varnishes – Determination of Pigment Content Graphical Symbol – Safety Colours and Safety Signs Standard Practice for Conducting a Patch Test to Assess Coating

ISO 14680 ISO 3864 ASTM D5064

Compatibility Standard Specification for Zinc Dust Pigment Standard Test Method for Isocyanate Groups in Urethane Materials or

ASTM D520 ASTM D2572

Prepolymers Standard Test Methods for Field Measurement of Surface Profile of

ASTM D4417

Blast Cleaned Steel Standard Test Method for Indicating Oil or Water in Compressed Air

ASTM 4285

Standard Practice for Operating Salt Spray (Fog) Apparatus

ASTM B117

Standard Test Method for Evaluation of Coated or Coated Specimens

ASTM D1654

Subjected to Corrosive Environments Standard Test Method for Pull-Off Strength of Coatings Using Portable

ASTM D4541

Adhesion Testers Standard Test Methods for Measuring Adhesion by Tape Test

ASTM D3359

Standard Test Method for Resistance of Organic Coatings to the Effects

ASTM D2794

of Rapid Deformation (Impact) Standard Test Method for Abrasion Resistance of Organic Coatings by

ASTM D4060

the Taber Abraser Standard Test Methods for Cathodic Disbonding of Pipeline Coatings

ASTM G8



Standard Practice for Operating Xenon Arc Light Apparatus for

ASTM G155

Exposure of Non-Metallic Materials Standard Test Methods for Evaluating Coatings for High Temperature

ASTM D2485

Service Standard Practice for Cyclic Salt Fog/UV Exposure of Coated

ASTM D5894

Metal.(Alternating Exposures in a Fog/Dry Cabinet and a UV Condensation Cabinet) Standard Test Method for Specular Gloss Standard Test Method for High-Shear Viscosity Using a Cone/Plate

ASTM D523 ASTM D4287

Viscometer Standard Test Method for Viscosity of Coatings and Related Materials

ASTM D5125

by ISO Flow Cups Standard Test Method for Consistency of Coatings Measuring Krebs

ASTM D562

Unit(KU) Viscosity Using a Stormer-Type Viscometer Standard Guide for FT-IR Fingerprinting of a Non-Aqueous Liquid

ASTM D7588

Coating as Supplied in the manufacturer’s Container Standard Test Methods for Water Vapour Transmission of Organic

ASTM D1653

Coating Films Standard Test Method for Evaluation of Painted or Coated Specimens

ASTM D1654

Subjected to Corrosive Environments Standard Test Method for Indentation Hardness of Rigid Plastics by

ASTM D2583

Means of a Barcol Impressor Standard Practice for Testing Water Resistance of Coatings Using Water

ASTM D870

Immersion Standard Test Method for Tensile Properties of Organic Coatings Standard Test Method for Measuring Humidity with a Psychrometer

ASTM D2370 ASTM E337

(the Measurement of Wet- and Dry-Bulb Temperatures) Standard Practice for Discontinuity (Holiday) Testing of Nonconductive

ASTM D5162

Protective Coating on Metallic Substrates Zinc Rich Primers(Type I, Inorganic, and Type II, Organic)

SSPC-Coating 20

Mineral and Slag Abrasives

SSPC-AB 1

Cleanliness of Recycled Ferrous Metallic Abrasive

SSPC-AB 2



Ferrous Metallic Abrasive

SSPC-AB 3

Procedure for Determining Conformance to Dry Coating Thickness

SSPC PA 2

Requirements Solvent Cleaning

SSPC-SP 1

Hand Tool Cleaning

SSPC-SP 2

Power Tool Cleaning

SSPC-SP 3

White Metal Blast Cleaning

SSPC-SP 5/NACE No.1

Commercial Blast Cleaning

SSPC-SP 6/NACE No.3

Brush-Off Blast Cleaning

SSPC-SP 7/NACE No.4

Pickling Near White Blast Cleaning

SSPC-SP 8 SSPC-SP 10/NACE No.2

Power Tool Cleaning to Bare Metal Surface Preparation and Cleaning of Metals by Waterjetting Prior to Recoating

SSPC-SP11 SSPC-SP 12/NACE No.5

Commercial Grade Power Tool Cleaning

SSPC-SP15

Guide and Reference Photographs for Steel Surfaces Prepared by Dry

SSPC VIS 1

Abrasive Blast Cleaning Field Methods for Extraction and Analysis of Soluble Salts on Steel and

SSPC Guide 15

Other NonPorous Substrates Wet Abrasive Blast Cleaning

SSPC-TR 2/NACE 6G198

Dehumidity and Temperature Control During Surface Preparation,

NACE 6A 192

Application, and Curing for Coatings/Linings of Steel Tanks, Vessels, and Other Enclosed Spaces Discontinuity (Holiday) Testing of New Protective Coatings on

NACE RP 0188

Conductive Substrates Scheme for Identification of Piping System

ANSI A13.1





Page 57 of 111

APPENDIX 1: COATING SYSTEM PRODUCT APPROVAL REQUIREMENT A.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. A.2

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)

ASTM B117 ASTM D1654 (Proc. B)

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

4,500 hours, coating defects as per ASTM D1654 Proc. B, area failed Rating No.9

Adhesion

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 coatings to resist cracking due

18 J (Intrusion)

Abrasion

ASTM D4060

To assess quantitatively the abrasion resistance of the coatings.

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



Cathodic Disbonding

ASTM G8

To assess resistance of coating to Cathodic

< 10 mm disbondment.

Accelerated Weathering

ASTM G155

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 D2485, Test Method B

To evaluate the heat-resistant 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

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

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

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 D523.



APPENDIX 2: COATING FINGERPRINT CERTIFICATE FOR 2-COMPONENT INTERMEDIATE MATERIALS OF POLYMERIC COATINGS B.0

COATING FINGERPRINT CERTIFICATE FOR 2-COMPONENT INTERMEDIATE MATERIALS OF POLYMERIC COATINGS

Company name:

Country:

Section 1: General information Product name:

Product type:

Date of issue:

Base material (e.g. epoxy / epoxy zinc / polyacrylate / polyester / inorganic zinc)

Specify base material & e.g. epoxy curing agent

e.g. epoxy, polyurethane, polyester, inorganic zinc, epoxy zinc, etc.

Curing agent / hardener (e.g. amine / isocyanate / peroxide / ethylsilicate)

e.g. amine

Trade name Generic Factory location Batch number Production date Shelf life Section 2: Test Methods and Results Section 2A: Physical analyses Parameters

Method

Viscosity

e.g. ASTM D4287 ASTM D5125 ASTM D562 ISO 2431 ISO 2884-1 e.g. ISO 2811-4 e.g. BS 4800 OSHA

Density Colour code Non-volatile matter (by mass) Weight Solid: Zn metal/Total Zn Note: submit certificate of % purity by manufacturer Note: applicable to organic and inorganic zinc only

e.g. ISO 3251

e.g. ISO14680-2

Specification (state method used)

Result

Specification

Result



Page 60 of 111

Infrared spectra

Base material: epoxy Curing agent: amine Base material: polyacrylate / polyester Curing agent: isocyanate Base material: polyester Curing agent: peroxide Base material: epoxy zinc Curing agent: amine Base material: inorganic zinc Curing agent: ethylsilicate

Section 2B: Structural analysis Wet sample as supplied in can. Matching criteria ≥ 0.9 Std. Ref. Base Hardener -1 ASTM D7588 600-4000 cm 600-4000 cm-1 ASTM D7588 1000-1300 cm-1 1000-1400 cm-1 700-900 cm-1 N/A ASTM D7588 -1

N/A

-1

ASTM D7588 ASTM D7588 ASTM D7588 ASTM D7588 ASTM D7588 ASTM D7588 ASTM D7588 ASTM D7588 ASTM D7588 ASTM D7588

600-4000 cm 1600-1800 cm-1 3000-3800 cm-1 600-4000 cm-1 1600-1800 cm-1 2700-3100 cm-1 600-4000 cm-1 1000-1300 cm-1 700-900 cm-1 600-4000 cm-1

600-4000 cm 2000-2500 cm-1 3000-3800 cm-1 600-4000 cm-1 900-1200 cm-1 N/A 600-4000 cm-1 1000-1400 cm-1 N/A 600-4000 cm-1

ASTM D7588

N/A

N/A

2700-3200 cm-1

ASTM D7588

N/A

N/A

1000-1500 cm-1

N/A

N/A

Section 3: FTIR test details (as per ASTM D7588)

Analyst & company name Brand & model of FTIR Benchtop: ATR crystal material Spectral correction Note: correction is NOT recommended. Spectral range (cm-1) No. of sample scans (min 32) Resolution (min 4 cm-1) Correlation search algorithm for matching % in absorbance mode

e.g. diamond, zinc selenide (ZnSe), zinc sulfide (ZnS), germanium YES / NO e.g. automatic baseline correction e.g. 600-4000 cm-1 e.g. 32 scans e.g. 4 cm-1 Note: Correlation search algorithm of the FTIR software must depend on both (wavenumber) and y - (absorbance) vectors. Dependence on x -vector (wavenumber / cm-1)

YES / NO

Dependence on y -vector (absorbance / a.u.)

x -

YES / NO

Trade name and batch number of reference spectrum for base material Trade name and batch number of reference spectrum for curing agent / hardener

Notes: 1. Full range of FTIR spectra for both base and curing agent without automatic baseline correction and in absorbance mode are to be attached with this report (raw data).



2. Compliance to matching criteria values do not exclude meeting the requirements of other QA/QC checks e.g. drying time, gloss, hiding power etc. 3. Methods used shall reference latest published document. Authorized QA/QC Executive:-

Validated by:-

Signature:

Signature:

Date:

Date: IMM membership member:

Section 4: Compulsory appendices (to be submitted in CD or other digital format)

Appendix 1 Appendix 2 Appendix 3 Appendix 4 Appendix 5

Overlay reference and sample FTIR spectra for base materials (Note: In addition, raw data of reference and sample FTIR spectra must be provided in two raw data files) Overlay reference and sample FTIR spectra for curing agent / hardener (Note: In addition, raw data of reference and sample FTIR spectra must be provided in two raw data files) Relevant MSDS Certificate of analyses which are relevant to the in-house standard testings Certificate of % purity of zinc by metal manufacturer for organic zinc and inorganic zinc



APPENDIX 3: APPROVED VENDOR COATINGS LIST































APPENDIX 4: GLASS FLAKE 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. D.1

Type of Polyester

The polyester resin shall be either Bisphenol A or Isophtalic. D.2

Wax Content

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). D.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. D.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. D.5

Volume Solids

The product shall have a volume solid of 95% minimum. D.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. D.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. D.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.



D.9

Hardness

The Barcol hardness shall be within the range of 35 – 45 as measured in accordance with ASTM D2583. D.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. D.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. between 10-90 x 10 -6/° C. D.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. D.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. D.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. D.15

Safety

The Manufacturer shall provide the Owner and the relevant applicator with a valid Materials Safety Data Sheets (MSDS).



APPENDIX 5 E.0

GLASS FLAKE 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.

E.1

Type of Epoxy

The epoxy resin will be based on liquid epoxy. E.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, the percentage of glass loading can be variable without a compromise on system performance with respect to water resistance during immersion; and i ts 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. E.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. E.4

Volume Solids

The product should have a minimum volume solids of 90%. E.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. E.6

Drying Times

The product shall hard dry within 4 to 10 hours at temperature range of 25° to 40° C. E.7

Hardness

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



E.9

Other Properties

Other properties required to achieve good mechanical properties are as follows: Tensile Strength (ASTM D2370) - 10 M Pa (1450 psi.) Elongation (ASTM D2370) - 2% The coefficient of thermal expansion shall be in the same order as that of steel i.e. between 10-90 x 10 -6/° C. E.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. E.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. E.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. E.13

Safety

The Manufacturer shall provide the Owner and the relevant applicator with a valid MSDS.



APPENDIX 6: STORAGE TANK IDENTIFICATION SYSTEM

LOCATION OF ITEM NUMBER AND SIZE OF LETTERING FOR STORAGE TANK  =  ℎ =

=

=

2 3 2 3

 −  

1 2





1 12



Lettering Location

: Black : Fixed at field



Page 82 of 111

APPENDIX 7: PIPING IDENTIFICATION SYSTEM G.1

PIPING IDENTIFICATION MARKING

TYPE

IDENTIFICATION LEGEND

PIPE O.D. A

B

C

FLOW DIRECTION ARROW D

E

1

0.75 – 1.25

0.5

0.75

8.00

0.75

4.00

2

1.50 – 2.00

0.75

1.00

8.00

1.00

5.00

3

2.50 – 6.00

1.25

2.25

12.00

2.25

8.00

4

8.00 – 10.00

2.25

4.00

24.00

4.00

12.00

5

Over 10.00

3.75

5.00

32.00

5.00

16.00

Note: Unit in Inches



Page 83 of 111

APPENDIX 8: PIPING COLOUR IDENTIFICATION LEGEND

SERVICE PROCESS LINE Gas Liquid Process DRAIN & RELIEF Drain, Hot Oil Drain, Pressurised Drain, Hazard Drain, Condensate Flare, High Pressure Flare, Low Pressure Vent Vent, Atmospheric STEAM & CONDENSATE Condensate Steam Boiler Feed Water UTILITY WATER Cooling Water Firewater Potable Water Service Water Ballast Water Sea Water Washdown Chilled Water UTILITY AIR & GENERAL Air, instrument Air, utility UTILITY GAS & FUEL Blanket gas Diesel fuel Aviation fuel Fuel gas Nitrogen Gas, Instrument Gas, Utility UTILITY OIL Lube oil Seal oil Hot oil Hydraulic CHEMICALS

IDENTIFICATION LEGEND

COLOUR DIRECTION ARROW

CODE

BACKGROUND

CODE

Black Black Black

00E53 00E53 00E53

OSHA Yellow OSHA Yellow OSHA Yellow

RAL 1003 RAL 1003 RAL 1003

Black Black Black Black Black Black OSHA Blue OSHA Blue

00E53 00E53 00E53 00E53 00E53 00E53 RAL 5005 RAL 5005

OSHA Yellow OSHA Yellow OSHA Yellow OSHA Yellow OSHA Yellow OSHA Yellow White White

RAL 1003 RAL 1003 RAL 1003 RAL 1003 RAL 1003 RAL 1003 00E55 00E55

Condensate Steam Boiler H2O

Black Black Black

00E53 00E53 00E53

OSHA Yellow OSHA Yellow OSHA Yellow

RAL 1003 RAL 1003 RAL 1003

Cooling H2O Fire H2O Potable H2O Service H2O Service H2O Service H2O Chilled H2O

OSHA Green OSHA Red OSHA Green OSHA Green OSHA Green OSHA Green OSHA Green

RAL 6032 RAL 3001 RAL 6032 RAL 6032 RAL 6032 RAL 6032 RAL 6032

White White White White White White White

00E55 00E55 00E55 00E55 00E55 00E55 00E55

inst. air utility air

OSHA Blue OSHA Blue

RAL 5005 RAL 5005

White White

00E55 00E55

blanket gas diesel fuel aviation fuel fuel gas nitrogen inst. gas utility gas

Black Black Black Black OSHA Blue Black Black

00E53 00E53 00E53 00E53 RAL 5005 00E53 00E53

OSHA Yellow OSHA Yellow OSHA Yellow OSHA Yellow White OSHA Yellow OSHA Yellow

RAL 1003 RAL 1003 RAL 1003 RAL 1003 00E55 RAL 1003 RAL 1003

Black Black Black Black

00E53 00E53 00E53 00E53

OSHA Yellow OSHA Yellow OSHA Yellow OSHA Yellow

RAL 1003 RAL 1003 RAL 1003 RAL 1003

Gas Liquid Process Hot oil drain Pressure, drain Hazard, drain Cond. drain H.P. Flare L.P. Flare Vent line Atm. vent

lube oil seal oil hot oil hydraulic



Page 84 of 111

SERVICE Chemical Glycol Caustic chlorine Chemical GENERAL Treated water Black water Grey water Hot water

IDENTIFICATION LEGEND chemical glycol caustic chlorine chemical treated H2O black H2O grey H2O hot H2O

COLOUR DIRECTION ARROW Black Black Black Black Black

CODE

BACKGROUND

CODE

00E53 00E53 00E53 00E53 00E53

OSHA Yellow OSHA Yellow OSHA Yellow OSHA Yellow OSHA Yellow

RAL 1003 RAL 1003 RAL 1003 RAL 1003 RAL 1003

OSHA Green OSHA Green OSHA Green Black

RAL 6032 RAL 6032 RAL 6032 00E53

White White White OSHA Yellow

00E55 00E55 00E55 1003



Page 85 of 111

APPENDIX 9: COLOUR SCHEME FOR ONSHORE/OFFSHORE INSTALLATION AND EQUIPMENT I.1

STRUCTURE COLOUR SCHEME

NO

COMPONENTS

1.1

Splash Zone/Spider Deck - Offshore structural members steel below castellation point (shim connection splash zone substructures), spider deck and boat landing Cellar Deck to Main Deck including Bridge Structure - Structural member, from cellar deck up to the main deck, castellation point outwards, beam, girder, pipe & cable support, conduits barrel

1.2

1.3

1.4

1.5

1.6

1.7

1.8

1.9

COLOUR

CODE BS4800

RAL

BS381C

RGB

Yellow

10E53

-

-

233;193;0

Yellow

10E53

-

-

233;193;0

Yellow

10E53

-

-

233;193;0

Yellow

10E53

-

-

233;193;0

Yellow

10E53

-

-

233;193;0

Yellow

10E53

-

-

233;193;0

OSHA orange

-

2009

-

222;83;7

White Yellow

00E55 10E53

-

-

241;242;234 233;193;0

Yellow White

10E53 00E55

-

-

241;242;234 233;193;0

Yellow WhiteWhite

10E53 00E55

-

309 -

233;193;0 241;242;234

9010/ 9003 1003

267 537 -

66;94;79 160;68;59 241;242;234

-

249;168;38

Deck Plate

Chequer Plate

Footway, walkway, stairway supports and monkey ladder Grating panel (maintenance only)

Handrail and kick plate

Module (including Living Quarter) - Interior Wall and Interior Ceiling - External part of partition wall at module - Deck Top of Living Quarter - Production Shed & Equipment Store Helideck Structure - Structure and underside helideck - Netting frame

1.10

Helideck landing area (as per CAP437 and PTS 37.19.10.31)

Dark Green Red White

14C39 04E53 -

1.11

Brucker Davit Structure for Lifeboat

OSHA Yellow

-



Page 86 of 111 -

1.12

The colour may be selected from the options listed according to specific operator practise.

OSHA Orange OSHA Red OSHA Green OSHA Blue

-

2009 3001 6032 5005

-

222;83;7 155;36;35 35;127;82 0;83;135

Yellow

10E53

-

-

233;193;0

Riser (splash zone until launcher/receiver)

Yellow

10E53

-

-

233;193;0

Pipe rack along with its support legs (for onshore application)

White

00E55

-

-

241;242;234

Instrument Control Panel, Instrument & Lighting Stand

White

00E55

-

-

241;242;234

Aluminium

-

9006

-

161;161;160

OSHA Red White

00E55

3001 -

-

155;36;35 241;242;234

00E55

3001 -

-

155;36;35 241;242;234

Conductor pipe (splash zone and above)

1.13

1.14

1.15

1.16

Offshore flare boom inclusive of piping and associated structure from bottom of the structure to the top of flare boom Note: High temperature coating system for application at flare boom. Onshore flare tower

1.17

(in seven alternate bands) 1.18

Communication tower

I.2

PIPING COLOUR SCHEME

NO

2.1

OSHA Red White (in seven alternate bands)

COMPONENTS

COLOUR

CODE BS4800

RAL

RGB

White

00E55

-

241;242;234

OSHA Red

-

3001

155;36;35

Aluminium

-

9006

161;161;160

OSHA Yellow

-

1003

249;168;38

Pipework Note: This excludes firewater line and foam line.

2.2 Pipework for firewater service 2.3

Process/Utility piping operating above 110 oC Note: This is also applicable for piping along flare boom.

2.4 Pipework for foam system



Page 87 of 111

I.3

VALVE COLOUR SCHEME

NO

3.1

COMPONENTS

3.3

3.4

3.5

CODE BS4800

RAL

RGB

White

00E55

-

241;242;234

OSHA Red

-

3001

155;36;35

As per operation practise

-

-

White OSHA Red OSHA Green Grey OSHA Red OSHA Green

00E55 00A05 -

3001 6032 3001 6032

241;242;234 155;36;35 35;127;82 177;176;174 155;36;35 35;127;82

Black

00E53

-

47;47;48

Valve body Note: This is applicable for all valves except valves for fire water system

3.2

COLOUR

Valve for fire water system

Pressure relief valve and other operated ON/OFF actuated valve or selector valve Actuated Control Valve - Body - SDV / ESD Valve Actuators - BDV Actuators - MOV Actuators - Control Valve actuators (Fail Close) - Control Valve actuators (Fail Open) Hand wheel/handle for valve



Page 88 of 111

I.4

EQUIPMENT COLOUR SCHEME

NO

4.1

COMPONENTS

Wellheads

4.3

Storage tank

4.4

Inside drip pan including pipeworks

4.5

Jib crane and gantry crane booms and monorail track

4.7

CODE BS4800

RAL

RGB

White

00E55

-

241;242;234

Irish Green

14E53

-

43;147;104

White

00E55

-

241;242;234

Black

00E53

-

47;47;48

Alternate

00E53

-

47;47;48

Black & Yellow

10E53

-

233;193,0

Yellow

10E53

-

233;193;0

Irish Green

14E53

-

43;147;104

Irish Green

14E53

-

43;147;104

Yellow White White Irish Green

10E53 00E55 00E55 14E53

-

233;193;0 241;242;234 241;242;234 43;147;104

White

00E55

-

241;242;234

Yellow White White Irish Green

10E53 00E55 00E55 14E53

-

233;193;0 241;242;234 241;242;234 43;147;104

OSHA Blue or as per manufacturer specification

-

5005

0;83;135

Yellow White

10E53 00E55 -

-

233;193;0 241;242;234

Pressure vessels, columns, heat exchangers

4.2

4.6

COLOUR

Pedestal crane - inclusive of crane structures (pedestal adaptor, machinery deck, powerpack and other steel structures), crane boom, operator cabin and tank Pumps, motors, generators and other rotating equipment Note : Excluding firewater pump

4.8

Compressor casing

Note: Other component’s colour scheme shall be as per OEM specification. 4.9

4.10

4.11

Equipment package skid - Structure - Piping - Tank - Pump & motor body Launcher & receiver barrel including end closure Chemical injection skid - Structure - Piping - Tank - Pump & motor body

4.12

Corrosion coupon/probe cover

4.13

Nitrogen package skid - Structure - Piping - Nitrogen bottle



Page 89 of 111 As per manufacturer specification 4.14

4.15

I.5

Foam System

Pig signaller

-

1003

As per manufacturer specification

-

-

249;168;38

SAFETY COLOUR SCHEME

NO

5.1

OSHA Yellow

COMPONENTS

Escape route on deck and grating

COLOUR

CODE RGB

BS4800 -

RAL 1003

249;168;38

00E53

-

47;47;48

00E53

1003 -

249;168;38 47;47;48

OSHA Orange

-

2009

222;83;7

OSHA Yellow at pathway with OSHA Yellow and Black (in alternate bands) at border and Black arrow showing the direction

5.2

Dangerous obstructions (inclusive piping & structure)

OSHA Yellow and Black (in alternate bands)

5.3

Dangerous or exposed parts of machinery

5.4

Fire Equipment and services

OSHA Red

-

3001

155;36;35

5.5

Firewater line – including sprinkler system

OSHA Red

-

3001

155;36;35

5.6

Foam System

OSHA Yellow

-

1003

249;168;38

5.7

First Aid Equipment

OSHA Green

-

6032

35;127;82

BS4800

RAL

RGB

10E53 00E53

-

233;193,0 47;47;48

-

-

I.6 NO

6.1

6.2

MISCELLANEOUS COMPONENTS

Platform Nameplate Background Lettering

Fire proofing – inclusive of Passive Fire Protection (PFP)

COLOUR

Yellow Black

As per equipment/ structure colour

CODE



APPENDIX 10: ESCAPE ROUTE



Page 91 of 111

APPENDIX 11: INSPECTION AND TESTING REQUIREMENTS

Environmental Condition

Abrasive Materials



Ambient and steel temperature



Relative humidity



Dew point



Wind speed



Particle Size and Sharpness check by visual at all work sites



    

Compressed Air Cleanliness

Standard Test Method for Indicating Oil or Water in Compressed Air

Visual Examination of Pre-Cleaned Metal

Visual Inspection for sharp edges, weld splatter, Slivers, lamination, structurally deleterious defects, rust grade etc.

Surface

Visual Assessment of Surface Cleanliness

Cleanliness (visual)





ISO 8502-6 (Bresle)

SSPC AB 1 SSPC AB 2 SSPC AB 3 ISO 11126 ISO 11127-6

ASTM D4285

N/A



Soluble Salts (Not required if



ASTM E 337



SSPC VIS 1 or ISO 8501 ISO 8502-3

ISO 8502-6 ISO 8502-9

Before start of each In accordance with specified work activity + Every 2 requirements and Coating Hours during surface Manufacturer’s TDS preparation and coating operations





UHP Water Jetting)

No visible contamination

Service, clean and replace

100% of all surfaces

No defects

No blasting or coating application until defect is repaired





 

100% visual of all surfaces Spot checks

In accordance with specified requirements

Immersion Service: 6 samples/2000 m2 (20,000 ft2) but not less than 2 samples/ pieces of equipment or structure

Average conductivity corresponding to 20 mg/m2 and maximum conductivity corresponding to 30 mg/m2 water soluble salt(s).

Atmospheric Surfaces: 2 samples/2000 m2 (20,000 ft2)but not less than 2 samples/ pieces of equipment or structure

Average conductivity corresponding to 30 mg/m2 and maximum conductivity corresponding to 40 mg/m2 water soluble salt(s)

(or) SSPC Guide 15 (Section 4.6 & 5.3)

SSPC Guide 15 Section 4.6 (Elcometer130 SC400) SSPC Guide 15 Section 5.3 (Conductometric) Comparator, Replica tape or Stylus instrument



ISO 8503

No blasting

Before start of each shift or change in air system

ISO 8502-9 (Conductometric)



Roughness

In accordance with specified requirements, as per relevant sections of ISO 11126 and ISO 11127-6 Test plates shall be abrasive blasted for use as reference of visual appearance / anchor profile

Final surface preparation by

Every new batch and spot checks Certificate checks

No blasting or coating application or rejection of prepared or coated surface





Each component or once per 10m2.

As specified

 

Re-blasting Re-cleaning and retesting until acceptable

Steam or clean water washing and retesting until entire 2000 m2 (20,00 ft2) test area is acceptable

Re-blasting



Page 92 of 111

Visual Examination of Coating

Visual to determine: Curing, contamination, solvent retention, pinholes/popping, sagging, surface defects

Dry Film Thickness

Measurement by Dry Film Thickness Gauge

N/A

 

SSPC PA2 ISO 19840

100% of surface after each coat

None observed

Repair of defects.

As per SSPC PA2 requirements

The average DFT of each measurement point shall be 100% specified DFT,

Repair, additional coats, or recoating as appropriate

Calibration on smooth surface

Holiday Test (Supplementary Test)

NACE RP 0188 Voltage, ref. TABLE 1

No single measurement shall be less than 20% below the specified DFT





NACE RP0188 ASTM D5162

As per system specification / 100% Surface of each coat

No holidays

Repair and retesting

ASTM D4541

Spot check – not to be used for coatings to be placed in immersion

For coating types other than PFP minimum 5MPa (72PSI)

Repair and retesting

Holiday Detection only for Internal Lining or Immersion/Buried Surfaces Adhesion (Supplementary Test)

Standard Test Method for Pull-Off Strength of Coatings Using Portable Adhesion Testers





ISO 4624



APPENDIX 12: RISK MATRIX Risk Evaluation The overriding or ultimate consideration in evaluating risks associated with coatings is whether the coating is maintaining structural integrity or if coating degradation is allowing corrosion to proceed, leading to the possibility of structural failure. There is no standard method to evaluate risks; However, the most basic approach is to compare estimated partial or total metal work replacement costs with the estimated costs of a maintenance coating program. Safety to the public and workers may also be a major consideration, and these associated costs may be difficult to assess. To provide a basis for risk evaluation, inspection of the coating and substrate is recommended.



Page 94 of 111

APPENDIX 13: TYPICAL COATING QUALITY INSPECTION AND TEST PLAN CHECKLIST (SUB) CONTRACTOR WORK LOCATION PROJECT TITLE CONTRACT NO. ITM.

DESCRIPTION OF ITEM

COATING SCHEDULE DOCUMENT REF. NO. EQUIPMENT DATE ACTIONS BY

INSPECTION REQ’D

T.P.I.

A

THROUGHOUT WORKING DAY

1 2 3 4

Safety/condition of equipment/machinery Correct PPE is worn by all personnel Atmospheric relative humidity/dew point Metal surface temperature

B

BEFORE PREPARATORY CLEANING

1 2

Work methods/QC system/safety measures Permit to work in order and authorised

3 4

Visual inspection Visual inspection Psychrometer and Tables Contact thermometer

OWNER

H H I I

H H W W

H H R/H R/H

Record inspection

I

H

H

Record inspection

H

H

H

Control/inspection instruments calibrated Presence of surface-breaking defects

Visual/record inspection Visual inspection

H I

H R

H R

5 6

Defects found are satisfactorily removed Presence of gross surface contamination

Visual inspection Visual inspection

I I

R R

R R

7 8

Rust grade/degree of coating breakdown Type of water/brand of degreasing agent


I I

H R

H R

9 10

Presence of residual oil or grease Presence of residual salts*

Water spray test Salt test

I I

R R

R R

11 12

Type, brand and grade of abrasive used Acceptance of power/hand tool cleaning


I I

R W

R W/H

C

DURING PREPARATORY CLEANING

1

Batch number and date of abrasive used

Visual inspection

I

R

R

2 3

Presence of oil/water in compressed air Air pressure used for blast cleaning

Blotting paper at exhaust Hypodermic needle gage.

I I

R W

R W

4

Blast cleaning surface cleaning standard

Visual inspection v. Std.

I

W/H

W/H

5

Profile height of blast cleaned surfaces

Replica tape/comparator

I

W/H

W/H

6

Residual dust and matter on surfaces

Tape/pocket microscope

I

W

W

7 8

Type/condition of power/hand tools used Standard of power/hand tool cleanliness


I I

R W/H

R W/H

9

Presence of residual millscale *(only if applicable)

Copper sulphate test

I

R

R

10

Presence of salts*

Salt Test

I

R

R

REMARKS



Page 95 of 111

ITM.

DESCRIPTION OF ITEM

ACTIONS BY

INSPECTION REQ’D

T.P.I.

OWNER

D

DURING COATING OR COMPOSITE TAPE WRAP APPLICATION

1 2

Types, brands, dates, condition of coatings Coating storage conditions


I I

R R

R R

3 4

Coating mixing procedure and control Rust present on blast cleaned surfaces


I I

W R

W R

5

Time between blast cleaning and priming

Record inspection

I

R

R

6

Coating/Wrap application technique and quality

Visual inspection

I

W

W

7

Stripe priming of edges, corners, crevices

Visual inspection

I

R

R

8 9

Full primer coat thickness Primer profile and appearance

Wet/dry film tkns. Check Visual inspection

I I

H H

H H

10 11

Time between primer and first midcoat First midcoat and stripe thickness

Record inspection Wet/dry film tkns. Check

I I

R W

R W

12 13

First midcoat and stripe profile/appearance Time between first and second midcoat (only if applicable) Second midcoat and stripe thickness (only if applicable) Second midcoat /stripe profile/appearance(only if applicable) Time between second midcoat and topcoat

Visual inspection Record inspection

I I

W R

W R

Wet/dry film thickness. Check Visual inspection

I

W

W

I

W

W

Record inspection

I

R

R

17

Complete coating coating/wrapping thickness

I

H

H

18

Complete coating coating profile/appearance

Wet/dry film thickness. check Visual inspection

I

H

H

19

Final curing time for coating system

Record inspection

I

R

R

20

Presence of holidays in coating (where applicable)

Low or high voltage test

I

H

H

21

Adhesion of coating (where applicable)

Dolly pull-off test

I

W

W

22 23 24

Identification of areas for repair Coating/wrapping appearance after repair Complete QIT form and associated docs.

Use of indelible marker Visual inspection Record inspection

I I I

W H H

W H H

14 15 16

KEY:

* I R W H

Subsidiary inspection test to be carried out at discretion of Owner Inspection item to be carried out where operation involved forms part of Contract work scope Inspection reports and records to be fully reviewed and approved Inspection activity to be witnessed and approved Mandatory Hold Point in schedule beyond which work shall not proceed without formal

approval

CONTRACTOR Signature Name Position Date

T.P.I. ( If Applicable)

OWNER

REMARKS



Page 96 of 111

APPENDIX 14: COATING DAILY INSPECTION REPORT TEMPLATE

Coated Defect-free

Wrapped Laminated/Pitted

Bare Ground

Rejected

Ri 0 / 10 Heavy …………………….

Ri 3 / 6 Light Swabbed

Ri 4 / 4

Ri 5 / 1

Sprayed

Water Tested

Dry Blasting Sweep Blasting Wet Blasting Power Tool Hand Tool Type………………. Brand………………. Batch No…………... Size Range……….. SSPC SP 5/*Sa 3 SSPC SP 10/*Sa 2.5 SSPC SP 7/*Sa 1 SSPC SP 3/*St 3 Other…………. 35-50 50-75 75-100 Range………... Using…………. Salts…..…. Yes/No

Airless Spray Product

Air Spray Brush Time Since Cleaning………………….. Base Batch Additive Thinner # and No. Batch No. percentage

DFT - Accept/Reject LV/HV Tester ………… Adhesion Tester……… % of Total Area………..

Trowel Other…………. Visible Surface Rusting…..……….Yes/No Overcoating WFT Range DFT Range Period (um) (um)

Test Voltage…………….. Pull Off Stress…………… Primary Locations……….

## CORRESPONDING DEGREES OF COATING RUSTING STANDARDS(ISO 4628-3 / SSPC Vis. 2): Ri 0/10- No visible rusting of coating; Ri 3/6- Marked localised rusting of 1% of surface area; Ri 4/4- Widespread localised rusting of 10% surface area (8% for Ri.4); Ri 5/1- Extensive rusting of up to 50% of surface area ^^ Bare Metal Rust Grade standard according to Visual Standard SSPC -Vis 3

Appearance - Accept/Reject Pass/Fail Accept/Reject Rejected Because……….



Page 97 of 111

APPENDIX 15: ITEMS TO BE EXCLUDED FROM PTS 15.20.03 Category

Coating

Type

PTS No. and Description

Bituminous Enamel

11.32.05: Bituminous Enamel Coating of Steel Linepipe

Typical Use 

Concrete

11.32.09: Concrete Coating of Linepipe



Ceramic

New PTS



Elastomer

11.32.08: Elastomer Coatings and Monel Sheathing for Offshore Riser Protection

External Polyethylene And Polypropylene Fusion Bonded Epoxy (FBE)

11.32.03: External Polyethylene And Polypropylene Coating Of Linepipe

Thermal Spray Application (TSA)

15.20.05: Thermal Spray Coatings Aluminium and 85/15 Zinc/Aluminium Alloy

11.30.07: Pipeline and Riser Engineering







 



Lining

Subsea

To refer to Norsork Standards or other industry recognized standards

Cement

15.20.04: Cement Lining of Pipes



 

Glass Flake

15.20.10: Glass Lined Steel Equipment and Piping

Rubber

15.20.07: Rubber-Lined Process Equipment



Subsea Pipeline External Heater Tubes External Offshore Riser External Buried Pipelines External

Buried Pipelines External Offshore Facilities Corrosion Under Insulation (CUI) Mitigation High temperature swing operations e.g. Regeneration system Subsea equipment, structure, piping etc. Pipeline Internal Seawater Piping Internal Vessel and Tank Internal

Thermoplastic

11.32.06: Thermoplastic Lined Pipelines



Sea Cooling Water Exchanger Internal Vessel and Piping Internal Pipeline Internal

Surface treatment + PTFE

New PTS



Bolts and nuts





Others

Buried Pipelines External



Other Exceptions: 

GRP Gratings



Equipment or Instrumentation designated to be hand or machine tool cleaned



All Electrical Wiring, Cables, and cable Trays



Safety Equipment, Sensors and Alarms



All piping/equipment operating above 55°C (NOTE: This refers to surface temp during coating operations, not service temperatures)



Shock Cell Pads and Wear pads on boat landing



Fire Proofed Surfaces and Cryogenic Lines (external Surfaces)



Greased nipples and fittings and lubricated surfaces



Machined and close working tolerance surfaces



Gasket contact surfaces and exposed seals, bearings and Glands.



Threaded Connections shall not be coated unless otherwise specified.



Friction grip surfaces



Equipment identification plates and information / warning sig ns.



Valve stems, stem threads, movable linkages, pump shafts.







Glass components, Sensitive parts of Instrumentations and Gauges. (Instrument tubing) Area of component to be site welded or welds subsequently to be modified especially during Shutdown. Bolt and Nuts which are subjected to removal



APPENDIX 16: MAINTENANCE COATING

Maintenance coating shall consist of two types of activity as follows: i.

Large-scale maintenance for existing facilities which have complete coating deterioration or technical integrity and safety impaired. In this case, local repairs are not economically justified and application of new coating system according to Section 3.0 is the only option.

ii.

Repair work to rectify coating damage caused by corrosion, ageing facilties, fire damage and mechanical damage.

Maintenance coating shall ensure coverage of field weld tie-in points which shall comply with the relevant coating system. The following needs to be considered to determine coating application requirements: Determine objectives Design life of equipment or piping Budget restraints Maintenance philosophy Special requirements    

Assess condition-related factors What is the substrate? What is the substrate condition? Any on-site application constraints? What is the existing coating system? Was it effective? Any problems reported? What is the existing coating age? What is the overall condition? Chalked? Peeling? Sagging? What is the extent of existing issues? Is it cost effective to spot repair? Is there hazardous material in the coating e.g. lead requiring removal? What is the probable cause of existing problems? Materials, specification, workmanship, maintenance, age, damage?        

Define service environment/exposure Operating temperature (min/max) pH (min/max) Specific exposures e.g. sunlight, marine, immersion, splash, abrasion etc. Chemical exposure and compatibility    

Establish service requirements Colour coding compliance, gloss, special texture, conductive, non-skid etc 

Identify limiting conditions Online or offline blasting? Any work schedule limitations e.g. monsoon season, relative humidity, applied at high temperatures etc.? Ventilation requirement  





Determine approach New application or maintenance For maintenance repair - spot repair only, spot repair and full recoat or total system replacement? Prioritisation of repair area, projected maintenance life, cost of application, expected performance etc.  



Select candidate coating systems What are the systems candidates (pros/cons) Technical merit, track record (experience), service and availability Surface preparation requirements Life Cycle Cost evaluation Any disassembly required? Any special requirements?      



APPENDIX 17: SURFACE PREPARATION BY BLAST CLEANING Q.1

GENERAL

Q.1.1

For optimum coating performance surfaces to be coated 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 coating is applied. If dry blast-cleaning is not strictly necessary or not feasible (e.g. due to limited access, risk of damage to equipment, light gauge steel, the proximity of electrical components or instrumentation) then power tool cleaning shall be applied.

Q.1.2

If the surface has been exposed to pollutants such as salt-lade from atmosphere, it shall be washed down with clean fresh water prior to blasting or power tool cleaning.

Q.1.3

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 Owner.

Q.1.4

Alternative surface cleaning is only acceptable with written approval by the Owner.

Q.1.5

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.

Q.1.6

Stainless steel surfaces shall not be treated with carbon steel cleaning tools.

Q.1.7

Any grit, dust or other contaminants shall be removed after substrate surface preparation. Primer layer shall be applied within four (4) hours after blasting to avoid corrosion initiation or recontamination occurs.

Q.1.8

Solvent cleaning or detergent degreasing shall be in accordance with SSPC-SP 1.

Q.1.9

Automated blast-cleaning machines are economically desirable as a means of preparing plate, beams, and tubular members prior to fabrication.

Q.1.10 Surface preparation performed outdoors should be completed during daylight hours, and early enough to permit proper priming of the surface prior to the development of any moisture or flash rusting of the prepared surface. Q.1.11 At the time of surface preparation and priming, the surface temperatures shall be at least 3°C above the dew point.



Q.2

PRE-CLEANING

Q.2.1

Prior to the blast cleaning and/or prior to any coating 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.

Q.2.2

Biodegradable detergent or freshwater solution treatment followed by copious rinsing with clean, potable water shall be used to remove oil or grease contamination.

Q.2.3

All edges shall be ground to a minimum radius of 2 mm or otherwise agreed with the Owner. Flame cut areas should be ground flushed. Weld spatter also shall be ground flushed. If this is not the case, the Owner shall be informed, and corrective action shall be taken prior to the application of the first layer of the coating system.

Q.2.4

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”.

Q.2.5

Maintenance coating should always start with a high pressure steam or 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 o r 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/ or steam cleaning shall not be allowed if the water temperature equal to or above 50°C. The requirements regarding the soluble salts and other surface contaminants in this document shall be adhered to at all times.

Q.2.6

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 coating activities by the best mechanical means and the edges smoothed or rendered flush.

Q.2.7

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. The equipment shall include but not necessarily limited to the following: i. ii. iii. iv. v. vi. vii. viii. ix. x. xi. xii.

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



Q.2.8

Adequate barricading of the work area by either canvas, tarpaulin or suitable material shall be constructed and accepted by the Owner in order to avoid damage to other areas or equipment. This enclosure shall be constructed such that 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.

Q.2.9

Where rectification has been necessary on blast-cleaned surfaces, the dressed areas shall be pre-cleaned as initially specified. All grating panels to be removed to expose supporting structure.

Q.2.10 The level of free halides in cleaning materials to be used on stainless steel shall be confirmed and reviewed by Owner. Particular care shall be given to 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 10 ppm while actual concentration shall be maintained between 20 to 30 ppm. Q.2.11 Detergents with a pH more than 9 shall not be used on aluminium substrates. Q.3

SURFACE PREPARATION BY BLAST CLEANING

Q.3.1

General

Q.3.1.1 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 Sa2.5 at the time of coating, unless specified by coating manufacturer on their surface tolerant coating systems. Q.3.1.2 Blast clean shall not be done close to coating operations or wet coated surfaces to prevent dust and abrasive contamination. Environmental restrictions shall be observed. Q.3.1.3 Blast clean steel surfaces shall not be touched by bare hands. Q.3.1.4 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. The following four preparation grades (in accordance with ISO 8501-1) are recognized: i. ii. iii. iv.

Sa 1 : Light blast-cleaning Sa 2 : Thorough blast-cleaning Sa 2½ : Very thorough blast-cleaning Sa 3 : Blast-cleaning to visually clean steel

Q.3.1.5 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.



Q.3.1.6 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 coating manufacturer. When not specified by the coating manufacturer or when otherwise specified in this document, the surface profile shall be between 40 μm and 70 μm. Q.3.1.7 If stainless steel, galvanised or non-ferrous metal surfaces are to be coated with liquid (organic) coating materials, blast cleaning of these surfaces shall be carried out by smooth sweep blasting, using fine sized 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 coating manufacturer. Q.3.1.8 After approval by the Owner, 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 coated, white zinc or aluminium corrosion products and/or rust present shall be removed. Q.3.2

Post Blast cleaning

Q.3.2.1 All masking to be removed and mechanical / hand tool cleaning / coating to be carried out on “exceptions” as required. Q.3.2.2 Scaffold contact points and surrounding GRP grating clamp screw points uncoated after removal of scaffold to be coated to specification standard. Q.3.2.3 Verify anchor profile in accordance with ASTM D4417 by using a spring-loaded micrometer and/or either a coarse or extra coarse replica tape, as required by the anchor profile depth. (Random-Spot check) Q.3.3

Blast Cleaning Equipment

Q.3.3.1 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. Q.3.3.2 Air cleanliness of air compressors shall be as described in Section 7.0 Quality Control. Air compressors shall not be allowed to deliver air at a temperature above 110 °C. Q.3.3.3 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. Q.3.4

Blasting Abrasives

Q.3.4.1 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: i. Chilled iron grit or shot ii. Steel and malleable iron grit or shot iii. Natural mineral abrasives iv. Non-metallic abrasives



Q.3.4.2 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. Q.3.4.3 Sand or other materials producing silica dust shall not be used. Q.3.4.4 All metallic blast cleaning abrasives shall meet the requirements of ISO 11124 and shall be tested in accordance with test methods specified in ISO 11125 Part 1-7. Q.3.4.5 All non-metallic blast cleaning abrasives shall meet the requirements of ISO 11126 and shall be tested in accordance with test methods specified in ISO 11127 Part 1-7. Q.3.4.6 Product shall be sealed in hermetic packaging. Any product delivered in defective packaging shall be rejected. Products must be stored sheltered from the elements. Q.3.4.7 The blast profile and angular anchor pattern shall be of that recommended by the coating manufacturer to suit the minimum requirement of their respective primers and the minimum peak-to-valley height shall be 25 microns. Q.3.5

Selection of abrasives

Q.3.5.1 Pre-qualification of the blast cleaning abrasives shall be conducted subject to acceptance and approval by the Owner 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. Q.3.5.2 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 Owner. Q.3.5.3 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. Q.3.5.4 The conductivity of abrasives to be used on carbon steels shall be less than 150 µS/cm. Q.3.5.5 The salt contamination of abrasives shall be less than 30 mg/m2. Q.3.7

Removal of residual salts from pitted areas

Q.3.7.1 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. Q.3.8

Techniques and Restrictions

Q.3.8.1 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. Q.3.8.2 Abrasive blasting shall not be conducted in open areas close to coating 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. Q.3.8.3 Work is recommended to 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. Q.3.8.4 Any blast cleaned steelworks on which rust develops shall be re-blasted prior to being coated. Q.4

ALTERNATIVE METHODS OF SURFACE CLEANING

Q.4.1

General

Q.4.1.1 Alternative surface cleaning is only acceptable after obtaining written approval from the Owner. 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. Q.4.1.2 Alternative primers such as surface tolerant primers may be required for alternative methods of surface cleaning and be in accordance with coating manufacturer’s recommendations. Alternative primers need the approval of the Owner. Q.4.2

Wet abrasive blasting and water jet cleaning

Q.4.2.1 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. Q.4.2.2 Corrosion inhibitors should not be used unless written approval from the Owner 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 coating manufacturer shall approve the use of an inhibitor or the removal of residues of the inhibitor before coating. Q.4.2.3 The cleaned surface shall be dry at the time of coating. Particular care shall be given to dry areas that are not self-draining to avoid water collection. Q.4.3

Water Jetting

Q.4.3.1 High-pressure and ultrahigh-pressure water jetting utilising potable water may be used for maintenance coating only and if abrasive blasting is not permitted for certain areas where dusting and over-blasting may damage process equipment. Q.4.3.2 Where black spots occur in pits or other surface defects, the surface shall be cleaned again at higher pressure to remove the residual salts.



Q.4.3.4 The cleaned surface shall be thoroughly dry at the time of coating. Particular care shall be taken to dry areas, which are not self-draining, so that water collected is removed. Q.4.4

Sponge Jet Blasting

Q.4.4.1 Sponge Jet blast cleaning is recognized as a dry and low dust system. This cleaning type shall only be used upon agreement with the Owner. Metallic or non-metallic abrasive used in the sponge jet media matrix shall conform to the ISO 11124 or ISO 11126 blast abrasive classification. Q.4.4.2 It shall be conducted in accordance with the vendor/manufacturer recommendation which includes proper site preparation, equipment set-up, choice of media and application. Q.4.4.3 A range of surface profile 25, 50, 75 and 100 microns shall be achieved using the different sponge jet media. Q.4.4.4 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. Q.4.4.5 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.

Q.4.5

Centrifugal Abrasive Blasting

R.4.5.1 A portable blasting machine may be used to prepare steel decks and tank floors using recyclable steel abrasives. Q.4.6

Vacuum Blasting

R.4.6.1 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. Q.4.7

Power-tool Cleaning

Q.4.7.1 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. Q.4.7.2 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 powertool 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 50 mm and the coated surface shall be feathered. Q.4.8

Performance and application conditions

Q.4.8.1 Blast-cleaning shall only be performed in conditions suitable for coating. Q.4.8.2 Sometimes it may be advantageous to use the wet abrasive or moisture injection blast cleaning techniques, so as to avoid dust or in cases where fire and/or explosion risks are



present. Fresh water may be either mixed with the abrasive in the pressure tank or introduced directly behind or ahead of the blast nozzle. Q.4.8.3 To prevent rusting the cleaned surface should be washed off immediately after blast cleaning using fresh water containing a suitable corrosion i nhibitor such as 0.3wt% sodium nitrite with 1.2wt% ammonium phosphate. A suitable corrosion inhibitor in the water used for blastcleaning should also be considered. Q.4.8.4 The cleaned surface shall be thoroughly dry before any coating is applied. In general it is not necessary to remove residues of the inhibitor before coating. However, the coating manufacturer should be consulted on the inhibitor/primer compatibility.



Page 109 of 111

APPENDIX 18: RECOMMENDED ORGANISATION CHART FOR COATING WORK EXECUTION

OWNER

Contractor

Manufacturer

Coating Advisor

Blasting and Painting Supervisor Lead Blaster and Painter Blaster and Painter



APPENDIX 19: REGULATIONS ON ABRASIVES, COATING PRODUCTS, WASTE PRODUCTION, PRODUCT STORAGE AND LEACHING OF COATINGS S.1

ABRASIVE BLAST CLEANING

S.1.1

Significant quantities of dust from the abrasive and the surface debris are made airborne and can contribute to air pollution. This dust is recognized as a fugitive emission that is often regulated. Control of mineral dust exposure shall be in compliance with the Environmental Quality (Clean Air) Regulations 1989 and Factories and Machinery (Mineral Dust) Regulations 1989. The PEL averaged over an 8-hour period without respirators shall be: i. ii. iii. iv.

S.1.2

S.2

Less than 10mg/m 3 concentration of free silica in total dust Less than 0.05mg/m3 concentration of respirable cristobalite in crystalline silica Less than 0.1mg/m3 concentration of respirable quartz in crystalline silica Less than 0.05mg/m3 concentration of respirable tridymite in crystalline silica

If respirators are used by employee and all control measures related to this hazard has been employed, the exposure level shall be determined by the protection factor provided by the respirator COATING APPLICATION

S.2.1

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.

S.3

WASTE PRODUCTION

S.3.1

Both coating removal and coating application generate waste products, which must be properly 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 coating or thinner.

S.3.2

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.

S.3.3

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.

S.4

PRODUCT STORAGE

S.4.1

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.

S.5

LEACHING OF COATINGS

S.5.1

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

PTS 15.20.03

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