SP-1246

Specification for Painting and Coating of Oil and Gas Production Facilities – Part. 2

Version 2

Petroleum Development Oman L.L.C.

UNRESTRICTED

Document ID : SP-1246

April 2010

Filing key : xxxx

Specification for Painting and Coating of Oil and Gas Production Facilities

PART 2: NEW CONSTRUCTION COATING SYSTEMS

Keywords: Application Coating Painting Surface Preparation Surface Protection Tanks Vessels

This document is the property of Petroleum Development Oman L.L.C. Neither the whole nor any part of this document may be disclosed to others nor reproduced, stored in a retrieval system, or transmitted in any form by any means (electronic, mechanical, reprographic recording or otherwise) without prior written consent of the owner.

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Version No. ERD-48-01 SP-1246 Ver.0 SP-1246 Ver.1 SP-1246 Ver.2

Date Jan 89 May 2002 July 2003 April 2010

Author ETH/5 OTT/11 TTO/11 UEC/121

Version 2

Scope / Remarks Original ERD Document Updated and in new PDO format Updated For issue

INSTRUCTIONS TO USER Make sure this is the latest issue of this specification. Refer to the EMDS for the last issue date. Where this Specification refers to DEPs and International Standards, it refers to the issues that were in use when the author wrote this Specification. Exceptions are references to specific issues. If you use DEPs or International Standards with this Specification, make sure you use the latest issues. Do not change this Specification without approval. Only the Custodian, the Corporate Functional Discipline Head (CFDH), who owns this Specification, can give approval for changes. If you think the Specification is not correct, write your comments on a copy of the User Comment Form in Section 9 of this Specification.

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Contents 1

Preface ....................................................................................................................................... 4 1.1 1.2 1.3

2

Introduction .............................................................................................................................. 6 2.1 2.2 2.2

3

New Construction Works.................................................................................................................................8

Coating Systems........................................................................................................................ 9 4.1 4.2 4.3 4.4 4.5

5

General.............................................................................................................................................................6 Scope ...............................................................................................................................................................6 Paint Terms and Generic Paint Types..............................................................................................................6

Painting and Coating Selection Schedules ............................................................................. 8 3.1

4

Background......................................................................................................................................................4 Applicability ....................................................................................................................................................4 Units of Measurement......................................................................................................................................5

System Compatibility ......................................................................................................................................9 Painting and Coating Schedules (PCS)............................................................................................................9 Protective Coatings for Stainless Steel ............................................................................................................9 Health and Environmental Restrictions ...........................................................................................................9 Colour Finishes................................................................................................................................................9

Painting and Coating Schedules (PCS) ................................................................................ 10 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13 5.14 5.15 5.16

PCS-1 External coating for above ground structures to 100oC.....................................................................10 PCS-2A External coating for below-ground structures up to 70oC...............................................................11 PCS-2B External coating for below-ground structures for more than 70oC ...............................................11 PCS-2C External coating for below-ground structures up to 70oC.............................................................11 PCS-3 External coating for above ground structures at 100-400oC..............................................................14 PCS-4 External coating for steel structures under insulation below ambient to 100oC ................................15 PCS-5 External coating for steel structures >400oC ....................................................................................16 PCS-6 External coating for galvanised steel and stainless steel structures...................................................17 PCS-7A Internal glass fibre reinforced epoxy lining for tanks up to 60oC....................................................18 PCS-7B Internal epoxy coating for tanks and vessels up to 60oC .................................................................19 PCS-8 Internal glassflake coating for tanks and vessels at temperatures of 60 to 93oC ...............................20 PCS-9 Internal coating for vessels at temperatures above 93oC ...................................................................21 PCS-10 Internal coating for tanks for potable water.....................................................................................22 PCS-11A External coating for marine structures..........................................................................................23 PCS-11B High solids epoxy coating for immersed marine structures..........................................................24 PCS-12 Internal Flow Coating for Gas Transmission Pipelines in Non-Corrosive Service……………….25

6

Related Business Control Documents................................................................................... 26

7

Appendix A Glossary of Terms, Definitions and Abbreviations ....................................... 27

8

User Comment Form ............................................................................................................. 28

Tables Table 1 Coating Schedules References..........................................................................................................................8

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Preface

1.1

Background This Specification SP-1246 covers the minimum requirements for protective painting and coating systems, materials and application methods for the internal and external surface of steel structures and equipment within the oil and gas production facilities. Relevant structures and equipment include aboveground and buried onshore tanks, vessels, in-station pipe work, structural steel, and surface electrical and mechanical equipment. Whilst the Specification is directed predominantly at protection of onshore oil and gas installations, it also covers external protective coating of marine facilities such as jetties, mooring buoys, barges and launches. Internal surfaces of pumps, valves and other mechanical equipment requiring special protective treatments are not dealt with in this Specification. For guidance on this contact UER/CFDH Materials and Corrosion. The external coating of new pipelines and existing pipelines requiring rehabilitation are covered in alternative Specifications and procedures which are shown below. GU-368 Guidelines For The Protection Of Buried Sections Of Surface Laid Pipelines/Flowlines PR-1180 Procedure for Qualification of Pipeline Rehabilitation Coating Systems DEP 31.40.30.31-Gen. Technical Specification for External Polyethylene and Polypropylene Coating for Line Pipe DEP 31.40.30.32-Gen. Technical Specification for External Fusion-bonded Epoxy Powder Coating for Line Pipe DEP 31.40.30.37-Gen External Field Joint and Rehabilitation Coatings System For Line Pipe.

1.2

Applicability All coating work shall be carried out in accordance with this Specification. If a variance is required then approval in writing from UER/CFDH Materials and Corrosion is required. This Specification is not applicable retroactively. This specification does not apply to concrete structures. For concrete structures in corrosive environment consult UER/CFDH Materials and Corrosion. This is Part 2 of a five-part Specification and must be read in conjunction with Parts 1, 3, 4 and 5. PART 1 specifies technical and related requirements. This part includes performance tests and acceptance criteria for assessing the acceptability of paint/coating/lining systems for each service specified in Parts 2 and 3. PART 2 contains recommended protective coating systems for the following categories with respect to new construction painting/coating activities: -

External surfaces of carbon steel structures, piping and equipment, onshore and marine External surfaces of buried carbon steel structures, piping and buried sections of above ground flowlines and pipelines. (except Class I and Class II pipelines) Internal surfaces of tanks and vessels Stainless steel and galvanised piping and equipment Areas beneath insulation Specialist applications

This Part also gives descriptions of the generic types of paint used for new construction projects. The descriptions apply equally to the maintenance paint systems presented in Part 3. SP-1246

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Protective coatings for new pipelines based on Polyethylene (PE), Polypropylene (PP) or Fusion Bonded Epoxy (FBE) are not covered in this Specification but the general good practices described in this part are equally applicable to the coating of line pipe.

PART 3 contains recommended Maintenance coating systems for the following categories with respect to location and painting/coating activities and inspection of old coatings: -

External coatings on carbon steel structures, piping and equipment, onshore and marine External surfaces of buried carbon steel structures, piping including Class I and Class II pipelines Internal coated surfaces of tanks and vessels Stainless steel and galvanised piping and equipment Coatings beneath insulation

PART 4 contains the detailed requirements for Surface Preparation and Application of Coatings to the categories stated in Parts 2 and 3. This Part contains HSE advice and general inspection requirements. PART 5 contains the list of approved coating systems and is a live document that will be updated by UER. This includes coating systems that have been grandfathered in. New Projects PARTS 1, 2 and 3 apply in their entirety to new projects where painting and coating activities are carried out at site or in the shop. For painting and coating of package items, carried out prior to delivery to site or to existing facilities, the requirements, stated in PARTS 1 and 4, apply in their entirety, whilst those of PART 2 apply where applicable. Maintenance Where maintenance painting is to be done, PDO’s technical requirements are stated in PART 1 and those sections of PART 3 and 4 as appropriate, dependent upon the Scope of Work.

1.3

Units of Measurement This specification uses and requires the use of the International System (SI) units of measurement in all documentation. Paint film thicknesses are expressed in microns, 1micron is 0.001mm. .

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2

Introduction

2.1

General

Version 2

This Part of specification SP-1246 gives generic systems and minimum DFT of painting and coating systems that PDO recommends for the various structures and service conditions identified. The schedules refer to the coating systems PCS-1 to PCS-12.

2.2

Scope This part of the specification covers the performance and acceptance requirements of the coating systems to be used. Testing has to be done by an independent laboratory or test facility. The proposed Vendor coating systems have to pass the performance criteria detailed in this part of the Specification and be submitted to PDO for approval.

2.2

Paint Terms and Generic Paint Types The following definitions and clarifications are presented below to assist with the understanding of the types of paints and paint terms used in this Specification: Alkyd resin

Polyester resin modified by a fatty acid. Made for example by reacting glycerol with phthalic anhydride and linseed fatty acid. Low alkali resistance.

Amine adduct

A resinous amine used as a curing agent for epoxy resins.

Amino resin

General term for resins made by reacting formaldehyde with an amine or amide, eg urea-formaldehyde resin.

Alkyl zinc silicates

Two component, moisture curing zinc silicate, containing minimum 87% metallic zinc. Hard abrasion resistant coating suitable for services up to 600oC.

Aluminium silicones

Aluminium silicone resin-based paint. Air drying for high temperature service, up to 400oC

Epoxy resins

Resins made by the polymerisation of hydroxyl and epoxy groups in the absence of esters. Excellent alkali resistance.

Galvanising

Zinc coating applied in a molten zinc bath

Gloss

The reflectivity of a surface film.

High-build amine-cured epoxies

Amine-cured epoxy resin coatings with good resistance to chemicals and solvents.

High-build polyamide-cured epoxy

Amide-cured epoxy resin coatings superior to amine-cured epoxies in respect of durability, flexibility and pot-life.

Holding primer

A low-build blast primer used to provide temporary protection to steelwork until the complete coating system can be applied. Areas that have been missed during paint application.

Holidays Leafing pigments

Paints containing plate-like pigments such as micaceous iron oxide or aluminium flakes. Platelets arrange themselves more or less parallel to the substrate surface and are effective in reducing water uptake. Two component, high build, amine-cured phenolic epoxy coatings,

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Phenolic epoxies

showing excellent resistance to solvents and organic acids

Polyester resin

Chemically, any resin that is made by esterification. Term usually applied to resins that are not formulated using fatty acids.

Polysiloxane

Two-component, inorganic polysiloxane used for extreme heat resistance up to 1110oC.

Polyisocyanate

A resinous isocyanate, used as a curing agent in a two-pack polyurethane paint system.

Polyurethanes

Resin systems inPartving urethane groups and cured with polyisocyanate. A wide variety of coating systems is available based on the various urethane formulations.

Polyurethanes, aliphatic, highi-build

Two-component isocyanate-free urethanes, designed to produce hard, durable and chemically resistant coatings.

Primer

The initial coat of paint in a protective coating system. Depending on the formulation, may be used: - to seal a porous substrate, - as an inhibitive coating to resist corrosion, to provide improved adhesion.

Sealer coat

A coating, that may be clear or pigmented, incorporated into a system as a barrier coat to prevent: - ‘bleeding though’ of a colour of a previous coat, - damage by solvents from subsequent coats.

Silicone acrylics

One component aluminium (or colour) pigmented acrylic-modified silicone resin. Room temperature cured and heat resistant up to 350oC.

Solvent-free epoxies

Two component, amine-cured modified epoxies without solvents. Applied as heavy-duty coatings in high film thicknesses.

Metallic coatings (clad or sprayed)

Used in applications where organic coatings are unsuitable because of high temperature/pressure service conditions.

Vinyl resin

Copolymer of vinyl chloride and vinyl acetate.

Zinc-rich epoxy primer

Two component epoxy initial coating used to provide sacrificial protection to the underlying steel.

Water-based paints

General name for resin systems in which organic solvents have been replaced completely or in part by water.

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3

Painting and Coating Selection Schedules

3.1

New Construction Works

Version 2

The following Table 1 summarises the selection of recommended coating systems, identified as PCS-1 to PCS-12, for the various structures, locations and service conditions. For painting and coating of package items and equipment coated at Vendors facilities alternatives to those shown below and approved in Part-5 can be used provided they are of the same generic type and the minimum coating thicknesses shown in the PCS. Details of such proposed systems must be submitted for approval by UER. Table 1 Coating Schedules References Area of Application External Above Ground External coating for carbon steel structures at up to 100oC

External Coating 100-400oC

External Coating for Steel beneath Insulation - Below ambient to 100oC External Coating for Steel >400oC External Coating for Galvanised Carbon Steel and Stainless steel Buried carbon steel External Below Ground <70 oC

Coating

Epoxy system comprising: Primer Intermediate coat PU Top coat Min DFT 200 microns Ambient curing system Inorganic zinc silicate Heat resistant aluminium silicone Min. DFT 100 microns Aluminium mastic to min. DFT 125 microns Silicone system or thermal sprayed aluminium Min. DFT 100 microns Epoxy Intermediate and PU top coat Min. DFT 125 microns

Reference Nos.

PCS-1

PCS-3

PCS-4 PCS-5 PCS-6

Amine cured epoxy min DFT 500 microns Solvent free epoxy or high solid phenolic epoxy min DFT 1000 microns Visco Elastic Wrapping and Shrink sleeve for maintenance

PCS-2A

GRE lining for steel in continuous water phase GRE lining to min DFT 3000 microns. Appurtenances & piping to be coated with PCS-7b

PCS-7A

<60oC Tanks/vessels in water/hydrocarbon service

GRE lining for steel in continuous water phase as in PCS-7a as appropriate for tank/vessel design. Rest of tank/vessel; High build solvent free epoxy to min. DFT 500 microns

PCS-7B

60 - 93oC Vessels/tanks in water/hydrocarbon service

Glassflake system Bisphenol A polyester or vinyl ester glassflake reinforced epoxy to min. DFT 900 microns or as Manufacturer’s recommendations Manufacturer’s recommended and qualified systems. Seek advice from CFDH.

PCS-8

External Below Ground >70 oC External Below Ground <70 oC Internal Coatings for Vessels and Tanks <60oC Crude oil storage tanks

>93oC Vessels in hydrocarbon service Potable Water Tanks/Equipment Gas Pipeline Flow Coat

High build solvent free polyamide cured epoxy Min. DFT 325 microns Epoxy coating Min.DFT 75 microns

PCS-2B PCS-2C

PCS-9

PCS-10 PCS-12

Coatings for Marine structures External Above Water Submerged

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As PCS-1 to min. DFT 250 microns High solids modified epoxy as PCS-2 Min. DFT 400microns

8

PCS-11A PCS-11B

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Coating Systems

4.1

System Compatibility The protective coating system should be selected on the basis of the complete installation so as to achieve a fully compatible system at the time of final construction. Each component of a coating system shall be supplied by the same manufacturer. Holding primers must not form part of the final coating system and must be removed before the approved coating system is applied. Approved coating system primers may be shop applied with subsequently coats applied at site providing the Manufacturer’s requirements are met.

4.2

Painting and Coating Schedules (PCS) No alterations or changes may be made to the PCS data sheets provided in this Part without prior approval of the Custodian of this Specification who will copy the data sheets and initial them to signify his approval of such changes. The Schedules in Section 5 give typical values for surface profile and minimum DFT for paint thicknesses. These may vary from those recommended by the paint manufacturers and should therefore be used as a guide to minimum values. Part 4 of this Specification gives information on the surface preparation, coating application, inspection requirements and HSE referred to in the data sheets. Part 5 of this specification gives the approved list of coating systems and will be continually updated by UER/CFDH Materials and Corrosion..

4.3

Protective Coatings for Stainless Steel Paints specified for application directly to austenitic, duplex or high nickel-chromium alloys shall not contain free chlorides or halides after curing. In addition, such coatings shall not contain metallic zinc although inhibitive paints containing zinc oxide or zinc phosphate are acceptable.

4.4

Health and Environmental Restrictions Because of hazards to health and the environment, PDO has restricted the use of the following paints: -

4.5

Paints containing lead High VOC containing paints Paints containing cadmium Paints containing coal tar Anti-fouling paints containing biocides or tributyl tin

Colour Finishes The requirements for colour finishes are given in section 3.3 of Part 1 of this Specification

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Painting and Coating Schedules (PCS) PCS-1 External coating for above ground structures to 100oC

5.1

Specification: SP-1246 Part 2

Rev. Date: Dec 2007

SCHEDULE: PCS-1 DESIGNATED USE External coating for above ground steel structures in onshore (desert) locations at service temperatures up to 100oC. APPLICABLE STRUCTURES Tanks, vessels, separators, flare stacks, exchangers, columns, supports, structural steel, pipework and fittings (uninsulated) in carbon or low alloy steel. TESTING AND ACCEPTANCE CRITERIA As shown in Table B1.1 1 in Part1 of this Specification SURFACE PREPARATION Surface preparation shall comply with Part 4 of this Specification. Blast cleaning standard: Surface profile:

ISO-8501-1:2001 Sa 2½ 50 to 75 microns

COATING SYSTEM Primer Type: Application method: DFT microns:

Polyamide cured epoxy primer Airless or conventional spray 50

Intermediate Coat Type: Application method: DFT microns:

Polyamide cured epoxy (high build) Airless spray

Top Coat Type: Application method: DFT microns:

Two-pack high build aliphatic polyurethane Airless spray

100

50

Total min DFT microns:

200

COATING REPAIR Surface preparation, coating application, inspection and repair all as required in Part 3 of this Specification. NOTES 1. Zinc rich epoxy primers may be used. 2. Water borne systems may be used. 3. Shop applied primers can be considered provided they are part of the final coating system.

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PCS-2A External coating for below-ground structures up to 70oC

5.2


Rev. Date: May 2009

SCHEDULE: PCS-2A DESIGNATED USE External coating for below ground (or immersed) steel structures in onshore locations at service temperatures up to 70oC. APPLICABLE STRUCTURES Buried tanks, vessels, tank bottom plates, buried sections of piping and fittings in carbon or low alloy steel, with or without cathodic protection. TESTING AND ACCEPTANCE CRITERIA As shown in Table B1.21 in Part 1 of this Specification

SURFACE PREPARATION Surface preparation shall comply with Part 4 of this Specification. Blast cleaning standard: Surface profile:

ISO-8501-1:2001 Sa 2½ 75 microns

COATING SYSTEM

Primer Type: Application method: DFT microns:

Not required


High build, high solids modified epoxy Airless or conventional spray


High build, high solids modified epoxy Airless spray

250

250


500

COATING REPAIR Surface preparation, coating application, inspection and repair all as required in Part 3 of this Specification. NOTES 1. This system replaces the previously used coal tar epoxy systems favoured for buried (or immersed) applications. 2. Coating to be applied by PDO approved applicators 3. Coating can be applied in one coat provided performance test data is also for a single coat system

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PCS-2B External coating for below-ground structures for more than 70oC

5.3


Rev. Date: May 2009

SCHEDULE: PCS-2B DESIGNATED USE External coating for below ground (or immersed) steel structures in onshore locations at service temperatures for more than 70oC. APPLICABLE STRUCTURES Buried tanks, vessels, tank bottom plates, buried sections of piping and fittings in carbon or low alloy steel, with or without cathodic protection. TESTING AND ACCEPTANCE CRITERIA As shown in Table B1.22 in Part 1 of this Specification


ISO-8501-1:2001 Sa 2½ 75 microns

COATING SYSTEM

Primer Type: Application method: DFT microns:

Not required


High build, high solids modified epoxy Airless or conventional spray


High build, high solids modified epoxy Airless spray

500

500


1000

COATING REPAIR Surface preparation, coating application, inspection and repair all as required in Part 3 of this Specification.

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PCS-2C External coating for below-ground structures up to 70oC

5.4


Rev. Date: May 2009

SCHEDULE: PCS-2C DESIGNATED USE External coating for below ground (or immersed) steel structures in onshore locations at service temperatures up to 70oC. APPLICABLE STRUCTURES Buried tanks, vessels, tank bottom plates, buried sections of piping and fittings, in carbon or low alloy steel, with or without cathodic protection. TESTING AND ACCEPTANCE CRITERIA As shown in Table B1.23 in Part 1 of this Specification


ISO-8501-1:2001 Sa 2½ no anchor pattern is required

COATING SYSTEM

Primer Type: Application method: DFT microns: Intermediate Coat Type: Application method: DFT microns: Top Coat Type: Application method: DFT microns:

Not required

Visco Elastic polymer wrapping or shrink sleeve for maintenance manual wrapping or machine 2 .08mm

PVC reinforce wrapping manual wrapping or machine 0.8mm


2.88mm

COATING REPAIR Surface preparation, coating application, inspection and repair all as required in Part 3 of this Specification. NOTES 1. Coating to be applied by PDO approved applicators 2. Coating can be applied in one coat provided performance test data is also for a single coat system 3. Testing shall be carried out at the specified design temperature. 4. Coating to be applied by PDO approved applicators. 5. The qualification requirements in part 1 is only applicable for visco elastic material. The Shrink sleeve qualification shall be as per this DEP 31.40.30.37.

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PCS-3 External coating for above ground structures at temperatures of 100 – 400ºC (insulated or non-insulated)


Rev. Date: Dec 2007

SCHEDULE: PCS-3 DESIGNATED USE External coating for above ground steel structures in onshore locations at service temperatures of 100-400oC. These can be insulated or not as required. APPLICABLE STRUCTURES Flare stacks, furnaces, furnace stacks, flue ducts, exchangers, associated pipework and fittings (insulated or uninsulated) in carbon or low alloy steel. TESTING AND ACCEPTANCE CRITERIA As shown in Table B1.1 in Part 1 of this Specification


ISO-8501-1:2001 Sa 2½ 30 to 40 microns

COATING SYSTEM Primer Type: Application method: DFT microns: Intermediate Coat Type: Application method: DFT microns: Top Coat Type: Application method: DFT microns:

Inorganic zinc silicate Airless or conventional spray 50

Aluminium pigmented silicone Airless or conventional spray 25

As intermediate coat 25


100

COATING REPAIR Small area of damage (<5cm2/1m2), apply intermediate and top coats. For larger areas of damage, prepare surface, apply coating system and inspect all as required in Part 3 of this Specification.

NOTES 1. Zinc silicate paint to contain min 60% solids by part 2. Silicate coating may be applied in single coat 3. All paints from same manufacturer 4. System must cure at ambient temperatures. SP-1246

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Version 2

PCS-4 External coating for above ground structures beneath insulation under 100oC


Rev. Date: Dec 2007

SCHEDULE: PCS-4 DESIGNATED USE External coating for above ground steel structures in onshore locations at service temperatures up to 100oC prior to applying insulation. APPLICABLE STRUCTURES Tanks, vessels, separators, flare stack piping, exchanger shells, columns, associated pipework and fittings in carbon and low alloy steel under insulation. TESTING AND ACCEPTANCE CRITERIA As shown in Table B1.5 in Part 1 of this Specification


ISO-8501-1: 2001 Sa 2½ 40 microns

COATING SYSTEM Primer Type: Application method: DFT microns: Single Coat Type: Application method: DFT microns:

Not required

One coat of aluminium pigmented polyamide cured epoxy mastic Airless or conventional spray 125

Total min DFT. Microns:

125

COATING REPAIR Sweep blast damaged area, apply single coat and inspect as required in Part 3 of this Specification.

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PCS-5 External coating for steel structures >400oC

5.7


Rev. Date: Dec 2007

SCHEDULE: PCS-5 DESIGNATED USE External coating for above ground steel structures in onshore locations at service temperatures >400oC APPLICABLE STRUCTURES Flare stacks, furnaces, furnace stacks, flue ducts, exchangers, associated pipework and fittings in carbon and low alloy steel. TESTING AND ACCEPTANCE CRITERIA As shown in Table B1.5 in Part 1 of this Specification


ISO-8501-1: 2001 Sa 2 25 microns

COATING SYSTEM Primer Type: Application method: DFT microns: Intermediate Coat Type: Application method: DFT microns: Finish Coat Type: Application method: DFT microns:

Heat-resistant aluminium silicone Airless or conventional spray 25

Not required

Heat resistant aluminium silicone Airless or conventional spray 25


50

COATING REPAIR Small areas of damage (<5cm2/1m2), apply finish coat. For larger areas, surface preparation, coating application and inspection, all as required in Part 3 of this Specification.

NOTES 1. 2.

System must cure at ambient temperatures For uninsulated service thermal sprayed aluminium can be considered.

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PCS-6 External coating for galvanised steel and above ground stainless steel structures


Rev. Date: May 2009

SCHEDULE: PCS-6 DESIGNATED USE External coating for above ground galvanised steel and stainless steel structures in onshore locations at service temperatures up to 100oC. APPLICABLE STRUCTURES Structural steelwork, supports, handrails, gratings and associated fittings in galvanised carbon steel or stainless steel. TESTING AND ACCEPTANCE CRITERIA As shown in Table B1.1 in Part 1 of this Specification

SURFACE PREPARATION Light sweep blast. For weathered galvanising sweep blasting is recommended. Cleaning standard: Surface profile:

Thoroughly degrease and rinse in clean water. Hand abrasion to remove zinc salts and other deposits. Roughened for key by sweep blasting

COATING SYSTEM Primer Type: Application method: DFT microns: Intermediate Coat Type: Application method: DFT microns:

High build polyamide cured epoxy Airless spray


High build aliphatic polyurethane Airless spray

50

50


100

COATING REPAIR Lightly abrade damaged area, apply primer and intermediate and final coats and inspect as required in Part 3 of this Specification.

NOTES

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PCS-7A Internal glass fibre reinforced epoxy lining for tanks up to 60oC

5.9


Rev. Date: Dec 2007

SCHEDULE: PCS-7A DESIGNATED USE Internal glass fibre reinforced epoxy lining for protection of steel oil storage tanks and vessels that are in a continuous water phase at temperatures up to 60oC. APPLICABLE STRUCTURES Bottom part of shells of carbon steel tanks and vessels that are subject to exposure to a continuous water phase. Such structures include, crude oil storage tanks, water knock-out and dehydration tanks, inlet separators in corrosive water and wet hydrocarbon service. TESTING AND ACCEPTANCE CRITERIA As shown in Table B1.3 in Part 1 of this Specification SURFACE PREPARATION Surface preparation shall comply with Part 4 of this Specification. Blast cleaning standard: Surface profile: COATING SYSTEM Primer Type: Application method: DFT microns:

ISO-8501-1:2001 Sa 2½ 100 microns

Two-pack epoxy resin/amine adduct Airless or conventional spray see below

Fill Coating for overlap welds etc. Type: Epoxy based sand-filled putty Application method: Hand trowel Intermediate Layer Type:

Application method: DFT microns:

Epoxy resin amine adduct cured Two layers of 300gm/m2 chopped strand mat One layer of 300 micron glass surfacing tissue Hand lay-up 1200 min

Top Layer Type: DFT microns:

All as intermediate layer

Overseal Layer Type: DFT microns

Flood coat of epoxy resin

1200 min

300min


2800

COATING REPAIR Surface preparation, coating application, inspection and repair all as required in Part 3 of this Specification. NOTES 1. Detailed method statement to be provided for review prior to commencement of work 2. Primer thickness as recommended by coating system manufacturer. 3. Lining on lower shell to cover complete area in water phase.

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PCS-7B Internal epoxy coating for tanks and vessels up to 60oC

5.10


Rev. Date: Dec 2007

SCHEDULE: PCS-7B DESIGNATED USE Internal high build epoxy coating for steel tanks and vessels in corrosive service at temperatures up to 60oC. APPLICABLE STRUCTURES Areas in the water phase such as piping, fittings and other appurtenances that are not practical to coat with GRE. Remainder of surfaces in GRE lined carbon steel tanks and vessels in corrosive service which are not in the water phase. This includes areas above the GRE lining such as, nozzles, internals, roof plates and rafters. This does not include areas above the GRE lining in crude oil storage tanks located at MAF which are considered not to be in corrosive service. TESTING AND ACCEPTANCE CRITERIA As shown in Table B1.3 in Part 1 of this Specification


ISO-8501-1:2001 Sa 2½ 75 microns


Polyamide cured epoxy primer Airless or conventional spray


Solvent-free high solids amine adduct cured epoxy Airless or conventional spray


Solvent-free high solids amine adduct cured epoxy Airless or conventional spray

50

225

225

Total DFT microns:

500


NOTES 1.

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Coating thickness may be achieved in a single high build application, if desired

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5.11

Version 2

PCS-8 Internal glassflake coating for tanks and vessels at temperatures of 60 to 93oC


Rev. Date: Dec 2007

SCHEDULE: PCS-8 DESIGNATED USE Internal corrosion resistant glassflake coating for steel tanks and vessels at temperatures of 60 to 93oC. APPLICABLE STRUCTURES Bottom part of shells of carbon steel tanks and vessels that are subject to exposure to a continuous water phase. Such structures include, crude oil storage tanks, water knock-out and dehydration tanks, inlet separators in corrosive water and wet hydrocarbon service. TESTING AND ACCEPTANCE CRITERIA As shown in Table B1.3 in Part 1 of this Specification


ISO-8501-1:2001 Sa 3 75 microns


System dependent


Glassflake Bisphenol A or vinyl ester Airless spray, plural component spray


Glassflake Bisphenol A or vinyl ester Airless spray, plural component spray

450

450


900

NOTE : Manufacturers may recommend and qualify alternative coating system thicknesses

COATING REPAIR Surface preparation, coating application, inspection and repair all as required in Part 3 of this Specification. NOTES 1. 2. 3. 4. 5.

SP-1246

Manufacturers recommendations for the qualified system must be followed. Resin system selection dependent on actual design temperature, coating manufacturers shall be consulted in all cases. Thicknesses are indicative. Coating thickness as used in qualification to be specified. Refer to part-5 for approved thickness. Detailed method statement to be provided for review prior to commencement of work. Vendor’s approved applicator to be used under Vendor’s supervision. Coatings for vessels to resist explosive decompression

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Version 2

PCS-9 Internal coating for vessels at temperatures above 93oC

5.12


Rev. Date: Dec 2007

SCHEDULE: PCS-9 DESIGNATED USE Internal coating for steel vessels for temperatures above 93oC. APPLICABLE STRUCTURES Carbon steel vessels in water/hydrocarbon service at temperatures >93 oC TESTING AND ACCEPTANCE CRITERIA As shown in Table B1.3 in Part 1 of this Specification. Vendor to specify maximum allowable service temperature and provide test data to verify this temperature


ISO-8501-1:2001 Sa3 System dependent

COATING SYSTEMS Specialist high temperature coatings such as epoxy novolac and vinyl ester novolac based systems to be proposed and qualified by Manufacturers.

NOTES 1. 2. 3. 4. 5.

SP-1246

Manufacturers recommendations for the qualified coating system must be followed. Coating thickness as used in qualification to be specified. Refer to Part 5 for approved thickness. Maximum operating temperature as used in qualification to be specified in Part 5 Detailed method statement to be provided for review prior to commencement of work. Coatings for vessels to resist explosive decompression Vendor’s approved applicator to be used under Vendor’s supervision

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5.13

Version 2

PCS-10 Internal coating for tanks for potable water


Rev. Date: Dec 2007

SCHEDULE: PCS-10 DESIGNATED USE Internal epoxy coating for potable water service for temperatures up to 60oC. APPLICABLE STRUCTURES All internal surfaces of carbon or low alloy steel tanks for potable water. All wetted surfaces, with or without cathodic protection. TESTING AND ACCEPTANCE CRITERIA As shown in Table B1.3 in Part 1 of this Specification


ISO-8501-1:2001 Sa 2½-3 50-75 microns

COATING SYSTEM Primer/First Coat Type: Application method: DFT microns:

System Dependent Airless or conventional spray


High build sloventless polyamine cured epoxy Airless spray


200

As for intermediate coat 200


400

COATING REPAIR Surface preparation, coating application, inspection and repair all as required in Part 3 of this Specification. NOTES 1. Epoxy holding primer, optional, may be required for large areas 2. Coatings must have appropriate potable water approval/certification eg. compliance with BS 6920.

3.

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5.14

Version 2

PCS-11A External coating for marine structures


Rev. Date: Dec 2007

SCHEDULE: PCS-11A DESIGNATED USE External coating for above water steel structures in a marine environment. APPLICABLE STRUCTURES Non-immersed topside steel structures of marine structures such as jetties, mooring buoys, launches and barges TESTING AND ACCEPTANCE CRITERIA As shown in Table B1.4 in Part 1 of this Specification SURFACE PREPARATION Surface preparation shall comply with Part 4 of this Specification. Blast cleaning standard: Surface profile:

ISO-8501-1:2001 Sa 2½ 50 to 75 microns


Polyamide cured epoxy primer Airless or conventional spray 50


Polyamide cured epoxy (high build) Airless spray


Two-pack high build polyurethane Airless spray

140

60

Total DFT microns:

250


NOTES 1. Zinc rich epoxy primer may be used

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April 2010


5.15

Version 2

PCS-11B High solids epoxy coating for immersed marine structures


Rev. Date: Dec 2007

SCHEDULE: PCS-11B DESIGNATED USE High solids epoxy coating for immersed marine applications and wetted areas of fixed structures. APPLICABLE STRUCTURES Below water areas of marine vessels such as SPMs, barges and launches, with or without cathodic protection. TESTING AND ACCEPTANCE CRITERIA As shown in Table B1.4 in Part 1 of this Specification


ISO-8501-1:2001 Sa 2½ 50-75 microns

COATING SYSTEM

Primer Type: Application method: DFT microns: Intermediate Coat Type: Application method: DFT microns: Top Coat Type: Application method: DFT microns:

Two-pack high solids modified epoxy Airless spray 250

As Primer 250

Fouling control system Airless spray

Optional


500


NOTES 1. 2. 3.

SP-1246

Where local restrictions apply, use biocide-free antifouling paints based on silicone elastomer An intermediate coating to enhance adhesion may need to precede the antifouling coat Coating system to cover the complete tidal zone

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April 2010


5.16

Version 2

PCS-12 Internal Flow Coating for Gas Transmission Pipelines in Non-Corrosive Service


Rev. Date: May2009

SCHEDULE: PCS-12 DESIGNATED USE Internal epoxy flow coating for gas transmission lines. APPLICABLE STRUCTURES Internal surface of gas transmission pipelines that are not in corrosive service.. TESTING AND ACCEPTANCE CRITERIA As shown in table B1.5 of Part 1 of this specification in general accordance with DEP.31.40.30.35 SURFACE PREPARATION Surface preparation shall comply with Part 4 of this Specification. Blast cleaning standard: Surface profile:

ISO-8501-1:2001 Sa 2½ 50 microns

COATING SYSTEM One coat Type: Application method: DFT microns:

Epoxy flow coat Airless or conventional spray 75


75

COATING REPAIR Surface preparation, coating application, inspection and repair all as required in Part 3 of this Specification. NOTES 1. This is not a corrosion resistant coating but used to reduce friction and increase volume through put.

SP-1246

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6

Version 2

Related Business Control Documents PDO and SIEP Documents

DEP 31.40.30.35-Gen

Technical Specification – Internal Coating of Line Pipe for Non-Corrosive Gas Transmission Service

GU-368

Guidelines For The Protection Of Buried Sections Of Surface Laid Pipelines/Flowlines

PR-1180

Performance Testing of Coating Systems for Pipeline Rehabilitation

DEP 31.40.30.37

EXTERNAL FIELD JOINT AND REHABILITATION COATING SYSTEMS FOR LINE PIPE

DEP 31.40.30.31-Gen.

Technical Specification for External polyethylene and polypropylene coating for line pipe

DEP 31.40.30.32-Gen

Technical Specification for External fusion-bonded epoxy powder coating for line pipe

Manufacturers recommendations for the qualified system must be followed International Standards ISO-8501-1

Preparation of steel substrates before application of paints and related products – Visual assessment of surface cleanliness.

BS EN ISO 1461

Specifications and test methods for hot dip galvanised coatings on iron and steel articles.

BS 6920

Suitability of non-metallic products for use in contact with water intended for human consumption.

SP-1246

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7

Version 2

Appendix A Glossary of Terms, Definitions and Abbreviations

SP-1246

CFDH

Corporate Functional Discipline Head

ISO

International Organisation for Standardisation

ASTM

American Society for Testing and Materials

BS

British Standards

DEP

Design and Engineering Practice (SIEP)

UER

CFDH Materials and Corrosion

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8

Version 2

User Comment Form

User Comment Form If you find something that is incorrect, ambiguous or could be better in this Procedure, write your comments and suggestions on this form. Send the form to the Document Control Section (DCS). They make a record of your comment and send the form to the correct CFDH. The form has spaces for your personal details. This lets DCS or the CFDH ask you about your comments and tell you about the decision. Title:

Procedure Details

Issue Date:

Number: Page Number:

Heading Number:

Figure Number:

Comments:

Suggestions:

User’s personal details Name:

Ref. Ind.:

Signature:

Date: Phone:

Document Control Section Actions Comment Date: Number: Recd.: CFDH Actions recd. Decision: Date: Reject: Accept, revise at next issue:

Accept, issue temporary amendment

CFDH Ref. Ind.: To CFDH:

Inits.:

Ref. Ind.

Date:

Comments:

Originator Advised:

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Date:

Inits.:

Document Control Advised.

28

Date:

Inits.:

April 2010

SP-1246

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