JO-AM-MGC-SP-203 (Rev. A1) Painting and Coating of Metal Surfaces SS - Copy

Project : MGC Revamp Project (JO/HC125/MP12) of 43

Doc. Title : Specification for Painting and Coating of Metal Surfaces – New Construction

Doc. No. (Rev) : JO-KOC-P-001 (Rev. A1)

JO Document Number: JO-AM-MGC-SP-203

Document Title:

MGC Revamp Project

(JO/HC125/MP12)

SPECIFICATION FOR PAINTING AND COATING OF METAL SURFACES – NEW CONSTRUCTION

A1 ISSUED FOR TENDER

ISSUE REV

ISSUE OR REVISION DESCRIPTION

ORIGIN BY DATE CHECKED BY

DATE DATE APPROVED BY DATE

Joint Operations




Revision Change Details

Revision Change Description Change Location

A1 Issued for tender




Contents

1 SCOPE 7

2 APPLICATION 7

3 TERMINOLOGY 7

3.1 Definitions 7

3.1.1 Abrasive 7

3.1.2 Grit 7

3.1.3 Shot 7

3.1.4 Comparator 7

3.1.5 Coat 8

3.1.6 Cure 8

3.1.7 Discontinuity (Holiday) 8

3.1.8 Dry Film Thickness 8

3.1.9 Pot-life 8

3.1.10 Rust grade (Degree of Rusting) 8

3.1.11 Atmospheric Zone 8

3.1.12 Surface Profile 8

3.2 Abbreviations 8

4 REFERENCE CODES AND STANDARDS 8

4.1 Conflicts 8

4.2 List of Standards, Codes and Specifications 9

4.2.1 National/International Standards 9

4.2.2 Painting/Coating - General 9

4.2.3 Surface Preparation 9

4.2.4 Inspection/Testing 9

4.2.5 Health and Safety 10

4.2.6 J Standards 10

5 ENVIRONMENTAL CONDITION 10

6 HEALTH, SAFETY AND ENVIRONMENT 11

6.1 General 11

6.2 Storage, Handling and Mixing Safety Precautions 11

6.2.1 Safe Storage 11

6.2.2 Manufacturer's Health/Safety Precautions 11

6.3 Safety Precautions for Blasting/Painting Equipment 11

6.4 Safety Precautions in Flammable Atmospheres 12

6.5 Safety Precautions in Confined Space 12




6.6 Site Clearance & Environmental Protection 12

7 PAINTS/COATING MATERIALS 13

7.1 General 13

7.2 Approvals 13

7.3 Zinc-Rich Epoxy Primer 13

7.4 Inorganic Zinc Silicate Primer 13

7.5 Zinc Phosphate Primer 13

7.6 Mordent Solution (T-wash) Pre-treatment Primer 13

7.7 High Build Epoxy Intermediate 13

7.8 Coal Tar Epoxy Primer/lntermediate/Finish 14

7.9 Two -Pack Polyurethane Finish 14

7.10 Amine Adduct Epoxy Paint 14

7.11 "Solvent Free" High Build Epoxy Paint 14

7.12 "Zinc Free" Inorganic Silicate Finish 14

7.13 High Temperature Aluminium Silicone Finish 14

7.14 Metal Spray Coatings 14

7.15 Restriction on Using Aluminium Pigments and Metal Spray 15

8 SURFACE PREPARATION 15

8.1 General 15

8.2 Working Restrictions 15

8.2.1 Weather Conditions 15

8.2.2 Work Conditions 15

8.3 Surface Imperfections Removal 16

8.4 Surface Contaminants Removal 16

8.5 Dry Abrasive Blast Cleaning Practice 16

8.6 Blast Cleaning Standard 17

8.7 Restrictions on Alternative Techniques to Blast Cleaning 18

8.8 Power Tool Cleaning 18

8.9 Hand Tool Cleaning 18

8.10 Acid Pickling (Etching) Preparation 18

8.11 Preparation of Stainless Steels 18

8.12 Preparation of Galvanized Surfaces 19

9 PAINT/COATING APPLICATION 19

9.1 General Requirements 19

9.2 Selection of Painting/Coating System 20

9.3 Paint Mixing and Thinning 20




9.4 Restrictions on Painting 20

9.4.1 Weather Conditions 20

9.4.2 Work Conditions 20

9.5 Paint Application Practice 21

9.5.1 General 21

9.5.2 Airless Spray Application 21

9.5.3 Brush Application 21

9.5.4 Roller Application 22

9.6 Priming 22

9.7 Shop Painting 22

9.7.1 Completely Fabricated Items 22

9.7.2 Partially Fabricated or Non-Fabricated ltems 22

9.8 Repair of Damages/Defects 23

10 INSPECTION AND TESTING 23

10.1 General Requirements 23

10.2 Materials and Equipment Inspection 24

10.3 Inspection/Testing Equipment 24

10.4 Environmental Conditions Testing 24

10.5 Blasted Surface Inspection Resting 24

10.5.1 Visual Inspection 24

10.5.2 Surface Profile Testing 24

10.5.3 Contaminants Free Testing 24

10.6 Painted Surface Inspection/Testing 25

10.6.1 Visual Inspection 25

10.6.2 Curing of Inorganic Zinc Silicate Primer Test 25

10.6.3 Paint Film Thickness Test 25

10.6.4 Paint Adhesion 25

10.6.5 Holiday Detection (Porosity Check) 26

11 QUALITY ASSURANCE 26

12 DOCUMENTATION 26

12.1 General 26

12.2 Work Proposal 26

12.3 Work Records/Reports 27

12.4 Final Report 27

13 PAINTING/COATING SCHEDULES 27

14 COLOUR SCHEDULE 27

15 Appendices 28




Appendix 1 – PAINTING RECORD/DATA SHEET 29

Appendix 2A – COLOUR SCHEDULE 31

Appendix 2B – COLOUR IDENTIFICATION FOR HAZARDS AND FIRE/SAFETY 32

Appendix 2C – Deleted 32




1 SCOPE

This document is derived from KOC Standard For Painting And Coating Of Metal Surfaces – New Construction Doc. No. KOC-P-001

This Standard specifies the minimum basic requirements for surface preparation, coating materials, method of application and inspection/testing for -protective external and where applicable, internal painting/coating of metallic surfaces for above ground oil, gas and sea water facilities and related utilities.

This Standard covers the painting/coating for both newly constructed onshore facilities. It also covers the repair of defects or damages to the new painted items.

This Standard is not applicable to buried pipelines and subsea lines, decorative paints for non-metal surfaces areas (concrete, masonry, wood, etc.), field trial of newly developed painting/coating systems.

The internal coating of piping, pressure vessels and tanks is specified in document JOS-02-05 Internal Coatings.

2 APPLICATION

The materials and equipment for surface preparation, paint and coating application and inspection/testing, shall conform to the requirements of this Standard and the referenced standards/codes mentioned herein.

Any exceptions or deviations from this Standard, along with their merits & justification, shall be brought to the attention of JO’s Controlling Department for their review, consideration and amendment by Standards Division (if required).

Compliance with this Standard does not of itself confer immunity from legal or statutory obligations.

3 TERMINOLOGY

3.1 Definitions

For the purposes of this Standard, the following definitions apply:-

3.1.1 Abrasive

Natural or synthetic solid material used as a medium in abrasive blast-cleaning.

3.1.2 Grit

A term used to describe the angular or irregularly shaped particles of abrasives used.

3.1.3 Shot

A term used to describe the spherically shaped panicles of abrasive used for blast cleaning.

3.1.4 Comparator

A specimen surface, or surfaces, of known average profile, representing a particular abrasive blast-cleaning process.




3.1.5 Coat

A continuous layer of a coating material that results from a single application.

3.1.6 Cure

The chemical reaction resulting in the final polymerized product in the paint/coating system.

3.1.7 Discontinuity (Holiday)

A void, crack, thin spot, foreign inclusion or contamination in the coating film that significantly lowers the dielectric strength of the coating.

3.1.8 Dry Film Thickness

The dry film thickness of paint is the thickness of paint without solvent and is measured by film thickness gauge & expressed in micron (1000 microns equivalent to 1mm).

3.1.9 Pot-life

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

3.1.10 Rust grade (Degree of Rusting)

Classification describing the degree of rust formation on a steel surface prior to cleaning.

3.1.11 Atmospheric Zone

The part of an offshore structure above the splash tone.

3.1.12 Surface Profile

The micro-roughness of a surface, generally expressed as the average height of the major peaks relative to the major valleys.

3.2 Abbreviations

JO Joint Operations Wafra

CS Carbon Steel

DFT Dry Film Thickness (of Paint)

WFT Wet Film Thickness (of Paint)

MIO Micaceous Iron Oxide

RH Relative Humidity

4 REFERENCE CODES AND STANDARDS

4.1 Conflicts

In the event of conflict between this Standard and the standards/codes referenced herein, or other contractual or purchase requirements, the most stringent requirement shall apply, unless otherwise specified.




4.2 List of Standards, Codes and Specifications

The latest edition of the following standards, codes and specifications shall apply:

4.2.1 National/International Standards

4.2.2 Painting/Coating - General

BS349 Identification of the Contents of Industrial Gas Containers

BS381C Specification for Colour for Identification, Coding and Special Purposes.

BS729 Specification for Hot-dip Galvanized Coatings on Iron and Steel Articles

BS1710 Specification for Identification of Pipelines and Services.

BS3416 Specification for Bitumen-based Coatings for Cold Application Suitable for Use in Contact with Potable Water.

BS4800 Schedule of Paint Colours for Building Purposes.

BS5493 Code of Practice for Protective Coating on Iron and Steel Structures against Corrosion.

BSEN 22063 Metallic and Other Inorganic Coatings. Thermal Spraying, Zinc, Aluminium and their Alloys.

4.2.3 Surface Preparation

ASTM D2092 Guide for Treatment of Zinc-Coated (Galvanised) Steel Surfaces for Painting.

ES 7079-A1 Specification for Rust Grades and Preparation Grades of Uncoated Steel (ISO 8501-1) Substrate and of Steel Substrate After Overall Removal of Previous

Coatings -Visual Assessment of Surface Cleanliness.

BS 7079-D2 Preparation of Steel Substrate Before Application of Paints and Related (IS0 8504-2) Products. Abrasive Blast Cleaning.

SIS 05 59 00 Pictorial Surface Preparation Standards for Painting Steel Surfaces.

SSPC-SP Steel Structures Painting Council Surface Preparation Specifications.

4.2.4 Inspection/Testing

ASTM Dl186 Test Method for Non-destructive Measurement of Dry Film Thickness of Nonmagnetic Coatings Applied to a Ferrous Base.

ASTM Dl212 Test Methods for Measurement of Wet Film Thickness of Organic Coatings.

ASTM D2697 Test Method for Volume of Non-volatile Matter in Clear or Pigmented Coatings.

ASTM D3276 Guide for Painting Inspectors (Metal Substrates).

ASTM D3359 Test Methods for Measuring Adhesion by Tape Test

ASTM 4417 Test Methods for Field Measurements of Surface Profile of Blast Cleaned Steel




ASTM D4541 Test Method for Pull-Off Strength of Coatings Using Portable Adhesion-Testers

BS 3900-H3 Designation of Degree of Rusting

IS0 9000 Model of Quality Assurance in Design, Development, Production, Installation and Servicing

NACE RP01BB Discontinuity (Holiday) Testing of Protective Coatings

NACE RP0287 Surface Profile Measurements of Abrasive Blast Cleaned Steel Surface Using a Replica Tape

SSPC-PA2 Measurement of Dry Paint Thickness with Magnetic Gauges

4.2.5 Health and Safety

API 2217 Guidelines for Confined Space Work in the Petroleum Industry

BS 5378 Safety Signs and Colours

NFPA 231 Standard for General Storage

OSHA 29 CFR 1910 Regulation, Pertaining Work in Confined Areas

4.2.6 JO Standards

-JO/AM-MGC-SP-001 Plant Design data

JOS-02-01 Piping Selection and Design

JOS-02-04 Insert Sleeves for Internally Coated Carbon Steel Pipes

JOS-02-05 Internal Coatings

4.2.7 KOC Standards

KOC-P-002 Internal Lining of Steel Tanks and Vessels Part 2. Rigid Reinforced Fibreglass Lining

KOC –P-017 Colour Coding Arrangement and Application for Piping

5 ENVIRONMENTAL CONDITION

The environment of Kuwait is severe on all plant and equipment and must be considered carefully before selection/approval of paints and coating materials.

The ambient temperature range is -3°C to + 55°C. The exposed black body metal temperature due to solar radiation is 85 °C.

Humidity can pose a serious problem with long periods of relative humidity (RH) level of 100% being part of the normal weather pattern.

For other environmental conditions in Kuwait, refer to JOS-00-001 Plant Design data, which provides the detailed design information regarding the environmental, site and utility supply conditions prevailing throughout the JO facilities.




6 HEALTH, SAFETY AND ENVIRONMENT

6.1 General

The contractor shall employ all necessary health and safety procedures to protect personnel and surrounding environment during on-site field works.

All relevant safety requirements of the JO Fire and Safety Regulations shall be conformed, in particular the requirements for blasting and power tool cleaning, for scaffolding and access platforms, for compressors and compressed air equipment for ventilation and ventilation equipment in confined areas and for personnel protection, protective equipment and clothing.

The contractor shall comply with the JO Fire & Safety Regulations and the Health & Hygiene Procedures while performing the works within JO areas.

Where there is a risk of flammable atmosphere being present in a particular work area JO may, with relevant safety authority, impose restrictions on methods of surface preparation. Flame heating equipment shall not be used in hazardous areas.

For internal painting/coating of drinking water facilities (tanks, vessels, etc.), the contractor shall submit evidence (Kuwait heath authority approval) that the paint system will not in any way contaminate the water and will not affect the drinking quality of the water.

6.2 Storage, Handling and Mixing Safety Precautions

6.2.1 Safe Storage

a) All paints, coatings and thinners shall be stored in enclosed storage areas or structures that are well-ventilated and protected from temperatures exceeding manufacturer's recommendations, open flames, electrical discharge and direct sunlight. Air conditioned storage areas shall be considered where excessive ambient temperatures are expected.

b) The storage area shall be secluded and no other materials shall be stored in the enclosed place. The enclosure shall be demarcated as “NO SMOKING” area strictly.

c) All paints, coatings, solvents, oil and equipment cleaners shall be stored in closed labelled original containers.

d) Portable fire extinguishers of suitable quality and appropriate quantity shall be provided at the storage areas and such extinguishers shall be inspected and approved by Fire & Safety Department.

6.2.2 Manufacturer's Health/Safety Precautions

Manufacturer's health/safety precautions and procedures for mixing, handling, storage and application of paints and coating materials shall be strictly adhered to. Safety precautions shall be clearly described on the technical data sheet of paint and coating materials supplied as well as on the containers.

6.3 Safety Precautions for Blasting/Painting Equipment

Blast cleaning and spray painting guns shall be earthed (spark proofing) to prevent building up of an electrostatic charge, especially when the application is in confined work places.




All blasting equipment shall be inspected and certified by an authorised competent third party. Pressurised hoses shall be tested and certified for maximum safe working pressure. Hoses and other pressure items shall be checked periodically to make sure that any damage or loss of electrical conductivity will not lead to a safety hazard.

Pressurised hose and blasting gun shall compulsorily be equipped with 'Deadman Switch'.

Suitable fire extinguishers shall be provided near the air compressor.

Enclosures shall be provided all around the area, where shot / grit blasting will be carried out.

Clean air-mask PPE shall be worn by the technicians while blasting or spray painting.

6.4 Safety Precautions in Flammable Atmospheres

JO will advise on the area classification for both plant design and construction/ maintenance projects. Certain paint compositions shall not be used in some plant design area classification (e.g. zone I), as it can ignite with explosive force at certain conditions (see clause 7.15 of this Standard).

The contractor shall provide JO with all necessary material safety data sheet for the proposed paint systems, solvents and painting procedure In order to determine area classification for the duration of painting work.

6.5 Safety Precautions in Confined Space

All tank/vessel interiors shall be gas-free. Approval under entry permit procedure is required before the tank/vessel can be entered.

A!I electrical equipment used including lighting equipment, ventilation equipment, high voltage holiday testing equipment, etc., shall be grounded and suitable for the hazardous area classification of the working areas as advised by JO. All other equipment including ladders, tools, etc., shall be spark- proof.

The procedures for performing safe work in confined spaces shall be in accordance OSHA 29 CFR 1910 or API 2217.

6.6 Site Clearance & Environmental Protection

On completion of painting works, facilities shall be arranged by contractor for effective and safe removal of spillage collection and disposal of paints/coating materials, brushes, scaffolding, waste, equipment, etc. All necessary precautions shall be taken to safeguard the surrounding environment.

For all new equipment, piping and structures, blasting and the application of primer shall be carried out in the shop. No blasting work shall be carried out inside the operating plant. When this is unavoidable and blasting and painting must be performed on site then CONTRACTOR shall arrange adequate protection around the equipment to be painted so as to not affect the adjacent facilities and shall be subjected toprior approval from JO.




7 PAINTS/COATING MATERIALS

7.1 General

All paints/coating materials shall be chemically pure, and free from foreign contaminants. The age of coating material components shall not exceed the recommended pot-life as limited by the manufacturers.

All paints/coating materials shall be delivered to the site in original sealed manufacturer's containers with batch/code numbers and date of manufacture clearly marked thereon.

7.2 Approvals

All paints and coating materials, including thinners and equipment cleaners, in any one system shall originate from one manufacturer.

The JO approved schemes are only those used in the painting/coating schedules A-C (Appendix 3) end as defined in clauses 7.3-7.14 of this Standard. The use of alternative schemes shall be approved in writing by JO

The contractor's submittal for painting/coating materials shall include details of generalized composition, service temperature and technical specifications of the products to be used for JO review and approval.

The selected composition of painting / coating materials shall comply with the relevant clauses pertaining to the materials given below.

Paint manufacturers shall be from a KOC/SAC approved vendor list.

7.3 Zinc-Rich Epoxy Primer

This primer based on polyamide cured 2 pack epoxy. Minimum volume of solids shall be 63% as per ASTM D2697.

7.4 Inorganic Zinc Silicate Primer

Based on ethyl silicate media. Minimum volume of solids shall be at least 58% as per ASTM D2697. Capable of withstanding continuous high temperature (up to 400oC) and have excellent abrasion and chemical resistance.

7.5 Zinc Phosphate Primer

Based on long oil alkyd and urethane alkyd media. Minimum volume of solids shall be 48% as per ASTM D2697.

7.6 Mordent Solution (T-wash) Pre-treatment Primer

Used for preparation of galvanized surfaces. It is a two component etch primer, based on phosphoric acid solution incorporating copper salts and corrosion inhibitive pigments in a solvent/water solution.

7.7 High Build Epoxy Intermediate

Based on polyamide cured two pack high build epoxy binder pigmented with Micaceous Iron Oxide (MIO).Minimum volume solids shall be 55% per ASTM D2697.




7.8 Coal Tar Epoxy Primer/intermediate/Finish

The formulation of the two pack incorporate:

Pack 1. Epoxy resin and suitable pigments.

Pack 2. Polyamide or amine curing agent and coal tar.

The Epoxy resin shall comprise at (east 35% by weight in the resin/coal tar blend as per ASTM 02697.

For contrasting of intermediate coats, aluminium or red oxide may be used.

7.9 Two -Pack Polyurethane Finish

Based on acrylic modified two pack aliphatic polyurethane with titanium dioxide or MIO pigment. Minimum volume of solids shall be 45% per ASTM D2697.

A semi-gloss and colour retention finish is required.

7.10 Amine Adduct Epoxy Paint

A two pack epoxy amine adduct cured paint which cures to a coating with excellent resistance to chemicals.

Minimum volume of solids shall be 48% as per ASTM D2697.

It shall be approved by the NWC (National Water Council) and Kuwait health authority.

7.11 "Solvent Free" High Build Epoxy Paint

Based on polyamide cured two pack epoxy with a coating with good resistance to fresh water and to abrasion.

Minimum volume of solids shall be 100%per ASTM D2697 (solvent free).

It shall be approved by the NWC (National Water Council) and health authority.

7.12 "Zinc Free" Inorganic Silicate Finish

Air curing zinc free inorganic silicate based on ethyl silicate media; capable of withstanding continuous high temperature (up to 400'C) and have excellent abrasion and chemical resistance.

7.13 High Temperature Aluminium Silicone Finish

Based on silicone alkyd or modified silicone alkyd media (e.g. acrylic silicone). Minimum volume of solids shall be 49% as per ASTM D2697.

Pigmented with leafing aluminium pigment.

Heat resistant, capable to withstand continuous high temperature up to 400°C. Must be capable of "curing" to handle at ambient temperature.

7.14 Metal Spray Coatings

a) Based on molten Aluminium metal sprayed on surfaces prepared in accordance with BS EN 22063.




b) Aluminium metal spray coating is suitable for high temperature (up to 550°C) surfaces with restriction (see clause 7.15). The sprayed aluminium may be silicon sealed and for temperatures up to 250'C silicon sealed sprayed aluminium can provide more protection and longer Iife.

7.15 Restriction on Using Aluminium Pigments and Metal Spray

Due to the susceptibility of metallic aluminium to ignite with explosive force, Aluminium metallic pigments and Aluminium metal spray shall not be used on any surface operating above 120oC in area zone 1 as specified in JO Hazardous Area drawings.

8 SURFACE PREPARATION

8.1 General

All fabrication works including cutting and drilling of holes shall be completed prior to surface preparation. In special areas, however, preparation and priming of structured steel members and piping maybe approved by JO prior to final assembly.

Surface preparation shall preferably, for optimum coating performance, be ' carried out by dry abrasive blast cleaning. Alternative techniques shall only be applied in some circumstances as described in clause 8.7.

The surface preparation requirements for painting systems are indicated in the painting schedules A-C Appendix 3) and detailed in the clauses as follows:

8.2 Working Restrictions

8.2.1 Weather Conditions

All surface preparation shall not be conducted in the following conditions:

a) When the steel surface temperature is less than 3% above dew point.

b) When the air temperature is below 5°C

c) When the relative humidity (RH) is 85% or higher.

d) Under adverse weather conditions, e.g. rain, fog, sandstorm, high wind velocity (56 Km/hr. or higher), high wave tide or when such conditions are likely prior to completion of the work (i.e. abrasive blast cleaning).

8.2.2 Work Conditions

Field surface preparation shall not be conducted in the following conditions:

a) Outside daylight hours on exterior locations, unless permitted by JO Approved special lighting shall be arranged for night blast cleaning.

b) When the initial primer coat cannot be completed within 4 hours of preparation. Surfaces which remain uncoated for longer than this period shall be re-blasted prior to priming.

c) When adjacent areas or equipment are insufficiently protected from damage or contamination by abrasive dust or debris.

d) In areas close to painting operations, to prevent damage or contamination of wet paint films by abrasive material.




8.3 Surface Imperfections Removal

Surface imperfections or irregularities shall be removed completely (made flush or smooth) prior to blast cleaning. Imperfections shall be considered as follows:

a) Weld spatter and slivers shall be removed. Sharp or rough welds shall be rounded and contoured. Any other observed defects in welds and material should be referred to JO for disposition.

b) Porosity (weld voids) shall be cleaned and filled with acceptable filler material or closed over by a suitable mechanical method approved by JO

c) Sharp or rough edges shall be rounded, chamfered or broken.

d) Such imperfections that appear after blast cleaning or acid pickling shall be similarly removed. If grinding is needed, checking of the remaining wall thickness and JO’s approval are required.

8.4 Surface Contaminants Removal

The metal surface shall be cleaned to remove any oil, grease, din, etc. using solvent and/or suitable emulsifying alkaline cleaners followed by washing with clean water or wet steam rinsing. SSPC-SP7 outlines these methods.

Degreasing by wiping the surface with solvent only is not recommended in heavily oil/grease surface contamination, because this invariably leads to the spreading of a thin film of oil over wide area. The solvent/emulsifying agent cleaned surface shall be allowed to dry before proceeding with further preparation or painting.

Soluble salts on steel surface exposed to a salt laden atmosphere shall be removed by washing or by any other suitable technique. See clause 10.5.3 for iron salts contaminant free testing.

8.5 Dry Abrasive Blast Cleaning Practice

Dry abrasive blast cleaning shall be used to remove all rust and mill scale and to achieve the required visual standard and surface profile defined in the approved painting/coating schedules (Appendix 3).

Abrasive material shall satisfy the following requirements:-

a) Abrasive material for mild / carbon steel preparation shall be industrial grade metal angular grit or shot (generally iron or steel). Contaminated or re-cycled grit or shot shall not be used. Abrasives for stainless steel substrate shall be non-metallic materials. New less-dust generating abrasive media such as "Garnet" plastic granulates and alike, capable of producing the required surface profile may be used for blast cleaning.

b) Sand may be used as abrasive material for field blast cleaning, subjected to JO’s approval. Sand material shall be graded (30-60 mesh), hard, version, silica or olivine sand with less than a 10 percent breakdown. No sand shall be used more than once.

c) The selected abrasive material shall be in accordance with SSPC-SP-COM or BS 7079 R.D2 (IS0 8504-2).

d) Abrasive material shall be dry and free from oil, grease, dust, salts and any other impurities or contaminants.




e) Abrasive materials shall be capable of achieving the required surface profile without contamination of the substrate. To produce the required surface profile, abrasive particle size shall follow the surface preparation commentary of SSPC manual as necessary to comply with visual blast cleaning standards mentioned in clause 8.6 of this Standard.

f) All abrasive materials shall be kept dry, and covered when not used.

g) Abrasive sample shall be provided by the contractor for JO’s testing and approval before work commencement.

The blasting equipment and technique shall comply with the following requirements:

a) The contractor's abrasive blast cleaning equipment shall satisfy JO’s safety requirements (See clause 6.3).

b) For field and shop blast cleaning, abrasive shall be carried by a jet of compressed air through a hand-held nozzle. The compressed air supply and volume shall meet work requirement and shall be substantially free from oil and water contamination. Traps and filters shall be cleaned regularly.

c) For blast cleaning of large horizontal surface areas, like tank roofs, bottoms etc., a self contained vacuum blast unit can be used. Such machines are usually operated by remote compressed air or hydraulically actuated for traction.

d) 'Deadman handles' shall be fixed to the blast line as close as practicable to the blast nozzle and shall be held by the blast operator alone.

e) Nozzles used shall have a maximum orifice size of 9 mm and shall be of venturi design.

Openings in vessels, piping, access fittings, nozzles, etc. shall be properly protected against entry of abrasive material. All previously painted or galvanised surfaces shall be adequately protected prior to commencing any blasting operation.

Blast cleaned rusty surface (due to rain or condensation) and surfaces with temporary holding primer, shall be re-blasted to the specified surface profile.

Surface blast cleaning to the specified surface profile shall extend a minimum of 150 mm beyond the area to be coated during the same day.

Surface blasting to the specified surface profile shall continue a minimum of 25 mm into adjoining previously coated surface. The edges of the previous coating shall be feathered.

All prepared surfaces shall be cleaned from any dust/abrasive material preferably by dry brushing and/or vacuuming with industrial vacuum cleaner. Pressure air blowing is not permitted. Any surface showing signs of contamination, after blast cleaning, shall be solvent cleaned and re-blasted.

8.6 Blast Cleaning Standard

The surface profile height shall be in accordance with the requirement of painting system. The measurement techniques of surface profile testing are specified in ASTM D4417.

Blast cleaning shall be carried out to a visual standard in accordance with SIS 05 59 00, either as Sa 2, Sa 2½ or Sa 3. (identical to BS 7079 Part A1 or IS0 8501-1) subjected to the requirements of paint manufacturer's data sheet. Reference shall be made to these standards for photographs of equivalents to the mentioned qualities.




8.7 Restrictions on Alternative Techniques to Blast Cleaning

In some circumstances, blast cleaning shall not be done and alternative surface .reparation techniques (like manual/power tool cleaning) shall be applied. These alternative techniques are subject to JO’s approval and restricted as follows:

a) When dry abrasive blast cleaning is unsafe or any of JO’s safety precautions/ requirements cannot be met.

b) When there is a risk of damage to instrumentation, equipment (e.g., electrical, rotating, etc.) within the proximity of blasting operations.

c) Where there is a flammable atmosphere or similar condition present, restrictions may be applied by JO.

d) Where blast cleaning is not practical, e.g. for welds, edges, bolts, nuts, corners, crevices etc. and for paint defects/damages repair.

8.8 Power Tool Cleaning

Power tool cleaning shall be to a visual standard in accordance with SIS 05 59 00 St 3 or BS 7079 Part A1 St 3 (equivalent to U.S. Standard SSPC-Sp3).

Where power tool cleaning is carried out, 100% of the surface shall be covered using abrasive or wire type power discs. In some locations which can not accommodate a power disk, e.g. welds, power impact tools shall be applied (vibratory and rotary, needle guns, scrapers) followed up by wire brush cleaning.

Power tool cleaning shall extend a minimum of 25 mm distance into adjoining coated surfaces.

8.9 Hand Tool Cleaning

Hand tool cleaning may be used for cleaning rusted surfaces in some circumstances as specified in clause 8.7 and for paint defects/damages repair.

Hand tool cleaning shall be to visual standard in accordance with SIS 05 59 00 St2 (BS7079 St2) which is equivalent to SSPC-SP2.

8.10 Acid Pickling (Etching) Preparation

This method may be used by contractors, in some circumstances and locations as an alternative to blasting provided that it is compatible with paint system and approved by JO

When using this method, the surface shall be etched to a degree suitable for the specified coating system. Details on this method are specified in SSPC- SP8.

JO Fire and Safety Regulations shall be adhered to when using this method

8.11 Preparation of Stainless Steels

Stainless steels shall not be painted unless specified by the relevant equipment data sheet. The surface specified to be painted shall be:

a) thoroughly degreased using solvent cleaning or suitable emulsifying agent and washed with fresh water to remove any contamination.




b) blast cleaned to a surface profile of 25-50micron using chloride free abrasive such as alumina. Copper slag abrasives shall not be used. Hand or power tools using P60 grade paper may be used for surface preparation, when grit blast cleaning is impractical. (see clause 8.7).

c) protected from any further contamination by debris produced during grit blasting of adjacent carbon steel because embedded panicles could promote corrosion. Any observed contamination should be referred to JO for disposition.

Blast/Power tool cleaning equipment used for carbon steel shall not be subsequently used on stainless steel.

8.12 Preparation of Galvanized Surfaces

Painting of new galvanized surfaces shall be only for top coating purposes in conformity with systems B1, Dl-10, Dl-11 of Appendix 3 of this Standard. The surface preparation method shall be carried out as follows:

a) The greasy film on the new galvanized steel surface and any other oil or grease contamination shall be removed using emulsifying agent:

b) The surface shall be chemically etched (primed) by using proprietary T-wash solution. (see clause 7.6 )

c) Weathered surfaces shall be cleaned using wire brushing or sweep blasted to remove all corrosion products or deposits and degreased with emulsifying agent.

Other surface preparation methods may be used in accordance with ASTM D 2092 for painting new galvanized surfaces subject to O’s approval.

9 PAINT/COATING APPLICATION

9.1 General Requirements

Painting/coating works shall be in accordance with the requirements established by this Standard and the recommendations of the paint/coating manufacturer. Any area not specifically covered, shall be in accordance with the principles and guidelines set forth in the SSPC Manual.

The contractor shall provide all materials, tools, equipment and manpower required for carrying out the works.

Surfaces, to be painted/coated, shall be inspected and approved by JO before any painting coating is applied. This shall be after surface preparation and between each subsequent coating. No primer or paint shall be applied without JO’s approval.

All surfaces, to be painted / coated, shall be dry and dust/contaminants free before application of the first coat.

Precautions shall be taken to prevent painting from being applied to name plates, couplings, shafts, valve stems, vent openings, gauge glasses, pressure gauges, etc. Masking tape, plastic film or any other suitable material shall be used, and all shall be removed after completion and acceptance of the painting application.

All areas prepared for field welds shall be kept free from paint over a distance of at least 100 mm from the weld centre, except welding / shop primer of 25 microns.




A minimum of 100 mm around edges of abrasive blasting shall be left unless adjoining a recently prepared and coated other surface.

Crevices created by two surfaces in close contact which cannot be protected by painting should be mastic sealed on both sides.

9.2 Selection of Painting/Coating System

The selection of painting/coating system for particular applications and required surface preparation shall be as given in the approved painting Schedules A, B, C, (Appendix 3) of this Standard.

9.3 Paint Mixing and Thinning

Mixing of paint to an even consistency, manufacturer's mixing instructions, environmental conditions and maximum pot life shall be strictly adhered to, especially for two -pack paints.

Mixing, by high speed mechanical agitators or rotary mixers, with flat blade and speed control, shall be used for containers larger than 5 litres. Hand mixing is permitted only for containers up to 5 litres.

For painting systems where pigment separation readily occur e.g. zinc silicate primers, continuous mixing shall be carried out during application.

After thorough mixing, the correct viscosity of the paint shall be proved by measuring with an approved flow cup.

Thinners shall not be added to paint without JO approval, only the thinners recommended by the paint manufacturer may be used, even for cleaning.

When thinning is permitted by JO paint manufacturer's instructions shall be strictly adhered and the accepted procedures mentioned in clause 7.3 of ASTM D3276 shall be followed.

9.4 Restrictions on Painting

9.4.1 Weather Conditions

Painting shall not be conducted in the similar weather conditions of abrasive blast cleaning as specified in clause 8.2.1 of this Standard and also under the following conditions:

a) When the metal surface temperature above 50°C.

b) Under adverse weather conditions, e.g. rain, fog, sandstorm, high wind velocity (56 Km/hr. or higher), high wave tide or when such conditions are likely before the paint/coating has become dry.

9.4.2 Work Conditions

Painting/Coating shall not be conducted in the following work conditions:

a) Where the specified surface finish is not existed at the time of applying the first coat.

b) When adjacent areas or equipment are not sufficiently protected from paint application.

c) Outside daylight hours on exterior locations unless permitted by JO Approved special lighting shall be arranged for night painting.




9.5 Paint Application Practice

9.5.1 General

a) The specified surface finish, of all areas to be painted, shall be prepared before applying the first coat if required surfaces shall be re-prepared to the specified finish.

b) The paint shall be applied in a uniform manner and to the prescribed number of coats and dry film thickness (DFT) given in Painting Schedules without any .runs, sags, marks or other blemishes. Finished application shall be uniform in colour, texture and appearance.

c) Intermediate and finish paintings shall be applied following final assembly of component pans. For surfaces inaccessible for proper painting and/or inspection, painting shall be applied prior to final assembly. The contractor and JO will designate inaccessible areas.

d) Where a multi-coat paint system is specified to be used, all intermediate coats shall be of contrasting colour to differentiate between coats. Colours for intermediate coats shall refer to the paint manufacturer's recommendations.

e) Time intervals between coats shall be kept to the minimum recommended by paint manufacturer in order to prevent contamination between coats. In case contamination does occur, it shall be removed by washing with suitable detergent solution and rinsing with clean fresh water.

9.5.2 Airless Spray Application

a) Paint application by airless spraying shall be the preferred paint application process. The use of air spray method shall conform to the requirement of coating system and shall be subject to JO’s approval.

b) Spraying equipment, guns, nozzle sizes, orifice sizes & shapes and pressure ranges shall meet the work requirements and the paint manufacturer's recommendations and shall be free from oil and water contamination.

c) All paint spraying lines and pots shall be cleaned and flushed before the addition of new material.

d) Large surfaces shall be painted with passes in two directions at right angles. Spray overlap of the previous pass shall be by 50%. .

9.5.3 Brush Application

a) Brush application shall be done on areas which cannot be properly sprayed e.g. for welds, edges, bolts, nuts, corners, crevices etc., and for touch-up maintenance where spray application is not practical.

b) Stripe coating of sharp edges, corners and welds can be done before application of finish paint to ensure that these areas receive the minimum specified film thickness.

c) Brushes shall be of a type, size and shape which permits proper application of paint and meets manufacturer’s recommendations.

d) Brush application shall be done such that a uniform coat, with no deep or detrimental brush marks is obtained. Runs and sags shall be avoided.




9.5.4 Roller Application

This method of application can be used subject to JO’s approval for painting large areas of relatively flat steel surfaces and where high film build is generally not to be attained. Roller application will ride over high spots and miss edges and shall not be used for painting corners, bolt heads, etc. Care must be taken to choose the correct roller pile length, depending on the type of paint and degree of roughness of the surface.

9.6 Priming

Priming shall be done on prepared surfaces before rusting occurs or within 4 hours of blast cleaning, whichever is sooner. The only relaxation allowable to this requirement is where the following three (3) conditions exist.

a) The work to be primed is fully enclosed

b) The ambient temperature is above 11oC

c) The relative humidity is below 75%

All acid de-scaled steel surfaces shall be primed as soon as the surface is dry and while it is still warm.

In order to facilitate shop or site handling procedure, holding (shop) primer of 25 microns may be applied on steel surface. If applied, however, this shall not replace the function or pan of the film thickness specified for the priming coat. Shop or welding primers shall be compatible with the specified painting system.

Zinc silicate primers shall be applied to abrasive blasted surfaces only. In order to protect the porous primer film from salt or chemical contamination, it shall be sealed with a tie coat as soon as practicable after complete curing has occurred. The tie coat shall achieve sound adhesion to the zinc silicate primer and be compatible with the finishing coat.

9.7 Shop Painting

Shop painting of items may be carried out by the contractor as below, subject to JO’s approval.

a) The contractor shall be responsible for paint condition on arrival of such items 'on-site' and shall carry out any paint damage repair needed.

b) The contractor shall comply with all aspects of this Standard and related aspects of JO’s safety regulations.

9.7.1 Completely Fabricated Items

a) Full surface preparation and painting works shall be done prior to transportation to site.

b) All painted items shall be protected/packed to avoid any coating damage during transportation. Care shall be taken in handling and installation to minimize coating damage.

9.7.2 Partially Fabricated or Non-Fabricated ltems

a) These items may be prepared/primed and further coated before transportation to site with the approval of JO.




b) The painting used shall have enough durability to withstand the 'on-site' construction period before further painting occurs.

9.8 Repair of Damages/Defects

New painted surfaces are likely to require repair and maintenance in the following cases:

a) for painted areas which have been damaged by other adjacent field activities or during handling/transportation of off-site painted items.

b) For areas which suffer paint defects e.g. disbonding, insufficient film thickness, blistering etc.

The type of coating materials used for repair and maintenance shall be identical to, or compatible with the original material.

The selection of suitable surface preparation shall depend on the size of areas to be painted, the type of repair painting materials to be used and the Safety regulations involved. The following order of preference shall be adopted.

a) Dry blast cleaning to the required visual standard (Sa 2-1/2 or Sa 3) and surface profile.

b) Power tool cleaning to standard St3 (only where blast cleaning is not practical or permitted).

c) Hand tool cleaning to standard St2 (only for minor touch up/repair work)

Surface preparation of defective or damaged areas shall be extended over the surrounding sound coating for a minimum of 25 mm on all sides and a further 25 mm of sound paint work shall be lightly blasted to etch the surface.

Surfaces to be painted that become contaminated with oil, grease, salts, etc. shall be cleaned with a proprietary solvent/detergent solution and rinsed with fresh clean water.

Repair works shall be in accordance with the specified painting system to restore the film thickness and shall cover the prepared surface and the etched pant work. For colour coding and/or cosmetic reasons it may be necessary to extend the finish coat over a large surrounding area.

It is mandatory that all defective work be corrected to the satisfaction of JO’s representative. Work shall not be deemed complete until the foregoing bas been achieved.

10 INSPECTION AND TESTING

10.1 General Requirements

Inspection and testing at all stages of surface preparation and painting/coating application shall be conducted by the contractor. The contractor shall provide all necessary inspection equipment and perform such inspections as necessary to assure that the painting/coating complies with the requirements of this Standard.

Surface preparation and painting/coating application may be subjected to inspection and approval at any stage by JO.

JO inspector shall have the right to inspect at all times any tools, materials or equipment used in the performance of surface preparation and paint application to ensure the compliance with the requirements of this Standard.




10.2 Materials and Equipment Inspection

Abrasive material shall be inspected to ensure compliance with the requirements of this Standard. (see clause 8.5.2)

Painting/coating materials shall be inspected to ensure compliance with the requirements of clause 7.0 and the specified painting schedules (Appendix 3) of this Standard.

Equipment for blast cleaning and paint application shall be inspected to ensure the compliance with the requirements of this Standard (see clauses 6.3, 8.5.3 and 9.5) and paint manufacturer's recommendations.

10.3 Inspection/Testing Equipment

The contractor shall have the necessary equipment and tools for inspection and testing of environmental conditions, surface preparation and painted/coated surfaces. All this equipment shall be approved by JO prior to starting any work. The contractor shall provide calibration certificates for all measurement and test equipment for JO’s review.

10.4 Environmental Conditions Testing

Prior to commencing any blast cleaning/paint application work, ambient temperature, metal surface temperature and relative humidity (RH) shall be measured. Readings shall comply with clauses 8.2.1 and 9.4.1. For works in confined areas, the oxygen deficiency and gas testing shall be performed.

Other environmental conditions, e.g. wind speed, sandy or rainy weather, shall be checked before the commencement of any work.

10.5 Blasted Surface Inspection Resting

10.5.1 Visual Inspection

a) Metal substrate shall be checked to ensure spatter / protrusions removal, cleanliness etc. prior to blast cleaning.

b) Blast cleaned surfaces shall be visually inspected (surface magnifier may be used) to ensure the absence of all types of imperfections and contaminants and for the conformance with the specified visual standard mentioned in the painting / coating schedules (Appendix 3).

10.5.2 Surface Profile Testing

On dry blast cleaned surfaces the profile height shall be spot checked by means of surface profile comparator or by replica tape and a calibrated micrometer in accordance with ASTM D4417 or NACE RP0287 to ensure the compliance with painting schedule requirements.

10.5.3 Contaminants Free Testing

When requested by JO, a Potassium Ferro-cyanide paper test shall be carried out to confirm the absence of contamination of the blast cleaned surface by soluble iron salts. This shall be done in accordance with BS 5493 Appendix G.




10.6 Painted Surface Inspection/Testing

10.6.1 Visual Inspection

All painted surfaces shall be visually inspected to ensure the absence of skips, overspray, sags, foreign panicles contamination, air pockets, drips, holidays and any other paint defects. The repair of damaged/defected coating shall be done In accordance with clause 9.8 of this Standard.

10.6.2 Curing of Inorganic Zinc Silicate Primer Test

a) Zinc silicate primed substrate shall be tested for adequate curing prior to over coating (see clause 9.6.4).The test shall be performed as follows:-

Rub the applied coating with a clean tissue or piece of cloth. There should be no trace of paint on the cloth. The cloth should then be soaked in cleaners as recommended by the paint manufacturer; and again rubbed on the coating. After about thirty seconds there should be no trace of zinc on the cloth. If there is any greyness, then the zinc silicate is not fully cured and shall not be over coated.

b) The manufacturer's recommendations/instructions shall be fully adhered when performing this test.

10.6.3 Paint Film Thickness Test

a) The paint shall conform to the system and to the minimum film thickness as specified in the painting schedules.

b) The wet film thickness (WFT) shall be spot measured as an initial indication of the expected dry film thickness (DFT). The measurement shall be in accordance with ASTM D1212.

c) The DFT of individual coats and of the total painting system shall be measured in accordance with ASTM Dl186 or SSPC-PA2. There shall be at least one area each for horizontal, vertical and curved surfaces. For internal painting in storage tanks, the film thickness shall be measured at ten (10) randomly selected areas.

d) A minimum of five (5) readings shall be taken in each area. Additional readings shall be taken, if there is any change in personnel, application equipment, spray nozzle size, thinning of the paint, etc.

e) The (DFT) shall be measured by using an approved coating thickness gauge suitable for the given type of painting system and thickness range.

f) The gauge shall be calibrated prior any measurement. The calibration shall be repeated at least once an hour if working on the same surface, and before measuring film thickness on the insides of angles and at points nearer than 15 mm from an edge.

10.6.4 Paint Adhesion

When requested by JO, a spot adhesion test may be carried out using a suitable Adhesion Tester. The paint adhesion recorded must be at least equal to the specified adhesion by the paint manufacturer for the type of paint and or system. The paint adhesion testing shall be in accordance with ASTM D3359 or ASTM D4541.




10.6.5 Holiday Detection (Porosity Check)

All coated metal surfaces shall be subjected to visual inspection for holidays, pinholes and overspray. For special coatings where pinholes cannot be allowed, a full scan holiday test shall be done, using suitable equipment for each type of coating as high voltage can cause damage to coatings. The acceptable level of pinhole shall be subjected to JO’s approval. Holiday detection test shall be carried out in accordance with NACE RP0188.

11 QUALITY ASSURANCE

The Contractor / Manufacturer shall operate quality systems to ensure that the requirements of this Standard are achieved. The quality systems shall be preferably based on IS0 9000 series of standards and the contractor / manufacturer shall demonstrate compliance by providing a copy of the accredited certificate or the quality manual. Verification of a contractor's / manufacturer's quality system is normally part of the pre-qualification procedure and is, therefore, not detailed in the core text of this Standard."

12 DOCUMENTATION

12.1 General

All correspondence, drawings, instructions, data sheets, design calculations, or any other written information shall be in English language. In case of dual languages, one language shall be English.

All dimensions, units of measurement, physical constants, etc. shall be in SI units, unless otherwise specified.

All documents (texts, specifications, data sheets, etc.) shall be provided with electronic files in the approved software/MSWord, Excel, AutoCAD, etc.).

Any design calculations shall be submitted in the approved and widely used software agreed by JO.

12.2 Work Proposal

The contractor shall submit his proposal for all aspects of work, for the approval of JO prior to the commencement of any work. This will include the following:

a) Information on work location, materials selection, equipment to be used, items to be coated, surface preparation, painting schedule to be used, etc.

b) Manufacturer's technical data sheet, material performance certificates and test approvals shall be provided for each paint/coating product.

c) Material safety data sheets and safety precautions to be taken

d) Inspection and test plans and procedures, and the equipment to be used.

e) Specific repair proposals to satisfy the requirements of clause 9.8 for both extensive and minor repair.




12.3 Work Records/Reports

The contractor shall operate a comprehensive recording/reporting system on all aspects of the painting work including inspection/testing work. The data shall be set out on painting work record/data sheet within 24 hours of carrying out a specific work. Appendix 1 shows a sample of this record/data sheet.

12.4 Final Report

A report shall be submitted on completion of the painting works. The final report shall include a summary on all aspects covered e.g., surface preparation, painting systems used and inspection and testing records performed.

13 PAINTING/COATING SCHEDULES

The painting/coating schedules (A-C) are attached to this Standard in Appendix 3. The requirements for surface preparation and painting/coating systems are listed for categories of onshore structure, equipment and other facilities.

The painting/coating schedules explained in Appendix 3 are:

Schedule A External Painting/Coating Systems for Onshore Storage & Processing Equipment.

Schedule B Painting Systems for Onshore Structural Steel works.

Schedule C - Painting Systems for Mechanical, Electrical and Instrumentation Equipment

Schedule D - Deleted

Schedule E - Deleted

N.B. For details of Internal Coatings of piping, pressure vessels and storage tanks, see document JOS-02-05 Internal Coatings.

For the coating of the base of storage tanks see KOC-P-002 part 2. Internal Lining of Steel Tanks and Vessels part 2. Rigid Reinforced Fibreglass Lining.

14 COLOUR SCHEDULE

The finishing colours to be applied to various equipment and facilities shall be in accordance with colours mentioned in colour schedule of Appendix 2. Selecting different colours are subject to JO’s approval.




15 APPENDICES

Appendix 1 – PAINTING RECORD/DATA SHEET

Appendix 2A – COLOUR SCHEDULE

Appendix 2B – COLOUR IDENTIFICATION FOR HAZARDS AND FIRE/SAFETY

Appendix 2C – DELETED

Appendix 2D –DELETED

Appendix 3A – EXTERNAL PAINTING/COATING SYSTEMS FOR CONSHORE STORAGE AND PROCESSING EQUIPMENT

Appendix 3A – EXTERNAL PAINTING/COATING SYSTEMS FOR CONSHORE STORAGE AND PROCESSING EQUIPMENT

Appendix 3B – SCHEDULE B PAINTING SYSTEMS FOR ONSHORE STRUCTURAL STEELWORKS

Appendix 3C – SCHEDULE C: PAINTING SYUSTEMS FOR MECHANICAL, ELECTRICAL AND INSTRUMENTATION EQUIPMENT

Appendix 3D –DELETED

Appendix 3E –DELETED




APPENDIX 1 – PAINTING RECORD/DATA SHEET




Appendix 1 - PAINTING RECORD/DATA SHEET (Continued)




APPENDIX 2A – COLOUR SCHEDULE

Table 1




APPENDIX 2B – COLOUR IDENTIFICATION FOR HAZARDS AND FIRE/SAFETY

Table2

APPENDIX 2C – DELETED

APPENDIX 2D - DELETED




Table 4Appendix 3A – EXTERNAL PAINTING/COATING SYSTEMS FOR ONSHORE STORAGE AND PROCESSING EQUIPMENT

A1 Tanks, Vessels, Exchangers, Heaters, Columns, Saddles and Others

SYSTEM SCOPE SPECIFICATION MIN THICKNESS DFT (MICRON)

REMARKS

A1.1 CS Uninsulated

Non fire proof vessel skirts

Tank roof

Outer run of floating roof

Up to 120oC

Preparation

Visual standard Sa 2½

Surface profile 25 – 35 micron

Priming

Zinc rich Epoxy

Intermediate

Two pack High build MIO Epoxy

Finish

Acrylic modified 2 pack

Polyurethane

50

125

70

Total 245

Where preparation is carried out in shop, it is mandatory that the first coat be carried out at the same location.

A1.2 Underside Of all Tanks

Severe exposure

Up to 120oC

Preparation

Visual standard Sa2½

Surface profile 75 microns

Priming/Intermediate/Finish

Three coats Coal Tar Epoxy

3 x 150

Total 450

A strip of 25mm wide at plate edge shall be left bare to avoid welding contamination.




Alternative

Primer

Modified urethane alkyd

Finish

Alkyd enamel

75

40

2 x 40

Total 195

Appendix 3A; Schedule A (Continued)

SYSTEM

SCOPE

SPECIFICATION

MIN THICKNESS DFT (MICRON)

REMARKS

A1.3 CS Uninsulated

121oC to 175

oC

Preparation

Visual standard Sa3


Priming

Inorganic zinc silicate

Finish

High temperature

Acrylic

75

50

Total 125

Primed surfaces to be free of zinc, salt prior to finish coating

Second coat to be applied as a mist prior to full coating

Inorganic zinc Silicate primed surface shall be tested for degree of cure prior to over coating (see clause 10.6.2)

A1.4 CS Uninsulated

176oC to 400

oC (Specially for

Columns, Vessels, Exchangers/ Heaters)

Preparation

Visual standard Sa3


Priming


Finish

High temperature modified

75

25

Total 100

As above A1.3 remarks

Alternative pigments to A1 shall be used in zone 1 area

Silicon Aluminium finish coat may not fully cure until equipment is in service





Al silicone

A1.5 CS/Low alloy steel

Uninsulated

Up to 550oC

Preparation

Visual standard Sa3

Priming

Al metal spray

Finish

High temperature

Al silicone

150

20

Total 170

This type of coating shall not be used on any service operating in hazardous area zone 1

Aluminium Silicone which fills the metal pores for smooth and long life coating shall be applied immediately after metal spray. It must generally be exposed to 175

oC or higher to cure.


SYSTEM

SCOPE

SPECIFICATION


REMARKS

A1.6 CS Uninsulated

Up to 120oC

Standard Exposure

Preparation



Priming

Zinc rich Epoxy

Finish

High temperature

Two pack high buils MIO Epoxy

75

125

Total 175

Where preparation is carried out in shop, it is mandatory that the first coat be carried out at the same location

A1.7 CS Uninsulated

Up to 120oC

Standard Exposure

Preparation



As above A1-6 remarks




Priming

Zinc rich Epoxy

Finish

Two pack high build MIO Epoxy

50

2 x 100

Total 250

A1.8 CS insulated

To be insulated/Fire proofed

Up to 400oC

Preparation



Priming

Zinc rich Epoxy

Finish

Zinc free inorganic silicate high temperature curing

75

75

Total 150

Primed surfaces to be free of zinc salts prior to finish coating


Inorganic Zinc Silicate primed surface shall be tested for degree of cure prior to over coating. (see clause 10.6.2)


SYSTEM

SCOPE

SPECIFICATION


REMARKS

A1.9 CS to be fire Proofed up to 120oC

Preparation

Visual standard Sa 3

Surface profile 50 micron

Priming


Finish

Two pack Epoxy tie coat

60

25

Total 85

As above A1.8” remarks




A1.10 Stainless steels A1S1 300 and 400 series and duplex types

Up to 120oC

Preparation



Priming

High build epoxy for stainless steels

Finish

Recoatable acrylic polyurethane

120

40

Total 160

Stainless steels shall not be painted except where specified by the relevant data sheet.

Under no circumstances shall Zinc containing paints be used on stainless surfaces.

This system may be applied for temporary protection of austenitic stainless steels during sea transportation

A1.11 Austenitic stainless steels

>120oC

Preparation



Coating

2 coats foster atlas heat resistance 57-73 or approved equivalent

2 x 80

Total 160

Same as “A1 – 10” above




Appendix 3A – EXTERNAL PAINTING/COATING SYSTEMS FOR ONSHORE STORAGE AND PROCESSING EQUIPMENT

A2 Above Ground Piping, Pipelines, Valves and Fittings

SYSTEM

SCOPE

SPECIFICATION


REMARKS

A2.1 CS Uninsulated

Up to 400oC

Preparation



Priming


Finish

Zinc free inorganic silicate high temperature air curing

75

75

Total 150

Same as “A1-8” above

The coating system for “off the shell valves could be manufacturer’s standard subject to the Company’s approval.

A2.2 CS / Low alloy steel

Uninsulated

Up to 550oC

Preparation


First coat

Al metal spray

Finish

High temperature Al Silicone

150

20

Total 170

Same as “A1 – 6” above remarks

A2.3 Stainless steels AISI 300 and 400 series and duplex types

Up to 120oC

Preparation


In accordance with clause 8.11

Priming

High build epoxy for stainless steel

Finish

Recoatable acrylic polyurethane

120

40

Total 160

Stainless steels shall not be painted/coated except where specified by the relevant data sheet

Under no circumstances shall Zinc containing paints be used on stainless steel surfaces




A2.4 Austenitic Stainless steels

> 120oC

Preparation


In accordance with clause 8.11

Coating

Two coats of Foster Atlas heat resistance 57-73 or approved equivalent

2 x 80

Total 160

Same as “A2 – 3” above




Appendix 3B – SCHEDULE B PAINTING SYSTEMS FOR ONSHORE STRUCTURAL STEELWORKS

Items: 1. Grating, Ladders, Handrail, Fencing, Stairways, Walkway, Stair treads, Cable trays, Ducting and Platforms.

2. General Concrete / Not Concrete Encased Structure Steel Work

SYSTEM

SCOPE

SPECIFICATION


REMARKS

B1 Ladders, platforms, handrails, stair treads, open grid flooring steel grating.

Hot dip galvanizing and top coating

Hot dip galvanizing preparation:


BS 729 requirements

Coating

Hot dip galvanize shall be carried out in accordance with BS 729. The minimum coating weight shall be 610 grams/m

2 surface

Top coating of galvanized surface maybe required for coding or for maintenance of several weathered items.

Preparation

In accordance with clause 8.12 of this standard

Intermediate

Two pack High build Epoxy

Finish

Recoatable Acrylic Polyurethane in the requirement colour

120

40

Total 160

When not galvanized, use system “B2” for all except handrails which shall be A1.1




B2 Stairs treads, open grid flooring steel gratings

Preparation

Visual Standard Sa 2

Painting Systems

Three coats, 40 micron each of Bituminous Paints to BS 3416 type 1 applied by dipping

3 x 40

Total 120

The system may only be used with specific approval of the Company.

Generally use system B1

B3 General not concrete encased structural steel work

Preparation



Primer

Inorganic Zinc Silicate

Intermediate

Two pack high build MIO Epoxy

Finish

Acrylic Modified Polyurethane

75

125

70

Total 270

Primed surface shall be free from zinc salts prior to finish painting

Intermediate coat to be applied as mist prior to finish painting

Inorganic Zinc Silicate primed surface shall be tested for degree of cure before over-coating.

B4 General concrete encased structural steel work

Preparation



Primer

Inorganic Zinc Silicate

Finish

“Zinc free” Inorganic Silicate high temperature air coating

75

75

Total 150

Primed surface to be free of salts prior to further painting.

Where concrete is applied off-side, the finish coat shall be applied to suit.

Inorganic Zinc Silicate primed surface shall be tested for degree of cure before over-coating




ITEMS: – ROTATING EQUIPMENT(PUMPS, COMPRESSOR, MOTORS, ETC) ELECTRICAL EQUIPMENT’S SUPPORTS

SYSTEM

SCOPE

SPECIFICATION

MIN THICKNESS DFT(MICRON)

REMARKS

C1 Pumps, compressors, Motors, Fans etc

As for A1.1, A1.3, A1.4 and A1.8 systems

Machinery and drivers, instruments & associated valves may be finish coated in accordance with manufacturer’s standard coating systems

Manufacturers should provide details of the proposed PAINTING systems for future maintenance and repair

The paint system must be capable of withstanding the environmental conditions for period of 5 years to Ri3 per BS 3900 H3 scale of degree of rusting

Total painting system to be shop applied

C2 Moving Parts

Flywheel Shafts, Couplings etc.

Preparation

Visual Standard Sa 3


Coating System

Shall be as for system A1.1

Total painting system to be shop applied

C3 Electrical Equipment

Motors, Switchgears, Standard Equipment, Transformers/Rectiliers

This type of equipment shall be prepared, primed and finished in accordance with the manufacturer’s standard

The system must be capable of withstanding the environmental conditions for period of 5 years to Ri3, per BS 3900 H3 scale of degree of rusting

Manufacturer’s standard shall be subject to JO approval.




C4 Housings and Equipment Supports Preparation


Surface profile 25 - 35 micron

Priming

Zinc rich Epoxy

Intermediate

Two pack High build MI0 Epoxy

Finish

Acrylic Modified Polyurethane

50

150

70

Total 245

Housings to be finish coated in sellers works

Shop fabricated supports shall be painted in workshop

C5 Control Panels As for C3 System

All panels must display a smooth finish appearance. Hammered of stippled etc are not acceptable.

JO-AM-MGC-SP-203 (Rev. A1) Painting and Coating of Metal Surfaces SS - Copy

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Transcript of JO-AM-MGC-SP-203 (Rev. A1) Painting and Coating of Metal Surfaces SS - Copy