CP Painting Revised Specs

TECHNICAL AMENDMENT NO.
01
NAME OF WORK BIDDING DOCUMENT NO. DEPARTMENT NAME : CLUSTER-7 WELL PLATFORM PROJECT : Tender No. : SMMS (Cathodic Protection and Protective Coating)
Doc.No.A097-01-16-43-AM-0001
Page 1 of 2
The terms, conditions and specifications of Bidding Document stand modified to the extent indicated under column MODIFICATIONS/ADDITION/DELETION. Corresponding implications of the same, else-where in the bid package shall be taken care appropriately. All other terms & conditions, stipulations and specifications of bidding document shall remain unaltered.
Sl. No. 1.
Part No./ Vol.No.
Clause No./ Item No. Spec A097-00-06-42- Clause no SP-01., Rev 0 5.2 ( g)
Section No./ Document No.
Subject
Modifications / Additions/Deletions
Cathodic protection
2. 3. 4 5
DO --- DO---- DO -Do
Clause 5.2 Cathodic (e) protection Clause 1.0 Cathodic protection Clause 4.0 Cathodic protection Clause Cathodic 5.3.3 protection
Following to be added Ah capacity of 2500 AH/Kg should be qualified by documented long term ( 6 12 months ) field testing results as per guidance note under clause 6.5.2 of DNV RP B-401 30 years as appearing in the specification stands deleted and to be replaced by 25 years. Word Monitoring facilities to be deleted. Items (ii) , (iii) and (iv) to be deleted from scope of supply Sentence No allowance ----------------- provided for pipelines shall be modified as under For preinstalled risers additional anodes to be provided on tne jacket legs near the riser to account for the coated riser as no insulating joint will be provided on the riser and bracelet sacrificial anodes will not be mounted on the riser. For existing platforms although anodes will be mounted on new riser, additional anodes need also be provided on jacket legs near the riser since no insulating
1 of 2
TECHNICAL AMENDMENT NO. 01

Sl. No. Part No./ Vol.No. Section No./ Document No. Clause No./ Item No. Subject
Doc.No.A097-01-16-43-AM-0001
Page 2 of 2
Modifications / Additions/Deletions joint will be provided on the riser. Clauses stands deleted.
Clause 5.4.2, 5.5, 5.5.1, 5.5.2, 5.5.3 Spec A097-00-06-42- 5.2 ( f) SP-01. Rev0 --Do --5.2( l )
--D0--
Cathodic protection monitoring Cathodic protection Cathodic protection Cathodic protection Cathodic Protection
Following to be added : iii) Coated ( thick film coating ) riser in sea water celsius Following to be added : Coated riser in sea water Following to be added:
2.8 mA/m2 at 25 Degree
5mA/m2 (at 25 Degree Celsius)
-- Do
5.2 ( m)
- Do -
5.2
10 11 12
Spec A097-00-06-42SP-03.Rev0 A097-00-06-42-TSASP-03.Rev 0 -
Coated riser in sea water 8mA/m2( at 25 degree Celsius ) Following to be added under a new clause 5.2 ( o ); For risers having service temperatures above 25 degree Celsius ( risers carrying hot fluids )the initial, mean ( average ) and final protection Current densities shall be increased @ 1 ma/m2 for each Degree Celsius rise in temperature above 25 degree Protective coating See amended / revised specification A097-00-06-42-SP03 Rev 1 attached
Thermally sprayed See amended / revised specification A097-00-06-42-TSA-SP-03 Rev 1 aluminium coating attached Cathodic Specification No. A097-00-06-42-SP-04 Rev 0 (9 sheets) added (attached). Protection for Vessel internal
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SPECIFICATION FOR CATHODIC PROTECTION FOR VESSEL INTERNAL, CLUSTER 7 WELL PLATFORM OIL AND NATURAL GAS CORPORATION LIMITED
SPECIFICATION NO. A097-00-06-42-SP-04 Rev. No. 0
SPECIFICATION FOR CATHODIC PROTECTION FOR VESSEL INTERNAL CLUSTER 7 WELL PLATFORM PROJECT
OIL AND NATURAL GAS CORPORATION LIMITED
0 Rev. No
09.05.2011 Date
ISSUED FOR BIDS REVISIONS
Dhananjay Prepared by
R.Chaudhury Reviewed by
.Rchaudhury Approved by
Template No. 5-0000-0001-T1 Rev. 1
Copyrights EIL All rights reserved
1.0
SCOPE The following sections give the requirement for design,,engineering,material supply,installation ,testing of sacrificial anode cathodic protection System for internal surface of vessel wall and associated internals below the highest water level . The anode manufacturer shall be regularly engaged in production of the Aluminum alloy anodes and should preferably have past supply records to ONGC for similar application or to other companies engaged in oil & gas production.
2.0
ANODE TYPE GALVALUM-III( A1-Zn-In-Si Alloy) OF DOW CHEMICALS/ORANZIO DE NORA Or ALANODE of MITSUBISHI The anode shall be suitable for use in separator/heater treater. The anode material should be capable of operating upto a temperature of 80 0 C in Brine having concentration of upto 5% Nacl without any tendency for passivation and should retain a driving voltage and reasonable capacity (AH/Kg) value at temperatures upto 80 0 C.
3.0 DESIGN CRITERIA Components to be protected Coated carbon steel vessel wall, all coated carbon steel components and bare 316 Stainless Steel internals under highest liquid level 5 years - 0.75 volts ( Ag/Agcl / Sat Kcl ) -_0.85 Volts (Ag/Agcl/Sat Kcl )
Anode Design life Minimum Protection Potential ( Carbon Steel ) Maximum Protection Potential ( C.Steel )
Overall Protection Maintenance Current Density ( Bare C.Steel+ 316 S Steel internals ) Overall Initial Current Density ( Bare C.steel + 316 S.Steel internals ) Coating Breakdown factor over 5 years ( For coated C.Steel components )
70 mA/M2 ( At 25 degree Celsius )
320 mA /M2 ( At 25 Degrees Celsius )
0.05
1 Temperature correction for protection C.Density @ )0.5 mA/M2 For 1degree Celsius For vessel operating Temperature above 25degrres rise above 25 Degrees Celsius Anode capacity @ 60 degree Celsius @ 80 degree Celsius @ 40 degree Celsius 1300Ah/Kg 900 Ah/Kg 2000 Ah/Kg
Protection Maintenance C.density shall be used to estimate total anode mass . It shall be ensured that No of anodes based on total mass shall meet the protection current demand, ,based on initial C.density, during entire period of design life as well as meet the design life . All bare 316 S..steel internals located under highest liquid level shall be brought under Cathodic Protection alongwith coated carbon steel vessel wall and other coated carbon steel components under highest liquid level. This consideration shall be taken into account while estimating total protection current demand. 4.0 ANODE SHAPE & DIMENSION Solid Cylindrical anode with castin insert/core, 8 dia x 9 long having one 25 mm NB sch 80 pipe as core.of suitable length Anode core shall be electrogalvanised. 5.0 ANODE NETT WEIGHT 18.5 Kg (Nett) each
6.0
ANODE CHEMICAL COMPOSITION
Fe Si Cu Zn Indium Others (each) Aluminum
0.12% by wt. 0.08 0.20% by wt. 0.006% Max by wt. 2.0-4.0% by wt. 0.01 0.02% by wt. 0.02% Max. by wt. Remainder by wt.
7.0 Anode must have following minimum guaranteed values. Closed circuit potential at 25 0 C (v/s Ag/Agcl) at anodic current density of 100-300 mA/ft2 in 3.4% Nacl. Capacity at 25 0 C at anodic current density of 100-300 mA/ft 2 in 3.4% Nacl. - 1.10 Volts.
2500 AH/Kg
-1.02 Volt. Closed circuit potential at 80 C (V/S Ag/Agcl) at 200 mA/ft2 in 3.4 % Nacl. Capacity at 80 0 C at 200 mA/ft 2 in 3.4 % Nacl. 8.0 ANODE DESIGN LIFE 1450 AH/Kg. 5 Years
0
9.0
ANODE FABRICATION/CASTING
Anode shall be free of any shrinkage, void or cavities. Tolerance shall be as per DNVRBB 401. Negative tolerance is not acceptable on weight or dimension.
10.0 DIMENSIONAL & WEIGHT TOLERANCE
11.0 ANODE LOCATION & FIXING ARRANGEMENT Anodes should be distributed uniformly and to be equally spaced. Anodes shall be installed by mounting on M.Steel angle supports of suitable size,using suitable size U Bolts,nuts and washers. The supports shall be directly welded to the to the tank vessel wall and coated as per tank coating system. Anodes should have a minimum stand off distance of 300mm from vessel wall and any nearby internal . 2 Nos of supports shall be required for each anode One 1core 10mm2 XLPE insulated, PVC sheathed copper cable shall be thermit welded to the anode insert and other end of the cable to be thermit welded to the to the M.steel angle support to ensure proper electrical connection..The connection area to be encapsulated using two part epoxy after testing of thermit weld connection by resistance test. A resistance of 0.1 ohm or less is acceptable Upon acceptance of connection the connection to be encapsulated. No anode to be mounted on stainless steel internals All anodes shall be located at 5-7O clock position and should be always below lowest water level. Anode shall be installed in longitudinally along the length of the vessel in staggered arrangement. Anode to anode longitudinal and lateral separation shall not be less than 1000 mm while separation between anode face and nearest part of vessel wall or internal should be strictly minimum 300 mm.
. 12.0
1 INSTALLATION PROCEDURE
The installation details of CP facilities and complete layout drawing of the cathodic protection grid system shall be prepared by contractor and submitted for approval by EIL. Installation shall commence after approval of drawings. The installation of cathodic protection system for the internal surface shall include the following activities :
13.0
ACCEPTANCE TEST FOR ANODES Before delivery of the anodes, anode manufacturer shall furnish results of following tests from an independent reputed laboratory or at manufacturers for owner approval. All tests shall be duly witnessed and certified by Third Party Inspection agency
13.1
CHEMICAL COMPOSITION Spectrographic analysis of as cast anodes shall be carried out for all the constituent elements and to be reported in wt%. For aluminum alloys all elements including aluminum as given in 6.0 above to be reported. Chemical analysis should be done on minimum 3 samples representative of different heats. In case only one heat is utilized during anode casting, then of 3 samples One should be taken during start of pouring, one during from end of heat and one from middle of heat.
13.2
OPEN CIRCUIT POTENTIAL TEST For this purpose 3 samples shall be tested and sampling shall be done as similar to chemical analysis. Pencil samples of size 14 mm dia x 100 mm long shall be cast during production. Each sample should be properly marked with heat nos. Synthetic sea water conforming to ASTM D 1144 at ambient temperature should be the electrolyte in which test shall be done for a duration of 96 hours. Exposed length of the samples in the electrolyte should be 70 mm. Periodic recording of potential of anodes samples with reference to saturated calomel electrode at every 24 hours should be recorded.
13.3
ANODE CAPACITY TEST/CLOSED CIRCUIT POTENTIAL TEST Routine anode capacity test and closed circuit potential test to be performed as per DNV-RP-B-401, Appendix-A. Test shall be conducted on the same 3 samples which had been exposed to open circuit potential test. Exposed length of the sample in the electrolyte shall be 70 mm. Thus anode capacity test shall be performed after completion of open circuit potential test.
13.4
REPORT PREPARATION All the test results of item 13.1, 13.2, 13.3 shall be properly documented alongwith procedure and description of various tests .
14.0 TEST CERTIFICATES
1 Results of following test shall be submitted by Anode manufacturer for approval before delivery. Each test result shall indicate the corresponding Heat No. Delivery shall be made only after approval of test results. 1. Chemical Analysis of each heat of production casting as per section 13.1 above (samples shall be drawn from each heat, one from start, one during middle of the heat and one from end of the heat). 2. Visual examination of casting for each anode 3. Weight & Dimension check for each anode 4. Electrical continuity test between anode & core. 5. Routine electrochemical test as per DNVRPB 401 APPENDIX-A as per section 13.2, 13.3 and 13.4 above.
15.0
VENDOR DATA REQUIREMENT
A) Following information to be furnished for approval before start of anode manufacture. Name of anode manufacturer and past supply records . Anode fabrication drawing. Electrochemical performance data of anodes at various temp ( 25,45,60 and 80 0 C in 3.4 % Nacl) Design calculation for anode sizing and Quantity Anode location and mounting details inside the vessel. Details of production facilities and QA/QC procedure for manufacture & Testing. B) Following informations to be furnished for approval before anode installation..
Anode fixing and arrangement details. Brief installatin procedure
1 16.0 SUGGESTED ANODE MANUFACTURERS Following are the suggested anode manufacturer name : C.P. Tech, Singapore PSL, Holding, India ALICO, Sharjah Corrpro Middle East,Sharjah DIMET, singapore
Other International reputed manufacturers having past supply records for similar application will also be acceptable provided they were in past or at present Licensee of M/s DOW CHEMICALS/ORANZIO DENORA for the manufacture of galvalum- III OR of M/s Mitsubishi corporation for manufacture of ALANODE. For such licensee or patents, documentary evidence to be furnished. 17.0 Codes And Standards Following codes will be applicable for the purpose of design, Engineering ,material supply Installation and commissioning of the Cathodic protection system . In the event of conflictBetween this specification and codes more stringent condition will apply
NACE Standard RP 0575-2001 ( Standard Recommended Practice for Internal Cathodic Protection System in oil Treating vessels ) DNV RP B-401 ,403 IEC 79 IS 5571,5572,2148,8289
SPECIFICATION FOR PROTECTIVE COATING FOR OFFSHORE WELL PLATFORMS, CLUSTER-7 WELL PLATFORM PROJECT
SECTION: C-3.11 Document No. A097-00-06-42-SP-03 Rev.1

Page 1 of 35
SPECIFICATION FOR PROTECTIVE COATING
PROJECT OWNER
: :
CLUSTER-7 WELL PLATFORM PROJECT OIL AND NATURAL GAS CORPORATION ENGINEERS INDIA LTD A097
CONSULTANT : JOB NO. :
1 0 Rev. No
4.05.2011 09.10.2010 Date
Revised and reissued for bids ISSUED FOR BID Purpose
S. Das S. Das Prepared by
R. Chaudhury R. Chaudhury Checked by
R. Chaudhury R. Chaudhury Approved by
Format No. EIL-1641-1924 Rev.1
Copyright EIL All rights reserved
SECTION: C-3.11
DOCUMENT No:
A097-00-06-42-SP-03 Rev. 1
Page 2 of 35
CONTENTS
S.No. PART-1 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0
Description SCOPE GENERAL SURFACE PREPARATION MIXING, THINNING AND STORAGE COATING PROCEDURE INSPECTION LIST OF PAINT MATERIALS USED RECOMMENDED LIST OF PAINT MANUFACTURERS PAINT MATERIALS RECOMMENDED LIST OF PAINT MATERIALS FOR EIL OFFSHORE PROJECTS
11.0 COATING SYSTEMS 12.0 COLOUR CODING SCHEDULE PART-2: TABLES 1.0 TABLE 1.0 FOR CLAUSE 3.0: SURFACE PREPERATION STANDARDS 2.0 TABLE NO.2.0 FOR CLAUSE 9.0: PAINT MATERIALS TECHNICAL SPECIFICATION 3.0 TABLE NO.3.0 FOR CLAUSE 10.0: RECOMMENDED LIST OF PAINT MATERIALS.
SECTION: C-3.11
DOCUMENT No:
A097-00-06-42-SP-03 Rev. 1
Page 3 of 35
PART 1 1.0 SCOPE This specification covers the requirements governing surface preparation, selection and application of the coating system to be used on the interior and exterior surfaces of production facilities including structural steel, vessels, piping and equipment on offshore platforms. Individual equipment specifications and/or drawings, when furnished, are to be used with these specifications, if conflict exists, the individual specifications and/or drawings shall govern. 2.0 2.1 GENERAL The following surface preparation codes and standards shall be followed for the work under this specification. Steel Structures Painting Council, U.S.A. - SSPC-SP (latest edition) Swedish Standard Institution SIS-05-5900 (latest edition) ISO 8501-1988
The Contractor shall arrange, at his own cost, to keep a set of latest edition of above standards and codes at the site of application. 2.2 2.2.1 2.2.2 2.2.3 2.3 Unless otherwise specified the following surfaces are not required to be blasted/coated: Non-ferrous materials Austenitic stainless steel Plastic or plastic-coated materials not susceptible to ultraviolet deterioration. Machined and threaded surfaces shall be protected with a suitable rust preventive: As per clause C-I(b). Any deviation from this specification shall be approved in writing by Company representative. Failure of applicator to consult with Company representative to clarify any item in the specification will in no way relieve applicator of his responsibility of satisfactory compliance with these specifications. SURFACE PREPARATION All oil and grease shall be removed with clean rags soaked in suitable solvent in accordance with SSPC-SP-1. All salt and chemical contamination shall be washed with potable water. All rough welds, burrs, weld spatter, indentations, and all other sharp surface projections shall be ground smooth prior to further surface preparation. Any surface on which grinding is done after blast cleaning shall be blast cleaned to obtain proper anchor pattern. All bolt holes shall be drilled and smoothed before blast cleaning. All surfaces to be coated shall be shot/grit blast cleaned to near white metal as per SSPC-SP10 or Sa 2 of SIS-05-5900 (ISO-8501-1988). ( SSPC SP-5 FOR THERMALLY SPRAYED ALUMINIUM COATINGS )
2.4
3.0 3.1
3.2
3.3 3.4
SECTION: C-3.11
DOCUMENT No:
A097-00-06-42-SP-03 Rev. 1
Page 4 of 35
3.5
The height of profile of the anchor pattern shall not be more than 50 microns and not less than 35 microns. Any dust, or foreign matter deposited on the surface after the surface preparation is completed shall be removed prior to painting. In the event rusting occurs after completion of surface preparation, the surface shall again be cleaned in accordance with the specified method. Cleaning shall be discontinued each day in advance to permit the cleaned surfaces to be primed. Primer shall be applied within four (4) hours of completion of surface preparation. Dry blast cleaning operation shall not be conducted on surfaces that will be wet after blasting and before painting. If relative humidity is greater than 85%, permission to blast shall be obtained from Company representative. If blasting is performed at night, the surfaces shall be reblasted the following day to provide the specified surface preparation standards and the anchor profile required for the specified coating system, blasting shall not be done adjacent to the painting operations or coated surfaces that are not fully dry. Blasting shall overlap previously coated surfaces by at least 150mm. Nameplates and other items in contact with the surface being blasted/coated shall be removed for protection system application. Items such as motors, machined surfaces, gauges, electrical and instrumentation items, tags, stainless steel, aluminum, brass plated surfaces etc. shall be protected to prevent damage or contamination during blasting and coating. After blast cleaning, the blasting materials and dust shall be removed by blowing air and vacuum cleaner. Areas to be welded subsequent to coating shall be marked to a distance of 75mm from the weld area prior to coating Blast Cleaning Abrassive Blast Cleaning The surfaces shall be blast cleaned using one of the abrasives: Al 2O3 particles, chilled cast iron or malleable iron and steel at a pressure of 7kg/cm at appropriate distance and angle depending on nozzle size maintaining constant velocity and pressure. Chilled cast iron, malleable iron and steel shall be in the form of shot or grit of size not greater than 0.055" maximum; and 0.04" minimum. Copper or Nickel slag or Garnet as abrasives will also be suitable having mesh size in the range of G-16 to G-24 confirming to SSPC-AB-1. Compressed air shall be free from moisture and oil. The blasting nozzles should be venturi style with tungsten carbide or boron carbide as the materials for liners. Nozzles orifice may vary from 3/16" to 3/4". On completion of blasting operation, the blasted surface shall be clean and free from any scale or rust and must show a Grey white metallic lusture. Primer or first coat of paint shall be applied within 4 hours of surface preparation and at least one hour prior to sun down of the day it is blasted and before any rusting occurs. Any steel surface not primed within these limits or that is wet shall be reblasted. Blast cleaning shall not be done outdoors in bad weather without adequate protection or when there is dew on the metal which is to be cleaned. Surface profile shall be uniform to provide good key to the paint adhesion (i.e. 25 to 50). If possible vacuum collector shall be installed for collecting the abrasives and recycling. No acid washing or other cleaning solutions or solvents shall be used on metal surfaces after they are blasted. This includes washes intended to prevent rusting. Bio degradable, water soluble cleaning solution used to clean previously painted surfaces shall not lift, soften or otherwise damage the existing coating.
3.6
3.7
3.8
3.9
3.10
3.11
3.12 3.12.1
SECTION: C-3.11
DOCUMENT No:
A097-00-06-42-SP-03 Rev. 1
Page 5 of 35
3.13
Mechanical or Power tool cleaning Power tool cleaning shall be done by mechanical striking tools, chipping hammers, grinding wheels or rotating steel wire-brushes. Excessive burnish of surface shall be avoided as it can reduce paint adhesion. On completion of cleaning, the detached rust mill scale etc. shall be removed by clean rags and/or washed by water or steam and thoroughly dried with compressed air jet before application of paint.
4.0 4.1
MIXING, THINNING AND STORAGE All containers of coating material and thinners shall remain in unopened original manufacturers containers until required for use. The containers should bear the manufacturers label batch numbers and instructions. Materials shall be stored in accordance with the manufacturers recommendations. For materials having a limited shelf life, the date of manufacture and the length of the life shall be shown. Materials older than their stated shelf life shall not be used. Coating material which has gelled or otherwise deteriorated during storage shall not be used. All ingredients in any container shall be thoroughly mixed before use to a smooth and uniform consistency. Mechanical agitation during application shall be sufficient to keep pigment in solution as per manufacturers recommendations. Coating material mixed in the original container shall not be transferred until all settled, pigment is incorporated in the vehicle. This does not imply that part of the vehicle may not be poured off temporarily to simplify the mixing. Coating material shall not be mixed or kept in suspension by using a bubbling air stream. Where a skin has formed in the container, the skin shall be cut loose and discarded. If such skins are sufficiently thick to have a practical effect on the composition and quality, the paint shall not be used. All pigmented material shall be strained after mixing except where application equipment is provided with adequate strainers. Strainers shall be capable of passing the pigment and removing any skin. Material which does not have a limited pot life, or does not deteriorate on standing may be mixed any time before using, but if settling has occurred, it must be re-mixed immediately before using. Coating material shall not remain in spray pots or buckets overnight but shall be gathered into a closed container and re-mixed before use. No thinner shall be added unless necessary for proper application. Thinning shall not exceed limitation established by manufacturer and only thinners specified by the manufacturer shall be used. Type of thinner shall comply with manufacturers instruction. When use of thinner is permissible, it shall be added during the mixing process. Painters shall not add thinner after it has been thinned to the proper consistency. All thinning shall be done under supervision of one acquainted with the correct amount and type to be added.
4.2
4.3
4.4
4.5 4.6
4.7
4.8
4.9
4.10 4.11
SECTION: C-3.11
DOCUMENT No:
A097-00-06-42-SP-03 Rev. 1
Page 6 of 35
5.0 5.1 5.1.1 . 5.1.2
COATING PROCEDURE Paint Material (Coating Systems) The Type, Brand, Number of coats, Colour, and Dry film thickness shall be per 9.0, 10.0 and 11.0 herein Manufacturers instructions, including safety precautions, are a part of this specification. In case of conflict, the manufacturers mandatory instructions shall govern. The compatibility of finishing coat with the primer/tie coat shall be confirmed from the manufacturer. In no case shall the coatings of different manufacturer be mixed in any one system. Application Paint application is normally by airless spray. Use of Air spray/brush application can be followed only after getting written approval by Engineer-in-charge only for limited areas.
5.1.3
5.2
5.2.1
Surface shall not be coated in rain, wind, snow, fog, mist, or in areas where injurious airborne elements exist, when the steel surface temperature is less than 3C above dew point or when the relative humidity is greater than 85%, or when the temperature is below 5C. In case the fabrication yard is selected at such a place where normal temperature is below 5C, the contractor shall propose alternate coating procedure for Companys approval at the bidding stage itself. The company(owner) has the right to suspend the application of coating when the damage to the coating may result from actual or impending weather conditions. Blast cleaned surfaces shall be coated with one complete application of primer as soon as practicable but in no case later than 4 hours on the same day as blast cleaned. Coating shall not be applied within 75mm of an un-blasted surface. To the maximum extent practicable, each coat of material shall be applied as a continuous film of uniform thickness free of pores. Any thin spots or areas missed in the application shall be re-coated and permitted to dry before the next coat is applied. To reduce the possibility of inter-coat contamination and assure proper adhesion between successive coats, all coats shall be applied as soon as possible after the minimum specified drying time of the preceding coat. Material shall be considered dry for recoating when an additional coat can be applied without the development of any detrimental film irregularities, such as lifting or loss of adhesion of the undercoat. When successive coats of the same color have been specified, alternate coats shall be tinted, when practical, sufficiently to produce enough contrast to indicate complete coverage of the surface. When the material is the color of the steel, or when the tinting of the final coat is objectionable, the first coat to be applied shall be tinted. The tinting material shall be compatible with the coating material and not detrimental to its service life. Brush application of paint shall be in accordance with the following: a. Brushes shall be of a style and quality that will enable proper application of paint. Round or oval brushes are most suitable for rivets, bolts, irregular surfaces, and rough or pitted steel. Wide, flat brushes are suitable for large flat areas, but they shall not have a width over five inches. The brushing shall be done so that a smooth coat as nearly uniform in thickness as possible is obtained.
5.2.2
5.2.3
5.2.4
5.2.5
5.2.6
b.
SECTION: C-3.11
DOCUMENT No:
A097-00-06-42-SP-03 Rev. 1
Page 7 of 35
c. d. e. f. 5.2.7
Paint shall be worked into all corners. Any runs or sags shall be brushed out. There shall be a minimum of brush marks left in the applied paint. Surfaces not accessible to brushes shall be painted by daubers or sheep skin.
Air spray application shall be in accordance with the following: The equipment used shall be suitable for the intended purpose, shall be capable of properly atomizing the paint to be applied and shall be equipped with suitable pressure regulators and gauges. The air caps, nozzles, and needles shall be those recommended by the manufacturer of the equipment for the material being sprayed. The equipment shall be kept in satisfactory condition to permit proper paint application. Traps or separators shall be provided to remove oil and condensed water from the air. These traps or separators must be of adequate size and must be drained periodically during operations. The air from the spray gun impinging against the surface shall show no condensed water or oil. Ingredients shall be kept properly mixed in the spray pots or containers during application by continuous mechanical agitation. The pressure on the material in the pot and of the air at the gun shall be adjusted for optimum spraying effectiveness. The pressure on the material in the pot shall be adjusted when necessary for changes in elevation of the gun above the pot. The atomizing air pressure at the gun shall be high enough to properly atomize the paint but not so high as to cause excessive fogging of paint, excessive evaporation of solvent, or loss by over spray. Spray equipment shall be kept sufficiently clean so that dirt, dried paint, and other foreign materials are not deposited in the paint film. Any solvent left in the equipment shall be completely removed before applying paint to the surface being painted. Paint shall be applied in uniform layer, with overlapping at the edge of the spray pattern. The spray pattern shall be adjusted so that the paint is deposited uniformly. During application, the gun shall be held perpendicular to the surface and at a distance which will ensure that a wet layer of paint is deposited on the surface. The trigger of the gun should be released at the end of each stroke. All runs and sags shall be brushed out immediately or the paint shall be removed and the surface repainted. Areas inaccessible to the spray gun shall be painted by brush; if not accessible by brush daubers, or sheepskins shall be used. Brushes shall be used to work paint into cracks crevices, and blind spots which are not adequately painted by spray. Particular precautions are necessary in spraying inorganic zinc. These are listed in the manufacturers instructions.
5.2.8
Airless spray application shall be in accordance with the following procedure: as per steel structure paint Manual Vol.1 & Vol.2 by SSPC, USA, Air less spray relies on hydraulic pressure rather than air atomisation to produce the desired spray. An air compressor or electric motor is used to operate a pump to produce pressures of 1,000 to 6,000 psi. Paint is delivered to the spray gun at this pressure through a single hose within the gun, a single paint stream is divided into separate streams, which are forced through a small orifice resulting in atomization of paint without the use of air. This results in more rapid coverage
SECTION: C-3.11
DOCUMENT No:
A097-00-06-42-SP-03 Rev. 1
Page 8 of 35
with less over spray. Airless spray usually is faster, cleaner, more economical and easier to use than conventional air spray. Airless spray equipment is mounted on wheels, and paint is aspirated in a hose that sucks paint from any container, including drums. The unit shall have inbuilt agitator that keep the paint uniformly mixed during the spraying. The unit shall consists of inbuilt strainer. Usually very small quantities of thinning is required before spray. In case of High Build epoxy coatings(two pack). 30:1 pump ratio and 0.020-0.023" tip size will provide a good spray pattern. Ideally fluid hoses should not be less than 3/8" ID and not longer than 50ft to obtain optimum results. In case of gun choking, de-choking steps shall be followed immediately. 5.2.9 All nameplates, manufacturers identification tags, machined surfaces, instrument glass, finished flange faces, control valve stems and similar items shall be masked to prevent coating deposition. If these surfaces are coated the component shall be cleaned and restored to its original condition. Edges of structural shapes and irregular coated surfaces shall be coated first and an extra pass made latter. Wet paint shall be protected against contamination from dust or other foreign matter. Drying of Coated Surfaces No coat shall be applied until the preceding coat has dried. The material shall be considered dry for re-coating when another coat can be applied without the development of any film irregularities such as lifting or loss of adhesion of undercoats, and the drying time of the applied coat does not exceed the maximum specified for it as a first coat. No paint shall be force dried under conditions which will cause checking, wrinkling, blistering, formation of pores, or detrimentally affect the condition of the paint. No drier shall be added to paint on the job unless specially called for in the manufacturers specification of the paint. Paint shall be protected from rain, condensation, contamination, snow and freezing until dry to the fullest extent practicable. Repair of Damaged Paint Surfaces. Where shop paint has been damaged in handling, all damaged and loosely adhering paint shall be removed and the surface thoroughly cleaned. Edges of the breaks shall be feathered, and the designated number of prime and finish coats applied to the thickness specified.
5.2.10
5.2.11
5.2.12 5.3 5.3.1
5.3.2
5.3.3
5.3.4
5.4 5.4.1
6.0
INSPECTION Procedures for testing and documentation for quality control shall be prepared prior to the initial start up of any work covered by this specification. The procedure shall include method to assure the meeting of specification requirement and forms to document environmental conditions, surface temperature, coating application, surfaces being coated, coating applied and status of required examinations and tests.
SECTION: C-3.11
DOCUMENT No:
A097-00-06-42-SP-03 Rev. 1
Page 9 of 35
6.1
All work and materials applied under this specification shall be subjected to inspection by a Company representative and NACE International certified inspectors and supervisors. All parts of the work shall be readily accessible to the inspector. Approval of each of the following shall be obtained before proceeding with any subsequent phase. Location of work Equipment Surface preparation First Coat Each subsequent coat
6.2 6.3
6.4
Standard panel or photographs of Swedish Standard. Surface profile shall be tested by Surface profile gauge. For primer and finish coat, both wet and dry film thickness shall be checked whereas for the intermediate coats, only wet film thickness shall be checked. Dry film thickness shall be checked with Microtest thickness gauge or Elcometer. The minimum DFT of any specified coating system shall not be less by 10% of specified DFT on any single point of measurement of each 9.3 square meters area and the average DFT measured as per the SSPC-PA 2 procedure shall not be less than the specified minimum DFT and in any case not more than 30% of specified DFT as the maximum DFT. Coating integrity of painting systems upto 15 mils dry film thickness shall be verified by using a holiday detector of Tinker and Rasor(M1) or Elcometer make. Electrode shall consist of a 12 square inch cellulose sponge dampened with a 1% solution of potable water and detergent. Instrument shall be calibrated and checked each day to indicate a holiday at 80,000 ohm under a potential of 67-1/2 volts between ground and damp sponge. A 90,000 ohm resistance will indicate no holiday. The sponge will be moved across the surface at a rate not greater than 0.3 metre per second (one foot per second). The actual inspection reading shall be taken on the second sweep of the sponge. The inspector shall mark the holiday to indicate location of repair.
6.5
6.6
6.7
Coating integrity of coating systems with coating having greater than 15 mils dry film thickness shall be verified by using a variable high voltage spark dry holiday detector of Elkometer make. The voltage for detection shall be set at twice the voltage required to detect a manufactured holiday under the conditions of actual detection. These conditions shall include the rate of travel of the detection brush, relative humidity, temperature, atmospheric pressure, type of coating, and the manufactured holiday made in a coating area of maximum coating thickness. The inspector shall mark the holiday to indicate location for repair.
6.8
Applicator shall correct work found defective under this specification at no cost to the Company.
SECTION: C-3.11
DOCUMENT No:
A097-00-06-42-SP-03 Rev. 1
Page 10 of 35
7.0
LIST OF PAINT MATERIALS USED IN THE SPECIFICATIONS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10 11 P-6 F-9 F-2 F-6 F-7 F-8 F-12 F-17 F-18 Two pack polyamide/polyamine cured epoxy zinc phosphate primer Inorganic zinc silicate primer/coating Two component Acrylic-Polyurethane finish paint Polyamine/polyamide cured two pack high build epoxy coating. Two-pack high build polyamine cured coal tar epoxy coating(Specially formulated). Polyamine cured self priming epoxy mastic. Heat resistant silicone aluminium paint Two component polyamine cured high solids Glass flake filled Epoxy tank coating Low flame spread paint Two component Glass flake filled Polyester lining Two component Glass flake filled Vinyl ester lining
8.0
RECOMMENDED LIST OF PAINT MANUFACTURERS 1) Ameron, USA Indian Licensee : M/s Chemguard Coatings Pvt. Ltd., Chennai Sigma Coatings, Singapore/Mumbai Hempel Marine Paints, USA/ Denmark/Singapore/India Carbonline Products, USA Indian License : M/s CDC Carbonline Ltd., Chennai Berger Paints ((I) Ltd., Calcutta Jotun Paints, Singapore/Chennai/Mumbai KCC Products, Korea Akzo Nobel Coatings, UK/Bangalore Chugokui J&N Ltd., Mumbai Paladin Paints & Chemicals, Mumbai Asian paints (I) Ltd., Mumbai Chemco International U.K. WINN & COALES(DENSO) LTD, UK Kirloskar Products Pune. (Corrocoat International, UK ). M/s Altas Minerals & Chemicals Corporation, USA. (Chemtreat India Ltd. Navi Mumbai) For (14), (15): The validity of foreign collaborators license to the Indian vendor shall be checked before supply of materials. (12),(13),(14)&(15) are recommended for glass flake filled coating/ lining materials only.
2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) Note 1: Note 2:
9.0
PAINT MATERIALS: ( TABLES 2.0 ATTACHED IN PART II)
10.0
RECOMMENDED LIST OF PAINT MATERIALS FOR EIL OFFSHORE PROJECTS: (TABLE NO.3.0 ATTACHED IN PART II)
SECTION: C-3.11
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11.0 A
COATING SYSTEMS: SCOPE These Coating Systems specifications shall be used for new construction. Items covered by these specifications and discussed individually are as follows: The items specified in the specification for coating are indicative only but not exhaustive. All the fabricated items, supplied items made as per the scope of work require coating/lining as per the relevant specifications given in this document.and elsewhere in the bid document for metallic coating. The contractor shall include all the items that require coating Section B Section C Section D Section E Section F Exterior surfaces of offshore structure and barges, structural skids, vessels, storage tanks, platform process piping and PLEM Process vessels and piping, manifolds, valves, fittings, fans, heat exchangers, pumps, and related equipment. Compressors, gas turbines, generators, engines, motors, instruments and panel boards. Internal surface of tanks and process vessels. Metal building
The primer and top coat(s) comprising each manufacturers systems shown in these specifications are compatible if properly applied. Manufacturers instructions with regard to temperature, humidity, pot life, thinning, curing agents, drying time, etc. shall be complied with, as well as directions from the manufacturers representative. Prior to applying any alternate coatings, approval must be obtained from the Company. In no case shall the coatings of different manufacturers be mixed in any one system. B. Exterior surfaces of offshore structure and barges, structural skids, vessels, storage tanks, platform process piping I For the exterior surfaces of all offshore structures including.all structural primary and secondary members conductors, appurtenances etc., structural skids, vessels, storage tanks external surfaces of flare booms, flare tower,crane pedestal, crane boom, top side piping, , pump casings columns, internal and external surfaces of sump cassion on alldeck areas . These items are indicative only, but not exhaustive. Application shall be done starting from above cellar deck to the top of the structure (for below celler deck see section II below ). However, cassion external shall be coated upto the top of structure and internal shall be painted from first baffle level to top of the structure. Surface preparation Blast cleaning to near white metal finish by shot and grit blasting as per SSPC-SP-10 or Sa 2 of SIS-05-5900/ISO 8501-1988 with a surface profile of 25-50 microns height from trough to peak. b. Paint System : Primer Coat : 1 coat of (F-9) inorganic zinc silicate primer (coating) @ minimum 65 microns DFT/coat (Maximum DFT 75 microns) Top Coats : 2 coats of (F-6) High build epoxy coating cured with polyamide/polyamine hardener @ 100 microns DFT/coat minimum (maximum DFT 120 microns/coat) = 2 x 100 = 200 microns. 1 coat of (F-2) Acrylic Polyurethane finish paint @40-50 microns DFT/Coat. Total DFT minimum : 305 Microns and maximum : 365 Microns
a.
SECTION: C-3.11
DOCUMENT No:
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Notes: 1. 2.
This system is satisfactory for surface temperatures to 90C continuous dry temperature. Color for final coat shall be as per colour code.
II
For external surfaces of all structural members including jacket structures, Jacket legs, braces, members, nodes, conductor guide framing, launch truss members,, risers(if not Monel sheeted), PLEM, Boat landing barge bumpers & guides, riser clamps, boat fenders stairways, apparantences, and cross supports,boat landing area in splash zone (-3M to +6M MSL)and above in atmospheric zone but upto cellar deck including all primary and secondary structures under cellar deck However, sump cassion/pump cassion shall be painted in total length from +6M MSL to the bottom point below the sea water (excepting gratings & hand rails): a. Surface preparation: As per enclosed specification A108-01-06-42- TSA- SP- 02, Rev1 b. Coating system: Thermally sprayed Aluminium coating as per Specification A10801-06-42- TSA- SP- 02, Rev1 For all conductors from bottom end in the sea water and extending above completely upto atmospheric zone excluding field weld joints a. Surface preparation: As per enclosed specification A108-01-06-42- TSA- SP- 02, Rev1 b. Coating system : Thermally sprayed Aluminium coating as per enclosed Specification A108-01-06-42- TSA- SP- 02, Rev1
III A
III B
For all field weld joints of all conductors for III A above. a. b. Surface preparation: As per enclosed specification A108-01-06-42- TSA- SP- 02, Rev1 Coating System : Thermally sprayed Aluminium coating as per encclosed Specification A108-01-06-42- TSA- SP- 02, Rev1
III C Repair system for the field damages on conductors during installation: a. Surface preparation: As per enclosed specification A108-01-06-42- TSA- SP- 02, Rev1. Coating system : Thermally sprayed Aluminium coating as per enclosed Specification A108-01-06-42- TSA- SP- 02, Rev1
b.
IV. a.
Galvanising for Gratings, Hand rails, ladders, cages and miscellaneous hardware: All steel gratings, hand rails, ladders, walkways, cages, side beams of stairways, stairs, supports for the stairs, and all miscellaneous hardware at all areas at all levels shall be hot dip galvanized having zinc coating thickness in the range of 80-85 microns ( 600-610 gm/m2) No specimen shall have thickness less than 100 microns. The galvanized surface shall be free from bare spots, dross samples, lumpiness and runs, flux or ash inclusions. Hot dip galvanizing shall be carried out as per IS 2629, 2633, 4759, 4736. Purity of zinc bath shall conform to IS 13229. All finished articles shall be tested for thickness of zinc coatings at coating plant and submitted for approval before delivery. Repair of the damaged area of galvanized coatings due to welding during erection shall be carried out as per recommended practice IS 11759 using cold galvanizing spray process. Organic Paint system is not acceptable for repair.
b.
SECTION: C-3.11
DOCUMENT No:
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c.
All hot dip galvanized members including repaired weld joints shall be top coated with following paint system.: i) Painting on all galvanized items under IV(a) above excepting gratings.( See ii below). Surface preparation: Remove all the dust and foreign matter, roughen the surface with emery paper followed by potable water wash. coating system: 1 coat of Etch/wash primer (P-4) @10 microns DFT/Coat + 2 coats of (F-2) 2 component Acrylic Polyurethane finish paint @40 microns DFT/coat=2x40=80 microns Total DFT=90 microns minimum ; 110 microns maximum Painting on Galvanized Gratings: Surface preparation: Same as C(I) Coating System: 1 Coat of (P-4) Etch/Wash Primer @10 microns DFT/coat + 2 coats of (F-7) Coal tar epoxy coating @125 microns DFT/coat = 2x125=250 microns Total DFT=260 microns minimum, 325 microns maximum Weld joints of Gratings after installation: Painting shall be done as given c(ii)
ii) -
iii)
VI A. COATING SYSTEM FOR ALL FIELD WELD JOINTS AND DAMAGED TSA COATED AREAS DURING FIELD WELDING FOR ALL ITEMS FROM -3 M BELOW MSL upto cellar deck (Items under BII above) a. b. Surface preparation: As per enclosed specification A108-01-06-42- TSA- SP- 02, Rev1 Coating system : Thermally sprayed Aluminium coating as per enclosed Specification A108-01-06-42- TSA- SP- 02, Rev1.
VI B. PAINT SYSTEM FOR ALL FIELD WELD JOINTS AND DAMAGED PAINTED AREAS DURING FIELD WELDING FOR ALL ITEMS ABOVE CELLER DECK IN ATMOSPHERIC ZONE EXCEPTING CONDUCTORS ( see BIIIA above ) Design temperature: 14 deg. C to 90 deg. C Surface Preparation: The heat affected zone shall be cleaned by manual hand tool cleaning, followed by emery paper roughening, if necessary power tool cleaning as per SSPC-SP3 to remove all weld flux. Paint System: 1 coat of (F-8) Self priming type epoxy mastic coating cured with polyamine hardener @ 125 Microns DFT/coat Minimum (maximum DFT 150 microns) Top Coat - 2 coats of (F-2) Two-component Acrylic Polyurethane finish paint @40 microns DFT/coat=2x40=80 microns Total DFT = 205 Microns minimum : Maximum 260 Microns a. Design temperature: 91 to 400 deg. C Surface preparation: Same as given in (a)
SECTION: C-3.11
DOCUMENT No:
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Paint System: 2 coats of ambient temperature curing, suitable for mechanically/manually cleaned surface heat resistant two component silicone aluminium paint @ 20 microns/coat = 2x20 = 40 microns. C. EXTERNAL SURFACE PROCESS VESSELS AND PIPING, VALVES, MANIFOLDS, PUMPS HEAT EXCHANGERS AND RELATED EQUIPMENT All submersible type pumps protective coating system shall be as per manufacturers standard which shall be suitable for sea water. I. Protective Coating Systems a. For other equipments. Same as Protective Coating System B.I(b) b. Flanges
Flanges on equipment to be installed on offshore platforms or barges shall be coated with the protective coating system in B.IA except for the seal surface. Care shall be used to prevent damage of ring and gasket seal surface by covering during the blasting and coating. After the coating has cured an anti-rust grease coating shall be applied to protect the seal surface. Apply a minimum dry film of an anti-rust grease coating such as Witco Chemicals SACT 300, Ashland Petroleum Companys Tectyl MC 121A Structural coating, Philips Petroleum Companys Anti-rust Oil 80690, or an anti-rust oil from MIL-C-161730 Amendment, 2., Grade I Qualified Products List. II Carbon Steel Insulated Vessels and Piping(under insulation painting) temperature upto 500C. a. operating
Surface preparation: As per enclosed specification A108-01-06-42- TSA- SP- 02, Rev1 Coating system : Thermally sprayed Aluminium coating as per enclosed Specification A108-01-06-42- TSA- SP- 02, Rev1
b.
III
Insulated stainless steel, including low alloy 20 piping, equipment paint(Painting under insulation) a. Design temperature: Below 0C to all minus temperature b. Metallic foil and Chloride free mineral sealant shall be applied.
Design temperature: 0C to 120C Surface preparation: Blast cleaning to Sa2 finish using stainless steel grits/shots or garnet as per SSPC-SP-10/ISO 8501-1988.
Paint System: 2 coats of Two component specially formulated coaltar Epoxy coating(F-7) cured with polyamine hardener @125 microns DFT/coat=2x125= 250 microns minimum, (300 microns Maximum) NOTE : Bidder can use an alternate coating sydtem based upon coating manufacturers recommendations
SECTION: C-3.11
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c.
Design temperature: 121C to 500C Surface preparation: Same as (b) above. Paint system: 3 coats of ambient temperature curing Heat resistant Silicone Aluminium paint @20 microns DFT/coat=3x20=60 microns minimum (70 microns max.)-
d.
Design temperature: 501C to 1000C & cyclic service 196 to 480C excepting 45 to 120C Surface preparation: Same as (b) above. Paint System: 1 coat of Polysiloxane coating; Amercoat 738 or equivalent @150 microns DFT/coat=150 microns minimum (170 microns maximum)
D.
COMPRESSORS, GAS TURBINES, GENERATORS, INSTRUMENTS AND PANELBOARDS
ENGINES,
MOTORS,
These equipments in covered/enclosed areas shall be coated as per manufacturers standard coating suitable for offshore environment. All equipments in open areas shall be coated as per Section B-I(b). All skid surfaces which can be cleaned by blasting shall be coated with the protective systems noted in Section B.IA(b). Protect critical moving parts, bearing surfaces, machined surfaces, nameplates, glass next to machinery, etc. from entrance of blasting dust and damage from blasting by masking with polyethylene sheeting and masking tape. Panel boards shall be disassembled before cleaning and coating. I When equipment manufacturers coating is unsatisfactory and blast cleaning is not permissible, Clean and protect as follows: a. b. c. Remove coating by use of a paint and varnish remover. Surface preparation : solvent cleaning (SSPC-SP1) followed by power tool cleaning (SSPC-SP3) or St 3 of SIS-05-5900. One coat of (F-8) Self priming type epoxy mastic coating @ 125 Microns DFT/coat Minimum (maximum DFT 150 microns)
d.
Top Coat : 1 coat of (F-6) High build epoxy coating cured with polyamide/polyamine hardener @ 125 microns DFT/coat minimum (maximum DFT 150 microns/coat) + 1 coat of (F-2) Two component Acrylic polyurethane finish paint @40 microns DFT/coat Total DFT: Minimum: 290 microns Maximum: 350 microns
II.
When equipment manufacturers shop primer is sound then clean and protect as follows: a. b. c. Surface preparation : Clean with potable water to remove all silt deposits and roughen the surface with emery paper. Apply one coat of self priming epoxy mastic coating (F-8) @ 125 microns DFT/coat minimum (maximum DFT-150 microns). Top coat: as per D I(d): Total DFT: same as D-I(d)
SECTION: C-3.11
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III.
Equipment with surface temperatures between 110C(230F) to 400C (752F), clean and protect as follows: a. Surface Preparation : Near white metal shot and grit blasting as per SSPCSP-10 or Sa 2 of SIS-05-5900/ISO 8501-1988 with a surface profile of 2550 microns height trough to peak. Items with metal to metal joints shall be seal welded prior to blasting and coating when possible or dismantled following all fittings and welding to obtain blasting and coating of the joint surfaces. Apply one coat of inorganic zinc silicate primer/coating (F-9) @ 65-75 microns DFT minimum(maximum - 75 microns). Apply 2 coats of ambient temperature curing Heat resistant silicon aluminium finish paint @ minimum 20 microns DFT per coat = 2 x 20 = 40 microns(maximum 2x25=50 Microns) Total DFT: 105 Microns minimum: 120 microns maximum.
b.
c.
IV.
Equipment with surface temperatures above 400C (752F): a. Surface preparation: Near white metal shot and grit blast cleaning as per SSPC-SP-10 or Sa2 of SIS-05-5900/ISO 8501-1988 with a surface profile of 25-50 microns height trough to peak Coating System: Ameron 878 from AMERON PRODUCTS, USA/ CHEMGUARD or AKZONOBELS INTERTHERM 50/INTERTHERM 601 shall be applied with a minimum of 25 microns DFT per coat. Total DFT = 50 Microns minimum: 60 microns maximum.
b.
INTERNAL SURFACES OF TANKS AND PROCESS VESSELS INCLUDING SS INTERNALS Design temperature for immersion service: 60C Maximum
I.
Salt Water and fresh water The following glass flake filled polyester lining system shall be applied to all surfaces normally exposed to salt water, overhead vapours, and fresh water.
1.
Surface Preparation for C. Steel : Near white metal shot/grit blasting as per SSPC-SP-10 or Sa 2 of SIS-05-5900/ISO 8501-1988 with a 25-50 microns anchor pattern height from trough to peak. Surface preparation for SS internals shall be as per C III above.
2.
Lining System: 1 coat of Two component glass flake filled polyester primer @100 microns DFT/coat + 3 coats of 2 component glass flake filled polyester lining @300 microns DFT/coat = 3x300=900 microns Total Dry film thickness: 1000 microns minimum : 1200 microns maximum Recommended materials & Manufacturers:
SECTION: C-3.11
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Polyglass 100 from M/s Kirloskar Brothers Ltd., Pune. Chempruf Glass flake filled polyester lining from Atlas Minerals & Chemicals USA. Chemtreat India Ltd., Navi Mumbai.(The foreign manufacturers license to the Indian Vendor shall be verified before supply of materials). RA 200 from M/s Chemco International, U.K. Denso Archco Rigidon Rig spray Product from M/s WINN & COALES (DENSO) LTD., UK.
II
INTERNAL SURFACES OF CARBON STEEL TEST SEPERATOR, VENT SCRUBBER, SLOP OIL SUMP, SKID CHAIN SUMP AND INSTRUMENT GAS SCRUBBER. Design temperature for immersion service : 115C maxmum 1. 2. Surface preparation; Same as I above. Protective Coating: Two-pack solvent free Glass Flake filled Vinyl Ester lining in three coats @500 microns DFT/Coat to obtain a total DFT of 1500 microns minimum. ( maximum DFT; 1800 microns) Application of coating shall be done by airless spray gun/Plural component gun. Recommended manufacturers and products; a) b) c) d) Polyglass VEG from M/s kirloskar Brothers Ltd., Pune GF6132 from Glass flake International Inc., Singapore/USA Deraken 470 from M/s Dow Chemicals, USA Chempruf 1410 from M/s Atlas Minerals and Chemicals Inc., USA. Indian Agent; M/s Chemtreat India Pvt. Ltd., Navi Mumbai. .(The foreign manufacturers license to the Indian Vendor shall be verified before supply of materials).
3. 4.
F.
METAL BUILDINGS I. Skid a) Surface Preparation : As per section :11 B1 b) Coating System : As per section :11 B1
II.
Structural Framing/Sheeting/Plating a) Exposed portions : Same as I (a) & (b) above.

SECTION: C-3.11
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b)
Unexposed portions (i.e. portions covered by wall panels, false roofing and false flooring): Surface Preparation : Commercial Blast Cleaning (SSPCSP-6) or Sa2 of SIS-05-5900/ISO-8501-1988 with anchor profile of 25-50 microns. Inorganic Zinc Silicate Primer DFT : 65-75 microns
Primer : One coat of (minimum).
Top coat: One coat of HB coal Tar epoxy coating DFT : 150 microns (minimum). Total DFT: Note: III. 215 microns minimum (250 microns maximum).
Coal Tar epoxy coating of low flame spread type. : As per
Coating below fire proofing and over fire proofing requirements/specification of manufacturer of fire proofing material.
IV.
All exposed roofs of building modules, platform decks and Helidecks shall be coated with anti skid painting. Surface preparation: Blast cleaning to near white metal finish by shot and grit blasting as per SSPC-SP10 or sa 2 of SIS-05-5900/ISO 8501-1988 with a surface profile of 25-50 microns height from trough to peak.
a.
b.
Coating system: 2 coats of two component polyamine cured high solids glass flake filled epoxy coating F-17 @300 microns DFT/coat =2x300= 600 microns + 2 coats of (F-2) Acrylic Polyurethane finish paint @40 microns DFT/coat=2x40 =80 microns Total DFT=680 microns minimum.(750 microns maximum) Anti skid material The anti-skid materials shall be mixed with Acrylic Polyurethane Top coat before application by using mechanical mixer or the anti-skid materials may be sprayed on wet condition after application of Acrylic Polyurethane top coat Recommended anti-skid materials and manufacturers: Manufacturers name Carboline Hemple paints Akzo Nobel paints Chugoku J&N Anti skid materials Reactic 1210 Non skid Hempels Antiskid beads 67500 Interzone 505 with GMA 132 Epicon Marine Peek
c.
12.0
COLOR CODING SCHEDULE Finish Coat Color Code (For TSA Coated items, colour coding shall be achieved by suitably pigmenting the sealer paint selected for application on TSA coated surface (vide Section 5.0 of Bid Specification A108-01-06-42- TSA- SP- 02, Rev2).This will be applicable for atmospheric zone above splash zone up to cellar deck
SECTION: C-3.11
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Service Water Makers Lower Deck Jacket up to Lower Deck Tanks and Vessels Pumps and Drivers Compressors and Drivers Generators and Drivers Instruments Electrical Equipment (incl. Cable Trays) Fire Fighting Equipment Structural Steel and Pipe Supports Overhead Obstructions First Aid Equipment Danger Points of Elec. Installation Pipework Building
Paint Color Light Blue or Factory Finish Yellow Yellow White Dark Grey or Factory Finish Dark Grey or Factory Finish Dark Grey or Factory Finish Factory Finish Aluminium Grey Red Yellow Yellow with Black Strips Signal Green Orange Aluminium Grey Spanish tilel Red
All piping shall be color coded to identify the service. This shall be accomplished by applying paint in 6" wide strips to all pipe work in accordance with the following schedule. Strips shall be applied 6 inches apart when more than one color is required. Maximum spacing shall be 60 inches. The lines shall also be suitably marked with arrows indicating flow directions as per piping isometrics. On all equipment, name of equipment, tag no., and service should bee marked with Capital letters, readable from floors.
Potable Water Sea Water (Other than Fire Water) Fire Water Gas Gas (Vent) Relief Header Crude Oil Utility Air Diesel All Drains Chemical Injection Thermal Fluid Instrument Air High Pressure Flare Sewer Condensate Header Produced Water Glycol Fuel Gas Dry Chemical I.P. Flare Cooling Water Well fluid
Blue - One Ring White - One Ring Red - One Ring Yellow - One Ring Yellow - Two rings Brown - One Ring Sky Blue - One Ring Brown - Two Rings Black - One Ring Orange - Two Rings Orange - One Ring Green - One Ring Yellow - One Ring+Red - One Ring Black - Two Rings Brown - One Ring+White-One Ring White - Two Rings Orange -One Ring+Green-One Ring Yellow - One Ring+Blue - 1 Ring Red - Two Rings Yellow/Red/Yellow - 3 Rings Blue - Two Rings Brown/Yellow/White - 3 Rings
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Lube Oil Orange (One Ring)+Brown (1 Ring) Seal Oil Orange/Brown/Orange - 3 Rings Inert Gas Yellow one ring+Organge One Ring Breathing Air Sky blue-One Ring+Orange One Ring Sodium Hypochloride White one Ring+Orange on Ring Injection Water (After D.O. Towers) White/Orange/White - 3 Rings Jet Fuel Brown - 3 Rings Closed Drain Black - One Ring Open Drain White - One Ring+Black one Ring Walkthrough area in each deck Green (500 mm wide) connecting to staircase/ladder. At starting/termination points of piping above each floor generation at a height of about l.5m from floors, the service, origin place, arrow for flow direction (from To) are to be marked with paints in Capital letters. The color or arrow shall be black or white and in contrast to the color on which they are superimposed. Size of the arrow shall be either of the following: Letters shall be 40-150 mm size stenciled in black or white color in contrast to the color on which they are superimposed.
SECTION: C-3.11
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PART-2 TABLE-I.0 (for clause 3.0) SURFACE PREPARATION STANDARDS S. NO. DESCRIPTION VARIOUS INTERNATIONAL STANDARDS (EQUIVALENT) SWEDISH STANDARD SIS-05-5900 1967 1.0 MANUAL OR HAND TOOL CLEANING REMOVAL OF LOOSE RUST, LOOSE MILL SCALE AND LOOSE PAINT. CHIPPING, SCRAPPING, SANDING AND WIRE BRUSHING. SURFACE SHOULD HAVE A FAINT METALLIC SHEEN 2.0 MECHANICAL OR POWER TOOL CLEANING REMOVAL OF LOOSE RUST, LOOSE MILL SCALE AND LOOSE PAINT TO DEGREE SPECIFIED BY POWER TOOL CHIPPING, DESCALING, SANDING, WIRE BRUSHING AND GRINDING, AFTER REMOVAL OF DUST, SURFACE SHOULD HAVE A PRONOUNCED METALLIC SHEEN. ST.2 SSPC-SP-2 SSPC-SP USA NACE USA BRITISH STANDARD BS-4232: 1967
ST.3
SSPC-SP-3
Remarks: THE METHODS GIVEN IN 1 & 2 ARE APPLIED WHEN THE SURFACE IS EXPOSED TO NORMAL ATMOSPHERIC CONDITIONS WHEN OTHER METHODS CANNOT BE ADOPTED AND ALSO FOR SPOT CLEANING DURING MAINTENANCE PAINTING
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TABLE-I.0 (for clause 3.0) SURFACE PREPARATION STANDARDS S. NO. DESCRIPTION VARIOUS INTERNATIONAL STANDARDS (EQUIVALENT) SWEDISH STANDARD SIS-05-5900 1967 3.0 BLAST CLEANING THERE ARE FOUR COMMON GRADES OF BLAST CLEANING *3.1 WHITE METAL BLAST CLEANING TO WHITE METAL CLEANLINESS, REMOVAL OF ALL VISIBLE RUST, MILL SCALE, PAINT & FOREIGN MATTER 100% CLEANLINESS WITH DESIRED SURFACE PROFILE. **3.2 NEAR WHITE METAL BLAST CLEANING TO NEAR WHITE METAL CLEANLINESS, UNTIL AT LEAST 95% OF EACH ELEMENT OF SURFACE AREA IS FREE OF ALL VISIBLE RESIDUES WITH DESIRED SURFACE PROFILE. Remarks: * WHERE EXTREMELY CLEAN SURFACE CAN BE EXPECTED FOR PROLONG LIFE OF PAINT SYSTEMS. THE MINIMUM REQUIREMENT FOR CHEMICALLY RESISTANT PAINT SYSTEMS SUCH AS EPOXY, VINYL, POLYURETHANE BASED AND INORGANIC ZINC SILICATE PAINTS, ALSO FOR CONVENTIONAL PAINT SYSTEMS USED UNDER FAIRLY CORROSIVE CONDITIONS TO OBTAIN DESIRED LIFE OF PAINT SYSTEM SA 2 SSPC-SP-10 NACE #2 SECOND QUALITY SA 3 SSPC-SP-5 NACE #1 FIRST QUALITY SSPC-SP USA NACE USA BRITISH STANDARD BS-4232: 1967
**
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TABLE-I.0 ( for clause 3.0) SURFACE PREPARATION STANDARDS S. NO. DESCRIPTION VARIOUS INTERNATIONAL STANDARDS (EQUIVALENT) SWEDISH STANDARD SIS-05-5900 1967 *3.3 COMMERCIAL BLAST BLAST CLEANING UNTIL AT LEAST TWOTHIRDS OF EACH ELEMENT OF SURFACE AREA IS FREE OF ALL VISIBLE RESIDUES WITH DESIRED SURFACE PROFILE. BRUSH-OFF BLAST BLAST CLEANING TO WHITE METAL CLEANLINESS, REMOVAL OF ALL VISIBLE RUST, MILL SCALE, PAINT & FOREIGN MATTER. SURFACE PROFILE IS NOT SO IMPORTANT. * SSPC-SP-6 SA 2 NO.3 THIRD QUALITY SSPC-SP USA NACE USA BRITISH STANDARD BS-4232: 1967
3.4
SA 1
SSPC-SP-7
NO.4
Remarks :
FOR STEEL REQUIRED TO BE PAINTED WITH CONVENTIONAL PAINTS FOR EXPOSURE TO MILDLY CORROSIVE ATMOSPHERE FOR LONGER LIFE OF THE PAINT SYSTEMS.
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TABLE-I.0 ( for clause 3.0) SURFACE PREPARATION STANDARDS TABLE NO. 2.0 : PAINT MATERIALS: Paint manufacturers shall furnish all the characteristics of paint materials on printed literature, alongwith the test certificate with actual test values of supplied batch for all the specified characteristics given in this specifications. All the paint materials shall be of first quality and conform approximately close to the following general characteristics. S.NO. 1. 2. DESCRIPTION Technical Name Type and composition P-4 Etch Primer/Wash primer Two pack polyvinyl Butyral resin medium cured with phosphoric acid solution pigmented with Zinc tetroxychromate Volume solids(approx.) 7-8% DFT(Dry film thickness) per coat(approx. in 8-10 microns) Theoritical covering capacity in 8-10 microns M2/coat/litre(approx.) Weight per litre in Kgs/litre(approx.) 1.2 Touch dry at 30C(approx) 2 Hard dry at 30C(approx) Min.: 2 hrs. Max: 24 hrs Overcoating interval(approx.) Min. 4-6 hrs. Max.: 24 hrs. Pot life(approx.) at 30C for two component N.A. paints(approx.) Resistance to dry temperature 90C
3. 4. 5. 6. 7. 8. 9. 10. 11.
SECTION: C-3.11
DOCUMENT No:
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TABLE NO. 2.0 :
PAINT MATERIALS: Paint manufacturers shall furnish all the characteristics of paint materials on printed literature, alongwith the test certificate with actual test values of supplied batch for all the specified characteristics given in this specifications. All the paint materials shall be of first quality and conform approximately close to the following general characteristics. S.NO. 1. 2. DESCRIPTION Technical Name Type and composition P-6 Epoxy Zinc phosphate primer Two component polyamide/Polyamine cured epoxy resin medium, pigmented with zinc phosphate 40% per 40-50 microns
3. 4. 5. 6. 7. 8. 9. 10. 11.
Volume solids(approx.) DFT(Dry film thickness) coat(approx.) Theoritical covering capacity in 8-10 M2/coat/litre(approx.) Weight per litre in Kgs/litre(approx.) 1.4 Touch dry at 30C(approx) After 30 mins. Hard dry at 30C(approx) Min.: 8 hrs. Max.: 3-6 months Overcoating interval(approx.) Min.:8 hrs. Max.: 3-6 months Pot life(approx.) at 30C for two 8 hrs. component paints(approx.) Resistance to dry temperature 90C
SECTION: C-3.11
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TABLE NO. 2.0 : S. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
PAINT MATERIALS (CONTINUED) DESCRIPTION F-2 Acrylic Polyurethane finish paint Two-pack aliphatic isocyanate cured acrylic semiglossy finish paint 40% 40 microns 10 1.3 1hr. Overnight Min.: Overnight Max.: Unlimited 6-8 hrs. 90 degree C
Technical Name Type and composition Volume Solids (approx.) DFT(Dry film thickness) per coat (approx). Theoritical covering capacity in M2/coat/litre(approx) Weight per litre in kgs/litre (approx.) Touch dry at 30 degree C (approx.) Hard dry at 30 degree C (approx.) Overcoating interval(approx) Pot life at 30 degree C for two component paints (approx) Resistance to dry temperature(minimum)
SECTION: C-3.11
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TABLE NO. 2.0 : PAINT MATERIALS (CONTINUED)
S. No. 1. 2.
DESCRIPTION Technical Name Type and composition
F-6 Epoxy-High Build finish paint Two-pack polyamide/polyamine cured epoxy resin medium suitably pigmented 62% 100-125 microns 5-6 1.4 3hrs. Overnight Min.: Overnight Max.: 5 days 4-6 hrs. 90 degree C
F-7 High build coaltar epoxy coating. Two pack polyamine cured epoxy resin blended with coaltar medium, suitably pigmented. 65% 100-125 microns 5.2-6.5 1.5 4 hrs. 48 hrs. Min.: 24 hrs. Max.: 5 days 4-6hrs. 90 degree C
3. 4. 5. 6. 7. 8. 9. 10. 11.
Volume Solids (approx.) DFT(Dry film thickness) per coat (approx). in microns Theoritical covering capacity in M2/coat/litre(approx) Weight per litre in kgs/litre (approx.) Touch dry at 30 degree C (approx.) Hard dry at 30 degree C (approx.) Overcoating interval(approx) Pot life at 30 degree C for two component paints (approx) Resistance to dry temperature(minimum)
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S. No. 1.
DESCRIPTION Technical Name
F-8 Self priming surface tolerant High Build Epoxy coating (Complete rust control coating) Two pack epoxy resin based suitably pigmented and capable of adhering to manually prepared surface and old coating. 72% 100-125 microns
F-9 Inorganic Zinc primer/coating Silicate
2.
Type and composition
3. 4.
5. 6. 7. 8. 9.
Volume Solids (approx.) DFT(Dry film thickness) per coat (approx). in microns Theoritical covering capacity in M2/coat/litre Weight per litre in kgs/litre (approx.) Touch dry at 30 degree C (approx.) Hard dry at 30 degree C (approx.) Overcoating interval(approx)
A two pack air drying self curing solvent based Inorganic Zinc silicate primer/coating with minimum 80% Zinc on Dry film coating 60% 65-75 microns
6.0-7.2 1.4 3 hrs. 24 hrs Min.: 10 hrs. Max.: 6 months
8-9 2.3 30 minutes 12 hrs Min.: Max. 4-6 hrs 8 hrs. at 20 degree C and 50% RH. Unlimited
10.
11.
Pot life at 30 degree C for 90 mts. two component paints (approx.) Resistance to dry 90 degree C temperature
50 degree C
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S. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
DESCRIPTION Technical Name Type and composition Volume Solids (approx.) DFT(Dry film thickness) per coat (approx) in microns Theoritical covering capacity in M2/coat/litre Weight per litre in kgs/litre (approx.) Touch dry at 30 degree C (approx.) Hard dry at 30 degree C (approx.) Overcoating interval(approx)
F-12 Heat resistant silicone Aluminium paint suitable Single pack silicone resin based medium with aluminium flakes. 20% 20-25 microns 8-10
1.1 30 mts. 24 hrs. Min.: 16 hrs. Max.: Unlimited Pot life at 30 degree C for two component Not applicable paints (approx.) Resistance to dry temperature 500 degree C
SECTION: C-3.11
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TABLE NO. 2.0 : PAINT MATERIALS ( CONTINUED) S. No. 1. 2. DESCRIPTION Technical Name Type and composition F-17 Glass flake filled epoxy coating Two component very high solids glass flake filled epoxy cured with polyamine hardner. 80% 300 microns 2.6 1.5 2-3 5 days F-18 Low Flame spread epoxy paint. Two pack epoxy top coat based on polyamide cured epoxy resin which is certified not to spread surface flames as per BS 476 Part 1, 1953 class 2. 50% 50-60 microns 8-10 30 mts. 4 hrs 3 days 6 hrs 90 degree C
3. 4. 5. 6. 7. 8. 9. 10. 11.
Volume Solids (approx.) DFT(Dry film thickness) per coat (approx.) in microns Theoretical covering capacity in M2/coat/litre Weight per litre in kgs/litre (approx.) Touch dry at 30 degree C (approx.) Hard dry at 30 degree C (approx.) Overcoating interval(approx.)
Min. 16 hrs. Max. 30 days Pot life at 30 degree C for two 45 mins component paints (approx.) Resistance to dry temperature 90 degree C
SECTION: C-3.11
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TABLE NO. 3.0 :
RECOMMENDED LIST OF PAINT MATERIALS FOR EIL OFFSHORE PROJECTS MANUFACTURERS NAME INORGANIC ZINC SILICATE PRIMER F-9 APCOSIL 605 ZINC ANODE 304 MZ THERMOSIL ZINC 1362L CARBOZINC 11 SIGMASIL GUARD MC 7551 GALVOSIL 1570 DIMETCOTE-9FT
S. No. 1. 2. 3. 4. 5. 6. 7.
8. 9. 10. 11.
ASIAN PAINTS(I) LTD., MUMBAI BERGER PAINTS LTD., CALCUTTA PALADIN PAINTS & CHEMICALS, MUMBAI CARBOLINE, USA (CDC CARBOLINE, CHENNAI) SIGMA COATINGS, SINGAPORE/MUMBAI HEMPEL MARINE PAINTS, DENMARK AMERON, USA (GOODLASS NEROLAC PAINTS LTD., /CHEMGUARD COATINGS PVT. LTD., MUMBAI JOTUN PAINTS, SINGAPORE/ MUMBAI KCC PRODUCTS, KOREA AKZO NOBEL COATINGS, UK/BANGALORE CHUGOKU J&N LTD., MUMBAI
JOTA COTE-2 EZ 180(N) INTER ZINC-78 GALBONS HB
SECTION: C-3.11
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TABLE NO. 3.0 :
RECOMMENDED LIST OF PAINT MATERIALS FOR EIL OFFSHORE PROJECTS ETCH PRIMER/WASH PRIMER P-4 APCONYL WP 636 BISON WASH PRIMER VEG WASH PRIMER 1181 SIGMA ETCH PRIMER(7185) AMERCOAT 178 EPOXY ZINC PHOSPHATE PRIMER P-6 APCODUR HB ZP PRIMER EPILUX 610 VEGEPOX PRIMER 1241 SIGMA COVER CM PRIMER 7412 HEMPEL'S SHOP PRIMER E 1530 AMERCOAT 71
S. No. 1. 2. 3. 4. 5. 6. 7.
MANUFACTURERS NAME ASIAN PAINTS(I) LTD., MUMBAI BERGER PAINTS LTD., CALCUTTA PALADIN PAINTS & CHEMICALS, MUMBAI CARBOLINE, USA (CDC CARBOLINE, CHENNAI) SIGMA COATINGS, SINGAPORE/MUMBAI HEMPEL MARINE PAINTS, DENMARK AMERON, USA (GOODLASS NEROLAC PAINTS LTD., /CHEMGUARD COATINGS PVT. LTD., MUMBAI JOTUN PAINTS, SINGAPORE/ MUMBAI KCC PRODUCTS, KOREA AKZO NOBEL COATINGS, UK/BANGALORE CHUGOKU J&N LTD., MUMBAI
8. 9. 10. 11.
INTER PRIME 932-1 -
EPOXY CQ SPECIAL ZINC PHOSPHATE PRIMER INTERGARD 906 CAMIDECK PRIMER
SECTION: C-3.11
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TABLE NO. 3.0 :
RECOMMENDED LIST OF PAINT MATERIALS FOR EIL OFFSHORE PROJECTS (CONTINUED) ACRYLIC PU FINISH PAINT F-2
S. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
APCOTHANE CF676(PC1109) BERGER ACRYLIC PU FINISH VEGTHANE FP 3641 CARBOLINE 132 SIGMADUR HB FINISH 7524 AMERCOAT 450GL HARD TOP AS INTERTHANE 138 UNIMARINE
SECTION: C-3.11
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TABLE NO. 3.0 :
RECOMMENDED LIST OF PAINT MATERIALS FOR EIL OFFSHORE PROJECTS
S. No. 1. 2. 3. 4. 5. 6. 7.
MANUFACTURERS NAME ASIAN PAINTS(I) LTD., MUMBAI BERGER PAINTS LTD., CALCUTTA PALADIN PAINTS & CHEMICALS, MUMBAI CARBOLINE, USA (CDC CARBOLINE, CHENNAI) SIGMA COATINGS, SINGAPORE/MUMBAI HEMPEL MARINE PAINTS, DENMARK AMERON, USA (GOODLASS NEROLAC PAINTS LTD., /CHEMGUARD COATINGS PVT. LTD., MUMBAI JOTUN PAINTS, SINGAPORE/ MUMBAI KCC PRODUCTS, KOREA AKZO NOBEL COATINGS, UK/BANGALORE CHUGOKU J&N LTD., MUMBAI
HIGH BUILD EPOXY FINISH COATING F-6 APCODUR HB EPOXY/CF699 EPILUX HB EPOXY EPIPLUS 4/78TL VEGEPOX HB 3265/3562(AA) CARBOLINE 190HB SIGMA COVER CM 7456 HEMPADUR HIGH BUILD 4520 AMERLOCK 400
HB COAL TAR EPOXY COATING F-7 AMINE CURED APCODUR CF 651/CF655 EPILUX 555/5 VEGEPOX COALTAR 4565(AA) CARBOMASTIC-14 SIGMA TCN 300 HEMPADUR 1510 AMERCOAT 78HB
8. 9. 10. 11.
PENGUARD HB
JOTA GUARD 85
KOEPOX TOPCOAT HB EH 173 ET5740 INTEGARD 906 INTERTUF 978 EPICON MARINE FINISH HB BISCON HB 200/AC HB
SECTION: C-3.11
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TABLE NO. 3.0:
RECOMMENDED LIST OF PAINT MATERIALS FOR EIL OFFSHORE PROJECTS (CONTINUED) HEAT RESISTANT LOW FLAME SPREAD SILICONE ALUMINIUM PAINT PAINT F-18 F-12 HR SILICONE ALUMINIUM PAINT(PC 189) LUMEROS HR/47 SILICONE AL. PAINT HR ALUMINIUM PAINT 3920 CARBOLINE 4674 SIGMATHERM SIGMA CM COATING SILOXANE 7563 (7466) AS PER BS 476 PART1, 1953 AMERCOAT 878 SOLVALITT HEAT PEN GUARD TOP COAT AS RESISTANT SILICONE PER B.S.476 PART-I, 1953 PAINT QT 606 INTERTHERM 972 -
S. No.
1.
POLYAMINE ADDUCT CURED SELF PRIMING EPOXY MASTIC F-8 ADCOUR-CF 640 (9469)
2. 3. 4. 5.
PROTECTOMASTIC VEGEPOX MASTIC 2272 CARBOMASTIC 15 SIGMA EPTCP ALUMINIUM
6. 7. 8.
HEMPADUR 1708 AMERLOCK 400 JOTUMATIC 87
9. 10. 11.
EH4158H INTERSEAL547 -
SPECIFICATION FOR THERMALLY SPRAYED ALUMINIUM COATING (METALLIZING) FOR CORROSION PROTECTION OF STEEL FOR OFFSHORE WELL PLATFORM, CLUSTER-7 WELL PLATFORM PROJECT
A097-00-06-42-TSA-SP-03 Rev. 1
Page 1 of 11
SPECIFICATION FOR THERMALLY SPRAYED ALUMINIUM COATING (METALLIZING) FOR CORROSION PROTECTION OF STEEL FOR OFFSHORE WELL PLATFORM
PROJECT OWNER
: :
CLUSTER-7 WELL PLATFORM PROJECT OIL AND NATURAL GAS CORPORATION ENGINEERS INDIA LTD A097
CONSULTANT : JOB NO. :
1 0 Rev. No
04.05.2011 09.10.2010 Date
REVISED & RE ISSUED FOR BIDS ISSUED FOR BIDS Purpose
S. Das S. Das Prepared by
R. Chaudhury R. Chaudhury Checked by
R. Chaudhury R. Chaudhury Approved by
A097-00-06-42-TSA-SP-03 Rev. 1
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CONTENTS
SL. NO. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 SCOPE
DESCRIPTION
ITEMS TO BE THERMALLY SPRAYED TSAC REQUIREMENTS THERMAL SPRAY APPLICATION PROCEDURE SEALER TESTING AND MEASUREMENT SCHEDULE TSAC PROCEDURE QUALIFICATION DOCUMENTATION RECORDS WARRANTY SAFETY CODES AND STANDARDS SUGGESTED LIST OF TSA APPLICATORS
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1.0
SCOPE
The following sections outlines the requirement of supply, application and testing of thermally sprayed aluminum coatings (TSAC) for corrosion protection of steel structures exposed to sea water or any immersion service, splash zone, atmospheric or salt spray exposure, sulfurous flue gases not exceeding 500 0 C and other hostile environments.
2.0 ITEMS TO BE THERMALLY SPRAYED Steel Structures/equipments to be protected by TSAC shall as per Section 11.0 of specification A097- 00-06-42-SP-03, Rev.1. Structures, components thermally sprayed shall not have any uncoated area or shall not be in mechanically connected by flanges etc to any uncoated bare steelwork. Such adjacent areas to TSA coated areas, if not coated by TSA shall have suitable paint coating system as per Specification A097-00-06-42-SP-03, rev.1. 3.0 3.1 TSAC REQUIREMENTS Surface Preparation All the parts to be sprayed shall be degreased according to SSPC-SP 1. The absence of oil and grease after degreasing shall be tested by method given elsewhere in the specification (Refer Sec. 6.7). Thereafter the surface to be abrasive blasted to white metal finish as per NACE 1/SSPC-SP 5 for marine and immersion service. Using SSPC VIS 1, it is to be visually assesed that the blast cleaned surface meets requirement of SSPC-SP 5. Thereafter clear cellophane tape test as per ISO 8502-3shall be used to confirm absence of dust on the blasted surface. Finally blasted surface shall be tested for presence of soluble salts as per method ISO8502-9 . Maximum allowable salt content shall be considered 50mg/M2. ( 5 micrograms/cm2 ) .In case salt content exceeds specified limit The contaminated surface shall be cleaned by method as per Annex C of IS 12944-4 ( Water Cleaning.) After cleaning the surface shall be retested for salt content after drying. The blasting media shall be either chilled iron or angular steel grit as per SSPC-AB-3 of mesh size G-16 to G-40. Copper or Nickel slag or Garret as abrasive will also be suitable having mesh size in the range of G16 to G24, conforming to SSPC-AB-1. Mesh size shall be required as appropriate to the anchor tooth depth profile requirement and blasting equipment used. The blasted surface should be having angular profile depth not less than 75 microns with sharp angular shape. The profile depth shall be measured according to NACE standard RP 0287 (Replica Tape) or ASTM D 4417 method B (Profile depth gauge). For manual blasting one profile depth measurement shall be taken every 10-20 M2 of blasted surface. Surface preparation shall be completed in one abrasive blast cleaning operation wherever possible. If rust bloom(visual appearance of rust ) appears on the blast cleaned surface before thermal spraying, the affected area shall be reblasted to achieve specified degree of cleanliness after which only thermal spraying shall commence. Air blasting pressure at nozzle shall be normally maintained at 100 psi. Air pressure and media size should be reduced and adjusted to preclude damage/distortion to thin gauge materials. Blasting time on work piece should be adjusted to only clean the surface and cut required anchor tooth with minimum loss of metal. Blast angle should be as close to perpendicular as possible but in no case greater than 30 0 from perpendicular to work surface. Blasting media must be free of debris, excessive fines, contaminants such as Nacl and sulfur salts (Ref. SEC 6.0 of this Spec). .
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3.1.1
Blasting Equipment The TSAC applicator shall use mechanical (centrifugal wheel) or pressure pot blast cleaning equipment and procedures. Suction blasting equipment shall not be used. Sec 6.6.2 shall be used to validate clean and dry air
3.1.2
Feed Stock The feed stock shall be in the form of wire. The feed stock shall be 99.5% aluminum of commercial purity grade, its composition shall be in accordance with requirement of BS 1475or ASTM B833 (wrought aluminum and aluminum alloys, wire).
3.1.3
Thickness Requirement The nominal thickness of finished TSAC shall be 225 microns having minimum value of 200 microns at low thickness areas (valleys) and not more than 250 microns at peak areas. The finished thickness shall be measured using SSPC-PA 2 type 2 fixed probe gauge (Magnetic Gauge).
3.1.4
Coating Bond Strength Requirement
The TSAC coating shall have a minimum individual tensile-bond strength value of 1000 psi for flame sprayed and 1500 psi for arc sprayed coating with an average of 2000 psi for arc sprayed coatings. Minimum tensile bond strength should be achieved by proper anchor tooth profile of blasted surface, laying down the TSA thickness in multiple passes and carrying out TSA application under controlled environment
3.1.5 Porosity All thermally sprayed metallic coatings will have porosity. For thermally sprayed aluminum coatings porosity shall not exceed 15% of total surface area for flame sprayed coating and 8% for arc spray coating. 4.0 THERMAL SPRAY APPLICATION PROCEDURE Items in the atmospheric zone to be coated by TSA shall be applied by either Flame spray or Arc spray method and all items under water ( Below -3M from MSL )and in splash zone ( from + 6 M above MSL down to -3M below MSL )shall be by Arc wire method only. 4.1 4.1.1 Equipment set up Thermal spray equipment shall be set up calibrated, operated (1) according to manufacturer instructions/technical manuals and also TSAC applicators refinement thereto and (2) as validated by Procedure Qualification (Sec 7.0 of this specification). Spray parameters Spray parameters (see 4.1.3 below) and thickness of each crossing pass shall be set and shall be validated with bend test (See 6.5 of this Spec).
4.1.2
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4.1.3
Spray Parameters Spray Parameters Arc voltage Air pressure Steel surface cleanliness Steel surface profile Arc current Coating thickness Coating adhesion Coating porosity Spray distance (spray Gun work piece) Spray Pass width Method of Application Arc wire Spray Flame Wire Spray 27 V 80 psi 80 psi NACE-1 white metal NACE-1 white metal / or Near white metal 75 microns (minimum) 75 microns (min.) 250-280A 225 microns (nominal) 225 microns(Nominal) > 1500 psi (Total coating),see 3.1.4 >1000 psi Less than 8% Less than 15%. 6-8 5-7 40mm 20 mm
The above parameters to be validated with a bend test by the contractor before start of work (for details of bend test see Sec 6.5 of this Spec). 4.2 4.2.1 Post Blasting Substrate condition and thermal spraying period. The steel surface temperature shall be at least 50C above dew point of ambient air temperature. Steel substrate surface temperature shall be recorded by with a contact pyrometer.. Thermal spraying should commence within 15 minutes from the time of completion of blasting Holding Period Time between the completion of final anchor tooth blasting and completion of thermal spraying of blasted surface should be no more than four hours. If within this period rust bloom appears Sec 4.4.1of this specification will apply. Pre-Heating
4.2.2
4.3
For flame spraying, the initial starting area of 1-2 square feet to be preheated to approx.1200C to prevent condensation of moisture in the flame on the substrate. For arc spraying the preheating is not required. 4.4 Thermal spraying
Spraying should commence only after validation of equipment set up by procedure qualification test and spray parameter validation tests described in Sec 7.0 and 6.5 respectively.Thermal spraying must commence within 15 minutes from the time of completion of blast cleaning The specified coating thickness shall be applied in several crossing passes. The coating bond strength is greater when the spray passes are kept thin. Laying down an excessively thick spray pass increases the internal stresses in TSAC and decreases the bond strength of total TSAC. The suitable thickness for crossing passes shall be determined by procedure qualification test described in Sec 7.0 of this specification. For manual spraying, spraying to be done in perpendicular crossing passes to minimize thin spots in coating. Approx. 75-100 microns of TSAC shall be laid down in each pass.
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The surface geometry of the item or area to be sprayed should be inspected before application. The spraying pass and sequence shall be planned according to following. Maintain Gun as close to perpendicular as possible and within 300 from perpendicular to the substrate. Maintain nominal stand off distance and spray pass width as given below : Spray method Arc Wire Flame wire 4.4.1 Standoff (Inches) 6-8 5-7 Spray pass width (Inches) 1 ( 40mm ) ( 20mm )
Rust Bloom (Visual appearance of rust or Discoloration) If Rust bloom appears on the blasted surface before thermal spraying ,the affected area shall be reblastedto achieve the specified level of cleanliness. If Rust bloom in form of discoloration, or any blistering or a degraded coating appears at any time during application of TSAC, then spraying shall be stopped and acceptable sprayed area shall be marked off. The unsatisfactory areas shall be repaired to the required degree of surface cleanliness and profile. Blast the edges of the TSAC to provide for 2-3 feathered area overlap of the new work into existing TSAC. Then apply TSAC to the newly prepared surfaces and overlap the existing TSAC to the extent of feathered edge so that overlap is a consistent thickness.
4.4.2
Masking Masking all those parts and surfaces which are not required to be thermally sprayed as instructed by purchaser should be inspected by applicator to ensure that they are properly marked and covered by purchaser. Complex geometries (flanges, valve manifolds, intersections) shall be masked by applicator to minimize overspray i.e. TSAC applied outside spray parameters (primarily gun to substrate distance and spray angle).
4.4.3
TSAC Finish The deposited TSAC shall be uniform without blisters, cracks, loose particles, or exposed steel as examined with 10 X magnification.
5.0
SEALER Sealant shall be applied after satisfactory application of TSAC and completion of all testing and measurements of the finished TSAC as per Sec 6.0 of this specification.
For shop workSealer shall be applied immediately after thermal spraying and for field work sealer shall be applied within 8 hours. The sealcoat shall be thin enough to penetrate into the body of TSAC. The sealant shall be polyvinyl butyral wash primer over-coated with 100% solid polyurethane having total 50 micron DFT, for service temperature upto 90 degree C, and Silicone Alkyd Aluminium paint having DFT not more than 35-40 micron for service temperature above 90 degree C. However, for splash zone areas, only silicone alkyd aluminium shall be applied. Typically seal
Format No. EIL-1641-1924 Rev.1 Copyright EIL All rights reserved
A097-00-06-42-TSA-SP-03 Rev. 1
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coat shall be applied at a spreading rate resulting in theoretical 38 microns DFT. The seal coat shall be applied in accordance with SSPC-PA 1 and the paint manufacturer instruction for sealing. During application of seal coat, complete coverage shall be ensured by visual observation. 6.0 6.1 TESTING AND MEASUREMENT SCHEDULE Surface Finish
That the blasted cleaned surface meets the required criteria (NACE 1/SSPC-SP 5 ) shall be visually inspected using SSPC-VIS 1. The clear cellophane-tape test shall be used to confirm absence of dust or foreign debris on the cleaned surface. 6.2 Blast Profile Measurement: ( In-Process testing during actual production before application of TSA coating ) The angular profile depth measurement shall be done by profile tape as per method NACE Standard RP 0287 or ASTM D 4417 method B (Profile depth gauge micrometer). Spot measurement shall be carried out every 15m2 of blasted surface. At each spot three measurements shall be taken over an area of 10 cm2 and average of measurements to be recorded and reported. If profile is <75 microns blasting shall continue till grater than 75 microns depth profile is achieved. 6.3 6.3.1 6.3.2 TSAC Thickness ( In-Process Testing For finished coating during regular production ) TSAC finished thickness shall be measured using SSPC-PA 2 type 2 fixed probe gauge. For flat surfaces, measurements shall be taken along a straight measurement line, one measurement line for every 15 m2 of applied TSAC shall be selected along which 5 measurements to be taken at 25 mm internal and average to be reported. For curved surface or complex geometry, 5 measurements shall be taken at a spot measuring 10 cm2 in area. One spot to be taken for every 15 m2 of applied TSAC area. The TSAC thickness in surface changes or contour changes, welds and attachments shall be also measured and reported. If TSAC is less than specified minimum thickness, apply additional TSAC until specified thickness range is achieved. All locations and values of TSAC thickness measurements shall be recorded in Job Record (JR). Tensile Bond Testing ( In-Process testing for finished coating during regular production ) Tensile Bond strength of the TSAC finish coat shall be determined according to ASTM D 4541 using a self-aligning adhesion tester. One measurement shall be made every 50 m2. If tensile bond at any individual spot is less than 1000 psi for flame sprayed coating and 1500 psi for arc sprayed coating the degraded TSAC shall completely removed and reapplied. The tensile bond portable test instrument to be calibrated according to ASTM C 633,
6.3.3
6.3.4
6.3.5
6.3.6 6.4
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6.5
Bend Tests
Bend test shall be carried out at beginning of each work shift. Bend tests shall also be conducted on sample coupons before start of thermal spraying work to qualify the following as mentioned earlier in this specification. To qualify spray parameters and thickness of each 6.5.1 Test Procedure a) Five corrosion control steel coupons each of dimension 50 mm x 150 mm x 1.3 mm thk. to be prepared. Surface shall be prepared by dry abrasive blast cleaning as per this specification. TSAC shall be applied as per specified thickness range. TSAC should be sprayed in crossing passes laying down approx. 75-100 microns in each pass. TSAC applied coupons shall be bent 180 0 around a 13 mm diameter mandrel. Bend test shall be considered passed if on bend radius there is f) 6.6 6.6.1 No cracking or spalling or lifting by a knife blade from the substrate Only minor cracking that cannot be lifted from substrate with a knife blade. crossing pass.
b) c)
d) e)
Bend test fails if coating cracks with lifting from substrate.
Tests for blasting media, blasting air Blasting Media( For every fresh batch of media and one random test during blasting) a) Blasting Media shall be visually inspected for absence of contamination and debris using 10 X magnification. Inspection for the absence of oil contamination shall be conducted using following procedure : Fill a small clean 200 ml bottle half full of abrasive. Fill the bottle with potable water, cap and shake the bottle. Inspect water for oil film/slick.If present, the blasting media is not to be used. Soluble salt contamination if suspected shall be verified by method ASTM D 4940. If present, media to be replaced. Clean blasting equipment, especially pot and hoses, then replace blasting media and retest.
a)
b)
c) 6.6.2
Test for Blasting Air ( Once Daily before start of blasting and once at random during blasting) The air for blasting shall be free from moisture and oil. The compressor air shall be checked for oil and water contamination per ASTM D 4285.
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6.7
Test for presence of oil/grease and contamination The steel substrate after degreasing as per SSPC-SP 1 shall be tested as per following procedure to validate absence of oil and grease contamination. a) Visual inspection - Continue degreasing until all visible signs of contamination are removed. b) Conduct a solvent evaporation test by applying several drops or a small splash of residuefree trichloromethane on the suspect area especially pitting, crevice corrosion areas or depressed areas. An evaporation ring formation is indicative of oil and grease contamination. Continue degreasing and inspection till test is passed.
7.0
TSAC APPLICATOR QUALIFICATION Following tests to be carried out as part of procedure qualification test for the applicator. Thickness measurement Coating bond strength Porosity test Bend strength TSAC applicators surface finishing and application process and equipment set up, calibration and operation shall be qualified by application of TSA on a reference sample which shall be used as a comparator to evaluate the suitability of application process. Only that applicator will be permitted to carry out the work when test specimens coated by the applicator meets the desired requirements as cited below. The sample shall be made of a steel plate measuring approx. 18x 18 x thick. If the actual work is less than thick then the sample to be made from material of representative thickness. The surface preparation, TSAC application shall be made with actual field equipments and process/spray parameters and procedures as per the specification. The depth profile of blasted surface, TSAC coating thickness for each cross pass and total thickness range shall be as per specification. The surface preparation and thermal spraying shall be carried out in representative environmental conditions spraying with makeshift enclosure.
7.1 After application of coating, thickness and tensile bond measurements shall be made in following manner. Divide the sample piece into four quadrants. Measure thickness along the diagonal line of each quadrant.
Four each quadrant five in-line thickness measurements at 1 interval shall be done using SSPC-PA 2 type 2 fixed probe gauge. Thus a total of four five in line thickness measurements to be done for the whole sample. One tensile bond measurement using ASTM D 4541 type III or IV portable self aligning test instrument to be done at centre of each quadrant. Total of 4 measurements for the sample. One porosity evaluation test by Metallographic examination shall be conducted to demonstrate the achievement of porosity within the limits specified. Sample shall be prepared for Metallographic examination as per ASTME 3. The procedure shall be considered qualified if thickness and tensile-bond strength and porosity values meets the specification requirement.
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A097-00-06-42-TSA-SP-03 Rev. 1
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7.2 Bend test: Bend test shall be carried out as detailed at sec. 6.5 of this specification. Applicators thermal spray equipment set-up, operation and procedure of application including in-process QC checkpoints adopted during procedure qualification as described above should be always subsequently followed during entire duration of work. 8.0 DOCUMENTATION The following information shall be provided by TSAC applicator before award of work. TSAC application process consisting of equipment capabilities and their technical parameters, feed stock material and source of procurement. Detailed application procedure and in-process quality control check points for (a) surface preparation (b) thermal spraying (c) seal coats. Type and specification of instruments to be deployed for measurement of blast profile depth, TSAC thickness and tensile bond. Paint manufacturer data sheet for the selected sealing coat to be applied.
9.0
RECORDS The TSAC applicator shall maintain a job record to record production and QC information. All the results of the tests and quality control checks shall be entered in the record for each component/part thermally sprayed. All the result of tests (thickness, tensile bond, bend tests) and other validation tests (e.g. procedure qualification test, test for surface cleanliness after abrasive blasting, test for cleanliness of abrasives and air) shall also be recorded and duly signed by owner. All the information mentioned in Sec 8.0 above should also form part of the Job record. Any modification affected after procedure qualification in the procedure, QC, spray parameter, equipment spec to the original information (submitted before award of the work) must also form part of Job record.
10.0
WARRANTY The TSAC applicator shall warrant the quality of material used by providing the purchaser with a certificate of materials used to include Spray feed stock: Alloy type/designation, Lot Number, wire diameter, chemical analysis, name of supplier, manufacturer. Sealant : Name of manufacturer, application data sheet. SAFETY The TSAC applicator shall follow all safety procedures required by the purchaser/owner. Owner shall also give compliance requirement to be followed by applicator. The applicator shall follow all appropriate regulatory requirements.
11.0
12.0
CODES AND STANDARDS This specification shall apply in case of conflict between specification and following applicable standards:
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AWS C. 2.17 ASTM C 633 ASTM D 4285 ASTM D 4417 BS 2569 NACE Standard RP 0287 ASTM D 4541 ANSI/AWS C2.18 NACE No. 12/AWS C2.23M/SSPC-CS 23.00 SSPC Publication SSPC-AB 1 SSPC-AB 3 SSPC-PA 1 SSPC-PA 2 NACE No. 1/SSPCSP 5 NACE No. 2/SSPCSP 10 SSPC-VIS 1
Recommended Practice for Electric arc Spray. Test Method for Adhesive/Cohesive Strength of Flame Sprayed Coatings. Method for indicating Oil or Water in Compressed Air. Test Method for Field Measurement of Surface Profile of Blasted Steel. Specification for Sprayed Metal Coating. Field Measurement of Surface Profile of Abrasive Blast Cleaned Steel Surfaces Using a Replica Tape. Test method for Pull-Off Strength of Coating Using Portable Adhesion Testers. Guide for the Protection of Steel with Thermal Spray Coatings of Aluminum, Zinc and Their Alloys and Composites. Specification for the application of thermal spray coatings (Metallizing) of aluminum, zinc, and their alloys and composites for the corrosion protection of steel. The inspection of coatings and linings : A Handbook of Basic practice for Inspectors, Owners , and Specifiers. Mineral and Slag Abrasives. Ferrous Metallic Abrasives. Shop, Field, and Maintenance Painting of Steel. Measurement of Dry Coating Thickness with Magnetic Gages. White Metal Blast Cleaning. Near White Metal Blast Cleaning. Guide and Reference Photographs for Steel Surfaces Prepared by Dry Abrasive Blast Cleaning.
13.0 1) 2) 3) 4) 5)
Suggested List of TSA applicators
Metallizing Equipment Corporation , Jodhpur Larsen & Tuobro Ltd (Eutectic division), New Delhi Chemtreat India Ltd, Navi Mumbai Deepwater MPE, Malaysia Associated Thermal Spray,Ahmedabad
Other applicators will also be acceptable if they qualify the applicator qualification procedure given in the specification. If any one of the above suggested applicator is selected , even then he has to perform the qualification test be

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TECHNICAL AMENDMENT NO.

Part No./ Vol.No.

Section No./ Document No.

DO --- DO---- DO -Do

TECHNICAL AMENDMENT NO. 01

2.8 mA/m2 at 25 Degree

5mA/m2 (at 25 Degree Celsius)

Spec A097-00-06-42SP-03.Rev0 A097-00-06-42-TSASP-03.Rev 0 -

SPECIFICATION NO. A097-00-06-42-SP-04 Rev. No. 0

OIL AND NATURAL GAS CORPORATION LIMITED

ISSUED FOR BIDS REVISIONS

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SPECIFICATION NO. A097-00-06-42-SP-04 Rev. No. 0

70 mA/M2 ( At 25 degree Celsius )

320 mA /M2 ( At 25 Degrees Celsius )

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SPECIFICATION NO. A097-00-06-42-SP-04 Rev. No. 0

ANODE CHEMICAL COMPOSITION

Fe Si Cu Zn Indium Others (each) Aluminum

Template No. 5-0000-0001-T2 Rev. 1

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10.0 DIMENSIONAL & WEIGHT TOLERANCE

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14.0 TEST CERTIFICATES

VENDOR DATA REQUIREMENT

Anode fixing and arrangement details. Brief installatin procedure

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SECTION: C-3.11 Document No. A097-00-06-42-SP-03 Rev.1

SPECIFICATION FOR PROTECTIVE COATING

CONSULTANT : JOB NO. :

4.05.2011 09.10.2010 Date

Revised and reissued for bids ISSUED FOR BID Purpose

S. Das S. Das Prepared by

R. Chaudhury R. Chaudhury Checked by

R. Chaudhury R. Chaudhury Approved by

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5.0 5.1 5.1.1 . 5.1.2

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5.2.12 5.3 5.3.1

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2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) Note 1: Note 2:

PAINT MATERIALS: ( TABLES 2.0 ATTACHED IN PART II)

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