Doc. No. MS-FBE-002 Rev.

00

METHOD STATEMENT

FOR

SURFACE PREPARATION AND PAINTING ON ALLOY PIPING EXTERNAL SURFACES WITH APCS-113A

Contract No. JI-194 SAUDI ARAMCO OIL COMPANY

KARAN UTILITY AND CO-GENERATION PROJECT Khursaniyah, Saudi Arabia

Signature 00 Rev. 9 Jul 2011 Date Print Name S.Mariappan Prepared by MMG M. Ramesh Babu Checked by MMG R.A.Dimatatac Approved by MMG P.Ranzenbacher Approved by PSAL

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Doc. No. MS-FBE-002 Rev.00

Table of Contents
1. Scope and Purpose 2. Definitions 3. References 4. Responsibilities 5. Procedure 6. Quality Control/Inspection and Acceptance Criteria 7. Personal Qualifications 8. Safety Precautions 9. Attachment

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Doc. No. MS-FBE-002 Rev.00

1.

SCOPE AND PURPOSE :

The scope of this working procedure is to define the criteria of workmanship for the proper execution of the liquid epoxy (APCS 113A) application works in accordance with Saudi Aramco Requirements, drawings, specifications, manufacturers instructions for storage, application, handling and applicable codes and standards.

This procedure also covers minimum requirements of APCS 113A (liquid type epoxy coating) for Alloy steel piping on shop application & filed weld joints external coating in buried piping spools and associated fittings in accordance with SAES-H-002.

2.

DEFINITIONS :
Coating : An application of protective or decorative covering which can be in the form of a liquid, paste, tape, or powder. Project Quality Assurance Manual Request for Inspection Quality Control Inspection Plan

PQAM RFI QCIP

: : :

3.

REFERENCES :
SAEP-316 SAES-H-002 SAES-H-002V : Performance Qualification of Coating Personnel : Internal & external coating of pipeline and piping : Approved Saudi Aramco Data Sheets for the pipelines Maintenance external coating : Coating Matls & Application Requirements for Industrial Facilities : Safety Requirements for Coating Application Page 3 of 8

SAES-H-100

SAES-H-102

Doc. No. MS-FBE-002 Rev.00 SAES-H-200 SATIP-H-002-06 : Storage, Handling and Installation of Externally Coated Pipe : Renovation& Repair coating for Submerged Services APCS113A : The requirements of External. Liquid Coatings for Buried P/L & Piping : Packaging requirements for coatings : Solvent Cleaning Specification : Hand Tool Cleaning Specification : Power Tool Cleaning Specification : Blast Cleaning to Near White Metal Specification : Pictorial Surface Preparation Standards for Painting Steel Structures SSPC-PA2 : Measurement of Dry film Thickness

09-SAMSS-113

09-SAMSS-060 SSPC-SP1 SSPC-SP2 SSPC-SP3 SSPC-SP10 SSPC VIS-1

4.

RESPONSIBILITIES :
Painting Supervisor: Ensure full compliance by all painting foremen, painters, Abrasive blaster, labour regarding execution of the work in accordance with PSAL/SAUDI ARAMCO project requirements and specifications. Confirm the availability of all materials, tools, equipment, and required personnel who will carry out the work. Conduct brief meeting with all personnel involved in the painting. Quality Control Inspector: Monitor daily coating activities and conducts inspections in accordance with the approved project SATIP and associated documents. Prepares daily documentation and final acceptance documents when required. Maintains close working relationship with customer representative.

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Doc. No. MS-FBE-002 Rev.00 Safety Supervisor: Check the work areas for any unsafe conditions. Ensure that all safety requirements have been adequately addressed and the work shall be carried out in accordance with PSAL/SAUDI ARAMCO project safety procedures.

5.
5.1

PROCEDURE :
Pre-Blast Check

5..1.1 QC Inspector shall carry out checks before blasting to determine whether cleaning is required either with the use of chemicals or solvents. Solvent clearing if required shall be carried out in accordance with SSPC - SPI. 5..1.2 No abrasive blasting shall be carried out unless the steel surface is at least minimum 3C above the Dew Point temperature. 5..1.3 Prior to start for blasting, all sharp edges and cut-offs shall be rounded to a smooth radius and all weld spatters shall be removed. 5..1.4 The compressed air supply shall be checked free of oil, moisture and contamination. As a minimum, the inspector shall check and approve the air quality at the start & midpoint of each 8-hour period. The method of checking shall be in accordance with SAES-H-100 Para 5.4.1 5..1.5 All compressed air hoses and paint lines shall be circular in section, free of cuts, kinks and twists. Any change in direction shall be by long radius curves to maintain constant and unrestricted flow where possible. 5..1.6 All hoses and nozzle connections shall be inspected prior to commencement of work to ensure they are secure. Any defective connection will be immediately replaced. 5.2 Surface Preparation:

5.2.1 Surface preparation shall be carried out in accordance with the relevant coating system as specified in SAES H-002, APCS-113-A 5.2.2 The type of abrasive to be used shall be determined by degree of cleanliness and surface Profile requirements as specified in SAES-H-002.

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Doc. No. MS-FBE-002 Rev.00 5.2.3 Abrasives shall be kept dry and free of contamination. and shall comply in accordance with SAES-H-100 Para 5.2.1 5.2.4 Sufficient capacity compressors shall be used to supply free air to all elements of the abrasive and coating operation as per SAES-H-100 Para 5.4 5.2.5 The Blast profile shall be measured with PRESS-O-FILM (Testex tape X coarse replica tape) and Profile thickness gauge. The replica tape shall be attached with inspection report as a permanent record. 5.2.6 Residual chloride on the surface shall not exceed 40 mg/m.

Cleaning 5.2.7 Used abrasives shall be removed from external surfaces using a dry brush, blow down with clean dry compressed air. 5.3 Paint, Storage and Preparation

5.3.1 Paint and thinner shall be stored in wellventilated building at storage temperature as recommended in the manufactures data sheet 5.3.2 The date of manufacture shall be clearly marked on each paint container and paints that have exceeded their shelf life shall be discarded 5.3.3 Paints that show signs of leakage or have gelled shall be discarded and any skins that have formed shall be cut and removed before application. Paint preparation shall be in accordance with manufacturers recommendation and/ or accordance with SAES-H-100- Para-7. 5.3.4 All paints shall be thoroughly mixed before application, quantities over 5 liters shall be mixed using a power mixer. If the paint cannot be mixed uniformly (thick sediment at the bottom of the can) it shall be discarded. 5.4 Paint Application

5.4.1 The prepared surface shall be visually inspected for cleanliness and profile prior to coating. 5.4.2 Prepared surface shall be coated within a maximum of four hours and before any deterioration begins. Surfaces that have begun to deteriorate, or have exceeded the four hours shall be re-blasted. 5.4.3 Approved Paint materials for APCS 113-A as per SAES-H-002V shall be used for external application of Alloy spools including associated fittings to specify DFT. WFT will be monitored to control the required DFT. Page 6 of 8

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5.4.4 Paint shall only be applied if the following conditions are met and as specified by the Manufacturer: Surface temperature to be above 10oC and below 60oC. Surface temperature to be also at least minimum 3oC above dew point temperature. The surface shall be free of oil, grease, dirt, loose paint, dust, rust and other surface contaminants. There is protection from adverse weather conditions, such as winds that may blow sand, or other foreign bodies on the painted surface or it may disrupt the paint pattern or cause dry spray.

5.4.5 Recoating intervals shall be maintained as per manufacturers data sheet. Color contrast between coats shall also be maintained. 5.4.6 Dry film thickness of each coat shall be measured in accordance with SSPC-PA2 using a suitable non ferrous thickness gauge. 5.4.7 All the work shall be documented for future reference. 5.5 Repairs 5.5.1 All defective areas shall be cleaned with solvents or detergents. 5.5.2 Areas less than 0.1M2 shall be hand abraded or ground back to the surface substrate using at least 80 grit disc sanders and paint touch up shall be by brush only. 5.5.3 Areas greater than 0.1M2 shall be blast cleaned to original specification and paint application shall be airless spray.

6.

QUALITY CONTROL/INSPECTION AND ACCEPTANCE CRITERIA :

6.1 Quality control requirements are to be carried out in accordance with Inspection and test plan of the project. All documents shall be the latest version. Abrasive blasting/Painting equipment shall be checked by the crew supervisor for suitability prior to the start of the surface preparation and coating activities (as per approved ITP) Record on a daily basis critical in process inspection activities.(As per approved ITP) Page 7 of 8

6.2

6.3

Doc. No. MS-FBE-002 Rev.00 6.4 Paint/Coating and Equipment check list is required to be completed and signed by the Coating Crew Supervisor and verified and signed by the client Inspector (As per approved ITP) TESTEX tape for the profile reading of the blasted area. Minimum 3 tests shall be performed during each shift.

6.5

7.

PERSONNEL QUALIFICATION :
7.1 MMG personnel involved in preparation, application, direct supervision or inspection of coatings shall be qualified and certified by MMG and ARAMCO as per SAEP-316. This includes abrasive blasters, coating applicators, crew supervisors and QC inspectors.

8.

SAFETY PRECAUTIONS :
8.1 Safety Requirements for Painting shall be observed at all times and shall be strictly followed in accordance with SAES-H-102 The Project safety plan will be fully enforced during the duration of the work. During application process, all lighting will be of the explosion proof type as per SAESH-102 item 4.1 A standby man will be at the work at all times during the work. His role will be observing activities in the painting work and to stop the work immediately while any safety concern arises. All operators will wear full personal protective equipment including coveralls, safety boots, gloves, helmets and positive air feed breathing masks in accordance with SAESH-102 item 4.3 All recommendations of the Material/Equipments manufacturers concerning the safe handling and application of their products shall be followed as per SAES-H-102 item 4.4.

8.2 8.3

8.4

8.5

8.6

9.

ATTACHMENT:
9.1 9.2 JSA SATIP-H-002-06 ------------------END ------------------

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