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COMPANY LIMITED
Y01
08-Oct-2013
AFD
C. Ogini
C. Ogini
M. Omotoso
N01
01-Oct-2013
IFR
C. Ogini
C. Ogini
M. Omotoso
Revision
Date
Status
Issued by
Checked by
Approved by
COMPANY
Approval
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TABLE OF CONTENTS
1.0
GENERAL................................................................................................................................................ 6
1.1
Definitions.................................................................................................................................... 6
1.2
Abbreviations .............................................................................................................................. 6
1.3
2.0
1.4
Purpose ..................................................................................................................................... 10
1.5
2.1
3.0
3.1
3.2
3.3
4.0
PAINTING LOCATIONS........................................................................................................................ 13
5.0
GENERAL.............................................................................................................................................. 14
5.1
Preconstruction Primers............................................................................................................ 14
5.2
5.3
5.4
Galvanized ................................................................................................................................ 15
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6.0
7.0
5.5
5.6
Flanges...................................................................................................................................... 15
5.7
5.8
5.9
Fireproofing ............................................................................................................................... 16
6.1
6.2
6.3
6.4
7.1
7.2
Weather Conditions................................................................................................................... 20
7.3
Materials.................................................................................................................................... 21
7.4
7.5
7.6
7.7
Priming ...................................................................................................................................... 22
7.8
7.9
7.10
Defects ...................................................................................................................................... 24
7.11
Touch-up ................................................................................................................................... 24
7.12
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8.0
9.0
INSPECTION ......................................................................................................................................... 25
8.1
8.2
8.3
8.4
8.5
8.6
Inspection by COMPANY.......................................................................................................... 27
8.7
9.1
Coating System......................................................................................................................... 29
9.2
10.1
10.2
10.3
12.1
General...................................................................................................................................... 33
12.2
12.3
12.4
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1.0 GENERAL
1.1
Definitions
COMPANY:
CONTRACTOR:
CONTRACT:
VENDOR:
means the party that carries out the painting or insulation works
including Engineering, materials supply, installation and quality
control.
1.2
Abbreviations
ATM:
Atmospheric
C:
Cold Conservation
CRA:
CS:
Carbon Steel
DFT:
FEF:
FRP:
GRE:
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GRP:
H:
Heat Conservation
MSDS:
NDE
PP:
Personnel Protection
PFP:
PU:
Polyurethane
PVC:
Polyvinyl Chloride
SS:
Stainless Steel
SDSS:
SSPC:
WFT:
VOC:
1.3
Reference Documents
1.3.1 COMPANY General Specifications
DEP 30.48.00.31-Gen.,
Dec 1995
DEP 31.38.01.29-Gen.,
Dec 1997
DEP 30.46.00.31-Gen.,
July 1999
DEP 31.40.30.35-Gen.,
July 1998
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1.3.2
ANE-SPINMS-MEC-SPC-334406
ISO/TR 15235
SSPC-SP-1
SSPC-SP-2
SSPC-SP-3
SSPC-SP11
SSPC-PA 1
SSPC-SP7
ISO 8501-1
ISO 8503-2
ISO 8504-1
ISO 8504-2
ISO 8502-3
ISO 37
Norsok M 501
ASTM C 534
ASTM C 795
ASTM D 1622
ASTM E 96
BS 476
IMO MSC
41(64)
DIN 52615
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NORSOK R004
ISO 12944-3
ASTM A385
ASTM A123
[31] Standard test method for weight (mass) of coating on Iron and
Steel articles with zinc or zinc alloy coatings
ASTM A153
ASTM A143
SSPC-VIS 1
[35] Standard Test Methods for Field Measurement of Surface Profile ASTM D4417
of Blast Cleaned Steel
ASTMD 4285
Air
SSPC-PA 2
ASTM C-795
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1.4
Purpose
The purpose of this specification is to cover the minimum requirements for the selection
and the execution of the external, internal and accessories painting works of SITE
PREPARATION AND INTEGRATION OF NPDC LACT UNITS AND INTERIM
METERING SYSTEMS PROJECT. This specification covers the minimum requirements
for the surface preparation, materials, application and testing of coatings for fabricated
sheet, equipment, piping, electrical, instrumentation and appurtenances on SITE
PREPARATION AND INTEGRATION OF NPDC LACT UNITS AND INTERIM
METERING SYSTEMS PROJECT.
This document shall be read in conjunction with COMPANY General Specifications
listed in section 1.3.1.
This specification also introduces new technical requirement to the COMPANY ref.
[3] with additional insulation materials for the purpose of providing thermal insulation
(where required) to the process piping for SITE PREPARATION AND
INTEGRATION OF NPDC LACT UNITS AND INTERIM METERING SYSTEMS
PROJECT.
1.5
Range of Application
This specification is applicable to all equipment, piping lines and associated fittings
to be painted internally or externally.
This specification is applicable to all equipments, piping lines and associated fittings
for the purpose of heat loss reduction, without or in association with electrical trace
heating.
Equipment and piping insulation is indicated on the P&ID and in the line list,
depicting both type and thickness of insulation.
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2.1
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3.2
3.3
are
defined
in
COMPANY
specifications
DEP
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5.0 GENERAL
Preconstruction Primers
5.1
Inorganic zinc primers may be used as preconstruction primers but weld bevels must be free of
all primer before welding. This can be accomplished by masking prior to coating or by grinding
or sandblasting before welding. The coating-free area shall extend a minimum of 2 inches from
the weld bevel.
Non organic zinc preconstruction primers shall be removed by blasting to bare metal prior to
application of the required paint system.
VENDOR shall not apply successive coating over any non organic zinc preconstruction
primers in order to avoid undermining the protection provided by inorganic zinc primers.
Weld-Through Primers
5.2
Weld-through primers shall not be used unless welding qualification tests show no detrimental
effects, such as unacceptable porosity or mechanical properties. The use of weld-through
primers must be approved by COMPANY in writing prior to their use. If the primers are
accepted, inspection for weld bevel cleanliness shall be performed on all production work prior
to priming.
5.3
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5.4
Galvanized
Gratings, ladders, cages, stairways, handrails and miscellaneous hardware shall be prepared
for hot-dipped galvanizing in accordance with ASTM A385, ref [29]. These items shall be
galvanized in accordance with ASTM A123, ref [30] . The weight of the zinc coating shall be
confirmed by testing to ASTM A90, ref [31]. All handrails shall be painted after galvanizing with
coating system 3.5. Grating in the splash zone shall be coated with splash zone coating after
galvanizing.
Hot dipped galvanizing of bolts, nuts and washers shall conform to ASTM A 153, ref [32] and
ASTM A 143, ref [33].
Handrails and stairways shall be painted after galvanizing with COMPANYs coating system
detailed in COMPANY specification DEP 30.48.00.31-Gen, ref [1]
The design of items requiring galvanizing shall take cognizance of maximum length, limited by
galvanizing process.
Fabrication of items to be galvanized shall be completed (including cutting, welding and clean
up) prior to solvent cleaning and acid pretreatment and galvanizing.
Steel grating shall be banded prior to galvanizing. Banded shall be steel welded.
Whenever possible, each item shall be galvanized in a single hot dip. The final surface shall be
free of overlaps, spikes, teardrops, cracks or flakes.
If weepholes are used to prevent overpressuring, they shall be sealed after galvanizing by a
method reviewed by COMPANY. Plastic and lead plugs are not acceptable.
Galvanised parts shall be repaired according to COMPANY specification DEP 30.48.00.31-Gen,
ref [1]
5.5
Compressed air shall be free of water and oil. Adequate separators or traps shall be provided
and properly maintained and shall be regularly emptied of water and oil.
5.6
Flanges
Flange faces (excluding gasket surfaces) and bolt holes shall be coated with the primer and
intermediate coat before assembly.
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5.7
Tank Interiors
Inside surfaces of manways, nozzles, bosses and other connections shall be blasted and
coated with the same system as the internal surfaces of the tank or vessel.
5.8
Fireproofing
Only fireproofing specified by COMPANY shall be provided. The specified primer (P15) shall be
provided unless the fireproofing MANUFACTURER recommends a different primer. The primer
shall be topcoated with the specified topcoats (F27 and F26).
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6.1
Solvent Cleaning
Prior to surface preparation, the surfaces shall be cleaned, as necessary, to remove all oil,
grease, dirt, salts or other foreign material. This cleaning shall be by appropriate detergent
and/or solvent cleaning. Detergent or solvent cleaning shall be performed as outlined in
SSPC-SP-1, ref [6] or NACE equivalent.
Solvents used to clean stainless steel shall be free of substances such as chlorides, sulfur,
halogens or metallic pigments. The degreased surface shall be further washed with fresh water
to remove all traces of degreaser chemicals.
Solvent cleaning shall be used prior to any tool or abrasive cleaning.
6.2
Hand tool cleaning or power tool cleaning shall be per SSPC-SP-2, ref [7], SSPC-SP-3, ref
[8],SSPC-SP-11, ref [9] or NACE equivalent.
COMPANY approval is required before power tool cleaning can be substituted for abrasive
blasting.
When hand or power tool cleaning is required on stainless steel, only stainless steel wire brush
that have not been previously on carbon steel surfaces may be used.
6.3
Abrasive Blasting
All abrasive blasted surfaces shall be blasted in accordance with the SSPC or NACE blast
specified in DEP 30.48.00.31-Gen, ref [1].
The anchor pattern shall be as specified in DEP 30.48.00.31-Gen, ref [1].
Abrasive blast cleaning shall be performed with a clean, sharp grade of abrasive. Only dry,
grit-type abrasives shall be utilized. The abrasive shall comply with government regulations.
Grain size shall be suitable for producing the specified anchor profile.
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Abrasives shall be free of dust, dirt and other foreign matter and shall be kept dry.
Prior to the start of blasting, an appropriate blast air pressure with abrasive and mesh size to
attain the specified anchor pattern.
After blasting and immediately before spraying, dust and loose residues shall be removed by
brushing, blowing off with clean dry air or vacuum cleaning
Blasting shall be performed in dry weather. Dry blast cleaning operations shall not be conducted
on surfaces exposed to rain, water spray or any other moisture.
Weld areas shall be ground, chipped or wire brushed as necessary prior to blasting to remove
rust, residual flux and weld spatter.
Steel surface slivers, laminations, laps, scabs or seams exposed by blasting shall be reported to
COMPANY, investigated, and repaired on any portion of the steel to be painted using rules from
the applicable code for repairs prior to coating. Repaired areas shall be re-blasted prior to
coating.
Prior to abrasive blasting, valves, sight glasses, name tags, machinery, electrical fixtures, etc.,
subject to damage from either the blast or from the abrasive material shall be protected. When
possible, nametags shall be installed after painting is complete. If it is not possible to coat under
tags, their edges shall be sealed with silicone to prevent moisture accumulation.
Cadmium-plated, electroplated, metallized or other specially coated items shall not be blasted
unless otherwise directed by COMPANY.
Blasting shall be accomplished so that previously painted surfaces are not contaminated by
abrasive or blast wastes.
Blast cleaned surfaces shall be inspected for proper cleaning prior to painting SSPC-VIS 1, ref
[34] shall be used as a visual standard for confirming the degree of surface cleanliness.
The anchor profile shall be verified in accordance with ASTM D4417 method C, ref [35] using
either course or extra-course replica tape or a spring loaded micrometer.
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6.4
All galvanized and aluminum surfaces specified to be painted shall be pretreated with an acid
wash base.
Galvanized surfaces which require painting shall be brush blasted (SSPC-SP7) with fine grit or
sand with lower nozzle pressure prior to painting.
Galvanized pieces, such as gratings, which will be installed over steel surfaces to be painted
that will interfere with painting, shall not be installed prior to painting the underlying steel. If the
galvanized pieces must be installed before final painting, they shall first be wash-primed and
coated with the same intermediate coating as the underlying steel. In all cases, the underlying
steel shall be abrasive blasted and primed with the intermediate coating prior to installing
galvanized pieces over the steel.
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7.1
Weather Conditions
7.2
on wet surfaces,
during strong or dusty conditions particularly for spray application.
If rain falls on painting surfaces prior to paint becoming rainproof, surfaces shall
be re-blasted and repainted.
Painting done outdoors shall be done in daylight hours and completed at least one hour prior to
sundown. Indoor painting shall be allowed 24 hours a day if the specified metal and air
temperatures and relative humidity requirements are met inside the building or vessel at all
times during preparation, painting and curing.
The following shall be checked and recorded at the beginning of each days operation and
several times during the application process:
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7.3
ambient temperature
relative humidity
dew point
moisture-free surface
temperature of the surface to be coated
Materials
7.4
7.5
Materials that have exceeded the coating MANUFACTURERs recommended shelf life shall not
be used.
The coating MANUFACTURER's recommended pot life shall not be exceeded. When this limit
is reached, the spray pot shall be emptied and cleaned, and new material mixed.
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7.6
Spray Application
CONTRACTOR's applicators shall be skilled in the proper application technique for each
coating.
Proper equipment, per the coating MANUFACTURER's data sheets and
recommendations, shall be utilized. Applicators or equipment failing to meet this requirement, to
COMPANY or the coating MANUFACTURER's satisfaction, shall be removed from coating
application.
Spray guns, lines and pressure pots shall be cleaned prior to adding new material. The air caps,
nozzles and meddles shall be those recommended by the coating MANUFACTURER for the
material being sprayed.
Moisture traps, separators and driers shall be installed between the air supply and the pressure
pot. The drain valve must be kept open slightly to permit continuous draining of any condensate
during operations.
Operating pressures shall comply with the recommendations of the coating MANUFACTURER.
Pressure pots shall be equipped with pressure regulators and gauges.
Paint shall be applied in a uniform layer, with 50% overlapping of the previous pass. During
application, the spray gun shall be held perpendicular to the surface being painted.
7.7
Priming
The specified coating system primer shall be applied within four hours from the time that
surfaces are cleaned and before rusting, discolouration or surface contamination occurs.
Surfaces to be coated shall be cleaned, dust-free and dry before application of any coating and
shall meet applicable hand, power tool or abrasive blasting surface preparation requirements
before priming.
Care shall be exercised to prevent overspray, spillage or application of coatings to surfaces for
which they are not intended. Skips, sags, and drips are to be repaired.
Inorganic zinc primer shall be applied using an agitated pot.
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7.8
Top - coating
7.9
Film Thickness
Wet film thickness shall be checked during the application of each coat to assure the specified
Dry Film Thickness (DFT) will be met.
The DFT of each coat shall be checked in accordance with the procedures defined by SSPC-PA
2, ref [6] using a magnetic gauge that has been properly calibrated.
Coating thickness on stainless steel shall be checked using a Type 2 gauge suitable for use on
non-ferrous substrates. Measurements shall be taken after removal of dry spray and overspray.
Gauges shall be adjusted to compensate for the substrates effect prior to application of any
coating.
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7.10 Defects
Coatings shall be free of defects such as sags, pin-holes, voids, blisters, wrinkles, mud cracking
and bubbles.
Dry spray and overspray shall be removed.
The DFT of each coat shall not be outside the specified range.
7.11 Touch-up
Prior to application of any coat, defects and damage to the previous coat shall be repaired.
Damage to finished work shall be thoroughly cleaned and recoated.
Damaged areas shall be spot blast cleaned or power tool cleaned as necessary to restore any
exposed steel to its original degree of cleanliness.
Loose, cracked and damaged coating shall be removed and the adjacent sound coating
feathered back to form a uniform and smooth surface.
Feathering shall be done by hand or power sanding with a grit wheel or sand paper.
The remainder of existing coating surface shall be properly protected with shields or screens to
prevent any possible damage to the coating.
Area with inadequate coating thickness shall be thoroughly cleaned and if necessary abraded.
Additional coat shall be applied blending in with the final coating on adjoining areas.
The prepared surface shall be free of loose, burnt or blistered coating.
Unless otherwise, the coating used for repair shall be the same as the original and shall have
the same DFT.
All repairs shall be specified in COMPANY specifications DEP 30.48.00.31-Gen, ref [1].
7.12 Brush or Roller Application
Written COMPANY approval shall be required before brush or roller application can be
substituted for spray application.
Brushes shall be of a style and quantity that will enable proper application of the coating.
Brushing shall be done so that a smooth coat with uniform thickness is obtained. When applying
coatings with a brush, multiple coats may be required to achieve the specified millage.
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8.0 INSPECTION
CONTRACTOR shall perform inspections necessary to ensure that surface preparation and
coating application complies with the requirements of this specification. The indicated records
shall be kept daily and shall be submitted to COMPANY at least weekly. Approved Coating
Inspection Record, shall be used to record this information.
COMPANYs authorized inspector(s) shall be given adequate notice prior to the start of surface
preparation and coating application so that they can witness the work. COMPANYs authorized
inspector shall have the option to witness or repeat any of these functions as necessary.
Materials, equipment, and work shall be available to COMPANYs authorized inspector(s).
COMPANYs authorized inspector(s) shall have access to the work site during the progress of
the work and shall have the right to conduct any inspection or testing deemed necessary to
ensure that the coatings are properly applied.
Instruments used in inspection activities (e.g., thermometer, pyrometers, hygrometers, thickness
gauges, profile gauges, and holiday detectors) shall be supplied by the SUPPLIER in proper
working order and calibrated prior to use.
8.1
The cleanliness of compressed air supply used for blast cleaning, pneumatic tools, and spray
equipment shall be checked for oil and water contamination in accordance with ASTM D 4285,
ref [36].
Lines shall be tested separately.
Testing shall be performed at the beginning and end of each work shift and at not less than
Four-hour intervals.
In the event that contamination is discovered, necessary corrective actions shall be made and
the air supply re-tested.
Surfaces that are determined to have been blasted with contaminated air shall be cleaned with
solvent and re-blasted with clean air and abrasive.
Coatings that are determined to have been applied using contaminated air shall be removed
and reapplied using clean air.
8.2
Abrasive Material
Recirculated shot and grit used for abrasive cleaning shall be tested for the presence of oil by
immersing in water and checking for oil flotation.
Tests shall be made at the start of blasting, at four-hour intervals thereafter, and at the end of
blasting.
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If oil is evident, contaminated abrasive shall be replaced with clean abrasive and retested before
proceeding.
Steel blasted since the last satisfactory test shall be re-blasted.
8.3
Environmental Conditions
The following shall be checked and recorded at the beginning of each days operation and
several times during the application process:
ambient temperature
relative humidity
dew point
moisture-free surface
temperature of the surface to be coated
These recordings shall be compared with criteria stated in item 4 of Section 6.2 in this
specification and the manufacturers data sheets.
If any criteria are exceeded, coating shall not be applied.
8.4
Immediately prior to priming, blasted surfaces shall be inspected by the following methods to
verify that the specified surface preparation has been achieved:
The anchor pattern shall be verified using Press-O-Film tape as described in ASTM D
4417 Method C, ref [35].
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8.5
Coating Application
Dry film thicknesses shall be measured using a Microtest Magnetic Film Thickness Gauge or
COMPANY-reviewed equal in accordance with SSPC-PA 2, ref [37].
The dry film thickness gauge shall be calibrated to the COMPANYs satisfaction at the beginning
of coating work and thereafter, regularly and whenever the COMPANY requests recalibration.
Calibration of the film thickness gauge shall be made using the procedures in SSPC-PA 2, ref
[37].
Record the thickness for each coat as work proceeds as well as the total thickness of each
finished coating system.
The entire surface of internal linings shall be inspected for holidays per NACE RP0188. When
testing hard-to-get-at locations around appurtenances and nozzles, a small sponge attachment
shall be used.
Areas containing holidays shall be locally sandblasted to bare metal, recoated with the same
system and retested for holidays. Detected holidays, correction and final holiday-free inspection
shall be recorded.
The entire surface of splash zone coatings shall be inspected for holidays using a COMPANY
reviewed high voltage spark type detector. The voltage setting shall be determined based on
Table 1 from NACE RP0188.
Areas containing holidays shall be locally sandblasted to bare metal, recoated and reinspected.
Areas found to contain runs; overspray, pinholes, sags and/or other signs of improper
application shall be repaired in accordance with the manufacturers recommendations at the
SUPPLIERs expense.
8.6
Inspection by COMPANY
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The COMPANYs inspectors shall ensure that necessary inspections are carried out at each
hold point.
COMPANYs inspectors shall have the right to condemn any materials, equipment or work not in
compliance with this specification.
Necessary corrective actions shall be performed by the SUPPLIER at SUPPLIERs expense.
Scaffolding, beam clamps, or any other equipment which will interfere with or damage coating
shall not be used.
SUPPLIER shall provide safe access to all areas for inspection by COMPANY.
SUPPLIER shall maintain the area to prevent contamination of coatings (i.e., wet down dusty
fabrication and painting areas including the surrounding grounds when dry conditions are
experienced).
Prior to final coating acceptance, SUPPLIER shall wash the entire platform with fresh water and
apply a finish coat to areas stained and contaminated by grinding, weld spatter, general traffic,
etc.
8.7
The coating MANUFACTURERs representatives shall have access to the work site during the
progress of the work to perform any inspection and testing deemed necessary to ensure that the
coatings are properly applied.
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Coating System
Coating system shall follow the list of systems as specified in COMPANY Specification DEP
30.48.00.31-Gen, ref [1] .
All coatings shall be provided in accordance with the COMPANY coating system Data sheets in
COMPANY Specification DEP 30.48.00.31-Gen, ref [1].
9.2
Colour Coding
Colour coding shall be in accordance with the Colour coding detailed in COMPANY
Specification DEP 30.48.00.31-Gen, ref [1].
The finish coat color of external coating systems shall follow this colour coding. Contrasting
colors shall be used for each of the intermediate coats to allow inspection for full coverage.
Finish colors for purchased equipment shall be specified otherwise on the purchase order.
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11.0 REPAIRS
Any repair shall be performed in accordance with the instructions given in the
MANUFACTURERs / SUPPLIERs Technical Data Sheet and shall be approved
by COMPANY.
Small areas of coatings that require repair may be abraded to bare steel with
sandpaper sanding disks, hand file or wire brush (mechanical or manual). Edges
of existing coatings around repair shall be firmly adherent and shall be feathered.
Coating may be applied to such repair areas using a brush, if suitable for the
particular type of coating. The repair technique for coatings with DFT below that
specified shall depend upon the state of cure of the coating. Coatings that have
exceeded the minimum recoat interval and have not exceeded the maximum
recoat interval may be cleaned, as required, and overcoated with the same
material. Coatings that have exceeded the maximum recoat interval shall be
repaired using approved procedures and MANUFACTURERs/ SUPPLIERs
recommendations.
Repairs of defects shall be in accordance with recommendations in DEP
30.48.00.31-Gen, ref [1].
When the coating is damaged down to the steel, and spot cleaning is necessary, these
areas shall be cleaned by blasting or power tool cleaning.
COMPANY approval is required on case by case basis prior to substituting power tool
cleaning for abrasive cleaning
After the metal surface has been cleaned, the edge of the surrounding coating shall be
feather-edged to remove all cracked, loose or damaged coating. Feather-edging shall be
accomplished by power or hand sanding with a grit wheel or sandpaper. The prepared
surface shall be free of all loose, burnt, or blistered coating.
Welding undercut and porosity shall be repaired prior to application of the coating.
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Any defect shall be repaired before the application of further coats. Subject to the
agreement of COMPANY, and after determining the type and size of the defects,
the following methods of repair shall be applied:
Major defects
The paint shall be removed completely by abrasive blast-cleaning and the entire
system shall be re-applied.
Subject to the agreement of the SUPPLIER of the product, the system shall be
removed by localized blast-cleaning, the edges of the sound coating shall be
feathered back about 50 mm, and the repair system shall be applied.
Where paint work and insulation is damaged or removed due to temporary bracing
/ supports, temporary attachments, lifting attachments / equipment, tie-down
operations on any other cause, the damaged insulation shall be removed, the
paint work removed
(if necessary) as per COMPANY specification DEP
30.48.00.31-Gen, ref [1] and the insulation re-applied in accordance with the
COMPANY specifications ref [3].
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