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HINDUSTAN PETROLEUM CORPORATION LTD

STANDARD

SPECIFICATION
FOR SHOP
AND

FIELD PAINTING

SPECIFICATION FOR PAINTING PAGE: 1 of 10


HINDUSTAN PETROLEUM CORPORATION LTD

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

1.0 GENERAL

1.1 These technical specifications shall be applicable for the work covered by the
Contract. It is understood that Contractor shall complete the work in all respects
with best quality materials and workmanship, best engineering practice,
Manufacturer recommendations, ITP and instructions of HPCL.

1.2 All the items covered in this specification are required to be supplied by the
Contractor only.

2.0 SCOPE
Scope of work covered in this specification shall include but not limited to the
following:

1. Surface preparation for all components of A/G product storage tanks covered in
this Contract.

2. Selection, procurement and application of primers, paints and other materials on


various metallic surfaces including providing all requisite scaffolding, spray
equipment, compressors, applicators, brushes, etc.

3. Lettering, marking as per HPCL requirements.

3.0 CODES AND STANDARDS

3.1 REFERENCE STANDARDS


IS : 5
IS : 101
ASTM STANDARDS

3.2 SURFACE PREPARATION STANDARDS

SWEDISH STANDARD : SIS-05-5900-1967/ISO-8501-1-1988


THIS STANDARD CONTAINS PHOTOGRAPHS OF THE VARIOUS
STANDARDS ON FOUR DIFFERENT DEGREES OF RUSTED STEEL.

MANUFACTURERS BROCHURES AND INSTRUCTIONS WITH RESPECT TO


STORAGE, SURFACE PREPARATION, MIXING AND THINNING, APPLICATION

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HINDUSTAN PETROLEUM CORPORATION LTD

AND CURING INTERVALS.

4.0 EQUIPMENT
All tools, brushes, rollers, spray guns, abrasive materials, sand, hand/ power tools
for cleaning, scaffolding materials, air compressors, instrument for measuring
humidity, profilemeter etc required for the works shall be supplied by the
Contractor.

5.0 SURFACE PREPARATION, COATING APPLICATION AND DOCUMENTATION

5.1 GENERAL

5.1.1 In order to achieve the maximum durability, copper slag cleaning shall be
followed.

5.1.2 Mill scale, rust, rust scale, etc. shall be fully removed by copper slag blast cleaning
to SA 2 or equivalent as per
SWEDISH STANDARD: IS-05-5900-1967/ISO-8501-1-1988.

5.1.3 Copper slag Blast cleaning shall not be performed where dust can contaminate
surfaces undergoing such cleaning or in conditions where the humidity exceeds
85%.
5.1.4 The first coat of primer must be applied on dry surface immediately and in any
case within 4 hrs of cleaning of surface.

5.1.5 Blasting and painting shall in general be avoided during unfavorable weather
conditions.

5.2 PROCEDURE FOR SURFACE PREPARATION


5.2.1 COPPER SLAG BLAST CLEANING

SPECIFICATIONS FOR COPPER SLAG BLASTING :

1. The surface shall be cleaned of all dust and heavier layers of rust by copper slag
blasting the entire internal surface to photographic standard SIS: 055900-1967.

2. The consumption rate of copper slag is 1.6 Kg/Sqm of the blasted area. This has
to be ensured strictly.

3. All tools, equipments, base material, hand and power tools for cleaning, including
scaffolding material, copper slag blasting equipment, air compressor etc. shall be
arranged by the contractor at site in sufficient quantity.

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HINDUSTAN PETROLEUM CORPORATION LTD

4. The compressor used shall be of size enough to produce displacement of 5.6 to


7.0 Cum/Min of air at a pressure of 7 Kg/sqcm. Standard blasting equipment,
hoppers, hoses nozzles and attachments shall be used to obtain best test results and
to maintain safety standards. The rate of cleaning shall be about 15 sq.mt. per hour
at a pressure of 7 kg/sq.cm.

5. The abrasive used shall be of the physical properties as mentioned below and
shall be free from oil, loan and mud etc.

6. The blast cleaned surface shall be blasted with dry compressed air before
applying primer. This should be done even if the surface appears very clean and
white in colour. The white colour may be due to deposition of silicon and reflection of
light on the surface.

7. Proper earthing and bonding arrangements shall be made to prevent any damage
by sparks produced by static electricity. Bonding shall be done between tank and
blast nozzles and hopper and air compressor also. The bonding conductor should
not be less than 16 SWG single strand copper cable.

8. The time gap between blast cleaning and application of primer shall not be more
than THREE hours. Blast cleaning work shall, commence from top to bottom.

9. The blast cleaning operation shall be carried out keeping the nozzle at an angle of
30 degree to the vertical in order to prevent rebounding abrasive from showing down
the abrasives emerging from nozzle and from under cutting the material to be
removed.

A blast cleaning, the percentage of bare metal obtained shall be between 95% to 100%
of each of sq.cm. of the blasted area corresponding to photographic visual standards
of SA 2 of the Swedish standard referred above.

10. Arrangements for inspection of various stages of the job shall be made available
by the Contractor so that the entire copper slag blasted area is available for
inspection. Any defective work noticed shall be immediately rectified and even
reblasting shall be done if necessary.

Physical Properties of Copper Slag :

Colour : Black.
Grain shape : Granulated, Angular multifaceted.
Hardness : 5 to 7 Mohs scale.
Sp. Gravity : 3.2 to 3.7

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HINDUSTAN PETROLEUM CORPORATION LTD

Bulk Density : 1.87 Kg/ltr.


Moisture Content : less than 1 %

Sieve Analysis of copper slag :

Sieve Size ( mm ) Range (%)


-4.0 to +3.0 2 to 4
-3 to +2.36 3 to 12
-2.36 to + 1 40 to 55
-1 to + 0.5 15 to 30
-0.5 to + 0.212 6 to 12
-0.212 below 0.2 to 1.0

5.3 COATING PROCEDURE AND APPLICATION

5.3.1 Copper Slag blasted surface upon inspection and clearance by HPCL shall be
coated with one complete application of primer as soon as practicable and in no
case later than 4 hrs on the same day. Applied paint shall have the required Dry
Film Thickness (DFT) after drying which shall be measured and recorded by the
contractor and should be submitted to HPCL.

5.3.2 Each coat shall be in a proper state of cure or dryness before the application of
succeeding coat. Manufacturers instructions shall be followed for intercoat
interval.

5.3.3 The type of application may be Airspray or Airless spray or Brush application as
per manufacturer recommendation and HPCL instructions for getting satisfactory
results.

5.3.4 For each coat, the painter should know the WFT corresponding to the specified
DFT and standardize the paint application technique accordingly. This has to be
ensured in a qualification trial by Contractor.

5.4 SCAFFOLDING

Double pipe scaffolding shall be used and all the painters shall be provided with
Safety belts for ensuring accident free working.

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HINDUSTAN PETROLEUM CORPORATION LTD

5.5 DOCUMENTATION

1. A written quality Plan with procedure for qualification trials and for actual work.

2. Daily progress Report with details of humidity, surface preparation, surface profile,
Dry film thickness particulars of applications, number of coats applied, type of
materials used, methodology-Air or Airless or Brush, progress of work vs
programme.

3. Code and Batch numbers of primers and paint materials used.

4. Type of testing equipments and their calibration.

5. Elcometer and Profilemeter readings for the various components jointly recorded
with HPCL.

6. Paint consumption statement along with the Theoretical consumption


requirements.

6.0 RECOMMENDED MANUFACTURERS


ASIAN PAINTS
BERGER PAINTS
GOODLASS NEROLAC
JENSON AND NICHOLSON
SHALIMAR PAINTS
BOMBAY PAINTS

7.0 HPCL LOGO AND LETTERING


HPCL will provide their LOGO with sizing, Flow, coloring and same is to be
provided to the Tanks.
HPCL will also convey to the Contractor in writing details of the lettering for
product and tank details along with the desired color-coding and same has to be
arranged by the Contractor.

8.0 INSPECTION AND TESTING

8.1 All painting materials including primers and thinners brought to site by the

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HINDUSTAN PETROLEUM CORPORATION LTD

Contractor for application shall be directly procured from Approved manufacturers


as per specifications and shall be accompanied by Manufacturer Test Certificates.

8.2 HPCL may call for tests for the primers and paints including verification of
batchwise tests for physical and chemical analysis. The Contractor shall carry out
the same at his own cost and provide the results to HPCL.

8.3 The painting work shall be subjected to inspection by HPCL at all times. Stages of
inspection are as follows:
1) Surface preparation
2) Primer application
3) Each coat of paint
All records of inspection shall be maintained in Registers and jointly signed by
HPCL and Contractor.
Any defect noticed during the various stages of inspection shall be rectified by the
Contractor to the satisfaction of HPCL before proceeding further. Irrespective of
the inspection, repair and approval at intermediate stages of work, Contractor
shall be fully responsible for making good any defects found during Final
inspection or during the Defect Liability period. DFT shall be checked and
wherever shot same shall be made up with additional coats.

8.4 The shades of successive coats should be slightly different in colour in order to
ensure application of individual coats in consultation with manufacturer.

8.5 Calibrated Digital Elcometers, surface profile gauges (calibrated Profilemeter) and
any other inspection instrument required by HPCL shall be provided by the
contractor at site.

8.6 The contractor shall arrange expert technical support at site by paint Manufacturer
who will cross verify independently regarding surface preparation and DFT and
quality and provide a report to HPCL.

9.0 PRIMERS AND FINISH COATS DESIGNATIONS

PRIMERS
P-6 : EPOXY ZINC PHOSPHATE PRIMER

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HINDUSTAN PETROLEUM CORPORATION LTD

FINSIH COATS/ PAINTS

F-2 : ACRYLIC POLYURETHANE FINISH


F-6 : HIGH BUILD EPOXY FINISH COATING
F-7 : HIGH BUILD COAL TAR EPOXY COATING
F-9 : INORGANIC ZINC SILICATE COATING

PAINTING FOR PIPING

SL.NO. TYPE OF SURFACE PAINT SYSTEM TOTAL


PIPING PREPARATION DFT IN
FIELD FINISH MICRONS
PRIMER PAINT
1 FIRE SA 2 1/2 1 COAT OF F-9 @ 65- 1 COAT OF F- P-6 AS
WATER 75 MICRONS DFT/ 6 @ 100 STRIPE
COAT + MICRONS COAT
1 COAT OF P-6 @ 40 DFT/COAT+ 1 (RED
MICRONS DFT/ COAT OF F-2 SHADE);
COAT @ 40 F-6
(65+40=105) MICRONS (GREY)
DFT/COAT AND F-2
(100+40 (FIRE
=140) RED;
IS:536)
2 FOAM SA 2 1/2 1 COAT OF F-9 @ 65- 1 COAT OF F- P-6 AS
75 MICRONS DFT/ 6 @ 100 STRIPE
COAT + MICRONS COAT
1 COAT OF P-6 @ 40 DFT/COAT+ 1 (RED
MICRONS DFT/ COAT OF F-2 SHADE);
COAT @ 40 F-6
(65+40=105) MICRONS (GREY)
DFT/COAT AND F-2
(100+40 (GOLDEN
=140) YELLOW;
IS:356)

ALL WELD JOINTS SHALL BE BUFFED AND COATED WITH STRIPE COAT OF
EPOXY ZINC PHOSPHATE PRIMER PRIOR TO TAKING UP F-6

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HINDUSTAN PETROLEUM CORPORATION LTD

PAINTING FOR FLOATING ROOF TANKS: INTERNAL

SL.NO. COMPONENT SURFACE PAINT SYSTEM TOTAL


PREPARATION DFT IN
FIELD FINISH MICRONS
PRIMER PAINT
1 Underside of Floating SA 2 1/2 1 COAT OF F-9 @ 3 COAT OF F-6
roof deck and pontoon 65-75 MICRONS F-6(AMINE (GREY)
bottom, product side of DFT/ COAT CURED) @ Total=365
annular and sketch 100 microns
bottom plate, inside MICRONS
surface of shell upto 1m DFT/COAT
ht from bottom, outer (300)
surface of still well from
bottom to max. Liquid
level, structural steel
roof ladders, ladder on
still well, roof supports
upto long leg ht, datum
plate, inside face of all
shell nozzles and
trough.
2 Inside pontoon SA 2 1/2 1 COAT OF F-9 @ 2 COAT OF F-6
65-75 MICRONS F-6(amine (GREY)
DFT/ COAT cured) @ 80 Total=225
MICRONS microns
DFT/COAT
(80x2=160)

ALL WELD JOINTS SHALL BE BUFFED AND COATED WITH STRIPE COAT OF
EPOXY ZINC PHOSPHATE PRIMER PRIOR TO TAKING UP F-6.

PAINTING FOR FLOATING ROOF TANKS: EXTERNAL


SL.NO. COMPONENT SURFACE PAINT SYSTEM TOTAL DFT IN
PREPARATION MICRONS
FIELD FINISH PAINT
PRIMER
1 Soil side of SA 2 1/2 1 COAT OF F-9 3 COATs OF F-7 @ Total=365 microns
bottom plates @ 65-75 100 MICRONS 1 coat-black shade; 2 nd
MICRONS DFT/ DFT/COAT (300) coat: tanned brown and
COAT 3 rd coat: black)

2 External shell, SA 2 1/2 1 COAT OF F-9 1 COAT OF F-6(AMIDE F-6(Grey)


wind girders, WG @ 65-75 CURED)@ 100 Total=285microns)
supports, Floating MICRONS DFT/ MICRONS DFT/COAT
COAT + 1 COAT + 2 COATS OF F-2 @
roof topside with
OF P-6(RED) @ 40MICRONS
associated 40 MICRONS DFT/COAT
structurals, roof DFT/COAT (100+2 X40=180)
supports above (65+40=105)

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HINDUSTAN PETROLEUM CORPORATION LTD
roof, rolling
ladder, spiral
stairway incldg.
Gratings,
chequered plates,
kerb angle, foam
dam, hatches,
covers, pontoon
top, sides and
deck top
3 Inside surface of SA 2 1/2 1 COAT OF F-9 1 COAT OF F-6(AMIDE F-6(Grey)
shell from top @ 65-75 CURED)@ 100 Total=285microns)
edge to Max. MICRONS DFT/ MICRONS DFT/COAT
COAT + 1 COAT + 2 COATS OF F-2 @
design liquid
OF P-6(RED) @ 40MICRONS
level(that is, 40 MICRONS DFT/COAT
1.50m above DFT/COAT (100+2 X40=180)
Max. liquid level) (65+40=105)

4 All still well pipes SA 2 1/2 1 COAT OF F-9 1 COAT OF F-6(AMIDE F-6(Grey)
above max. liquid @ 65-75 CURED)@ 100
Total=285microns)
level MICRONS DFT/ MICRONS DFT/COAT
COAT + 1 COAT + 2 COATS OF F-2 @
OF P-6(RED) @ 40MICRONS
40 MICRONS DFT/COAT
DFT/COAT (100+2 X40=180)
(65+40=105)

ALL WELD JOINTS SHALL BE BUFFED AND COATED WITH STRIPE COAT OF EPOXY ZINC
PHOSPHATE PRIMER PRIOR TO TAKING UP F-6.

PAINTING FOR FIXED CONE ROOF OF INTERNAL FLOATING ROOF TANKS:


EXTERNAL

SL.NO. COMPONENT SURFACE PAINT SYSTEM TOTAL DFT IN


PREPARATION MICRONS
FIELD FINISH PAINT
PRIMER
1 EXTERNAL SA 2 1/2 1 COAT OF F-9 1 COAT OF F-6(AMIDE F-6(Grey)
SURFACE OF @ 65-75 CURED)@ 100 Total=285microns)
FIXED CONE MICRONS DFT/ MICRONS DFT/COAT
COAT + 1 COAT + 2 COATS OF F-2 @
ROOF OF
OF P-6(RED) @ 40MICRONS
INTERNAL 40 MICRONS DFT/COAT
FLOATING ROOF DFT/COAT (100+2 X40=180)
(65+40=105)

ALL WELD JOINTS SHALL BE BUFFED AND COATED WITH STRIPE COAT OF EPOXY ZINC
PHOSPHATE PRIMER PRIOR TO TAKING UP F-6.

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