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N-PARAFFINS & LAB PLANT PROJECT PROTECTIVE PAINT AND COATINGS

PART V SECT 2.11

16940-00-SP-837

STANDARDS

 

PROJECT SPECIFICATION

 

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REVISION

O1

02

03

04

05

DATE

SEPT 02

ORIG BY

D Brittain

APP BY

A Bryce

QA REVIEW:

 

ENGINEERING STANDARD

PROTECTIVE PAINT AND COATINGS

CONTENTS

Issued

for

ITB

SECTION

SUBJECT

1.

GENERAL

2.

REFERENCES

2.1.

Miscellaneous Standards

3.

DEFINITIONS

4.

DESIGN REQUIREMENTS

5.

SURFACE PREPARATION

5.1.

Shop Preparation

5.2.

Field Preparation

6.

APPLICATION CONDITIONS

6.1.

Weather and Surface Conditions

6.2.

Compressed Air

6.3.

Paint Mixing

6.4.

Film Thickness

6.5.

Application

7.

APPLICATION RESPONSIBILITY

7.1.

General

7.2.

Safety Requirements

7.3.

Inspection Requirements

8.

GALVANISED ITEMS

8.1.

Requirements

8.2.

Repairs

9.

VENDOR STANDARD SYSTEMS

9.1.

General

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PART V SECT 2.11

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N-PARAFFINS & LAB PLANT PROJECT PROTECTIVE PAINT AND COATINGS

STANDARDS

PROJECT SPECIFICATION

10.

MATERIALS

10.1.

General

10.2.

Material Storage

11.

DOCUMENTATION

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N-PARAFFINS & LAB PLANT PROJECT PROTECTIVE PAINT AND COATINGS

PART V SECT 2.11

16940-00-SP-837

STANDARDS

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PROJECT SPECIFICATION

1.

GENERAL

This Project Standard outlines the requirements for the protection of the external surfaces of carbon and low alloy steels (less than 12% Cr) and insulated 300 series stainless steel from corrosion.

The protective coating system specified includes surface preparation, paint material selection, paint application method, inspection requirements and acceptable nominal dried film thicknesses.

Plant items covered by this Project Standard include above ground piping, equipment, non-galvanised structural steelwork, furnace plating, storage tanks and other miscellaneous unprotected steel items. This Project Standard excludes internal linings, protective coatings applied specifically for transportation and shipment, and painted markings applied to identify materials of construction.

This Project Standard does not specify high temperature resistant painting systems for operating temperatures above 600 o C.

This Project Standard shall be read in conjunction with Licensor and Saudi Arabian mandatory standards, codes and regulations that also apply. In the event of any conflict, CONTRACTOR shall seek clarification from GULF FARABI before proceeding.

2.

REFERENCES

The following documentation is referenced within the text of this Project Standard:

2.1. Miscellaneous Standards

The latest edition of the following standards shall apply:

NACE Standard RP0287

BS 1461

Field Measurement of Surface

Profile

Cleaned Surfaces Using a Replica Tape

Abrasive Blast

of

dip

galvanised coatings on iron and steel articles

Specification

for

hot

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PART V SECT 2.11

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STANDARDS

 

PROJECT SPECIFICATION

 

BS 5493

Code of practice for protective coating of iron and steel structures against corrosion

BS 7079 Pt.A1/ISO 8501-1 Specification for rust grades and preparation grades of uncoated steel substrates after overall removal of previous coatings

SSPC-SP1

Steel

Structures Painting

 

Council Surface Preparation Specification No.1 – Solvent Cleaning

 

SSPC-PA2

Steel

Structures

Painting

 

Council

Standard

-

Measurement

of

Dry

Film

Thickness

with

Magnetic

Gauges

3.

DEFINITIONS

The following definitions of terms used within this Project Standard shall apply:

Shop

Preparation and painting of new, bare steel surfaces in a VENDOR’S shop or plant works prior to transportation to the site of construction or a controlled environment paint facility erected at the permanent site of construction

Field

Preparation and painting of new, bare or shop primed steel surfaces or even completely painted shop steel surfaces at the permanent site of plant construction

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N-PARAFFINS & LAB PLANT PROJECT PROTECTIVE PAINT AND COATINGS

PART V SECT 2.11

16940-00-SP-837

STANDARDS

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PROJECT SPECIFICATION

 
 

Protective Coating System

The

complete

and

total

 

protection

including

surface

preparation

and

intercoat

cleaning,

primer

material,

undercoat

and

top

coat

materials

 

DFT

Nominal dried film thickness

4.

DESIGN REQUIREMENTS

Equipment surfaces requiring protective coating shall be prepared and primed as a minimum in VENDORS’ shops, ready for paint over-coating, unless identified in Table 2 as being supplied to site fully painted.

Shop applied coatings shall be dried and cured sufficiently to permit transport to the construction site without excessive damage.

Field applied finishing coatings shall be subject to the requirements of this Project Standard and shall include repair and touch-up of shop applied coatings.

Equipment and piping welds shall not be painted until all approved heat treatment, non-destructive testing, and pressure testing has been completed and approved.

Shop and field weld margins subject to field inspection shall have the surface prepared and taped for a distance of 50mm either side of the weld line in the shop. The protective tape shall be of sufficient quality to protect the achieved profile from deterioration. Unless coated with a primer that is safe for welding, previously painted surfaces that require further fabrication shall have all coatings completely removed from areas about 50mm wide either side of the line of burning or welding. The remainder of the paint shall be chamfered back for approximately a further 100mm to

150mm.

CONTRACTOR shall ensure that all slag, spatter and flux residues are removed from welded areas and grind out any sharp edges. Prior to painting, the weld and surrounding area shall be prepared by washing thoroughly with fresh water followed by chipping or blast-cleaning. Preparation shall include the cleaning of the chamfered paint edges and the removal of any burnt or scorched paint.

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N-PARAFFINS & LAB PLANT PROJECT PROTECTIVE PAINT AND COATINGS

STANDARDS

PROJECT SPECIFICATION

Particular attention shall be paid to the preparation and painting of corners, edges, welds, rivet heads, small brackets, nuts and interstices. Prior to applying each coat of the coating system, these positions shall be pre-coated by brush, i.e. 'stripe coated' to ensure specified DFT is achieved.

Care shall be taken to preserve the friction characteristics of faying surfaces of structural connections made with high strength friction - grip bolts and guidance given in BS 5493, Clause 25, shall be followed.

Aluminium paint shall not be applied to any steel or iron surfaces likely to attain a temperature greater than 100°C in any building where inflammable vapour may be present.

At the construction site, CONTRACTOR shall be responsible for properly handling and storing the primed and painted items prior to erection to minimise damage to primed and painted surfaces.

The protective coating system applied by the VENDOR to proprietary items such as motors, compressors, pumps, turbines, instrument panels, valves etc. shall be suitable for the intended operational and environmental conditions at the site of construction (refer to Section 9). The site environment shall be classified as severe tropical atmosphere.

Structural supports such as vessel skirts, legs, saddles etc., shall be painted in accordance with Table 2, Systems 5(A) or 5(B).

All non-insulated portions of insulated equipment, comprising vessel nozzles, man-way covers, brackets, clips, valves, relief valves, etc., shall be painted in accordance with temperature conditions involved.

The selected protective paint systems shall be based on the normal operating temperatures of pipework or equipment items with the following exceptions:

Items internally lined where paint systems shall be selected to suit the anticipated outside wall temperatures

Items subjected to pre-commissioning steam out where the paint system employed shall take into account the designated steam out temperature and shall be suitable for that temperature

Items affected by requirements of this standard

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STANDARDS

N-PARAFFINS & LAB PLANT PROJECT PROTECTIVE PAINT AND COATINGS

PROJECT SPECIFICATION

PART V SECT 2.11

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All predictable, (not emergency and/or upset), temperature for known periods of either recurring frequency and/or prolonged duration.

The following surfaces and items shall not be painted unless specifically instructed otherwise:

Non-insulated 300 series stainless steel unless located on the jetty

Hot dipped galvanised steel (unless for colour identification), plastic including plastic coated materials, aluminium and other non-ferrous metals

Sheeting, slate, brick, tile, glass and similar weather resistant materials

Insulation finishing materials

Buried steel piping

Insulated metal surfaces in continuous service with operating temperatures below -4ºC or above 150ºC. This excludes surfaces subject to Personnel Protection considerations

Concrete or mortar fireproofing

Machined surfaces of machinery and gasket contact surfaces

Any equipment furnished completely primed and finish coated by the VENDOR (pumps, motors and other machinery, instruments, instrument boards etc.)

Equipment nameplates or any special instructions attached or included as part of an equipment unit

Tripping mechanisms of steam turbines, valve stems, movable lineage on equipment, grease fittings, compressor or pumpshafts or any such surfaces on equipment that are normally lubricated or have close working tolerances

The items listed below shall be shielded and protected to prevent damage during surface preparation and paint material application operations. All openings, including those that are flanged or threaded shall be sealed to prevent entry of blast abrasive or paint material. After completion of painting operations all material used for shielding and sealing shall be removed unless instructed otherwise.

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N-PARAFFINS & LAB PLANT PROJECT PROTECTIVE PAINT AND COATINGS

STANDARDS

PROJECT SPECIFICATION

Nameplates

Packing glands and seals

Bearings

Rotating equipment couplings and shafts

Lubrication fittings

Pressure gauges

Gauge and Flow Indicator glasses

Motor starters

Instrument dials

Vents

Exposed linkages

Valve stems

Light bulbs, enclosures and reflectors

Air intakes

Rubber parts and plastic

Surfaces subject to Personnel Protection shall be fully painted in accordance with temperature conditions involved.

The painting requirements of individual pipes shall be identified on Line Classification Lists. CONTRACTOR shall provide details of the method of identifying protective coating systems on the Line Classification List for GULF FARABI review and approval.

CONTRACTOR shall produce a schedule of finish colours applicable to equipment, piping and structural steelwork for GULF FARABI review and approval.

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STANDARDS

N-PARAFFINS & LAB PLANT PROJECT PROTECTIVE PAINT AND COATINGS

PROJECT SPECIFICATION

PART V SECT 2.11

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5. SURFACE PREPARATION

5.1. Shop Preparation

Prior to commencement of surface preparation all surface defects likely to be detrimental to the protective painting system shall be removed. All fins at saw cuts, burrs and sharp edges shall be similarly removed. Where extensive grinding has been necessary the dressed areas shall be re-prepared to remove all rust and provide an adequate paint key.

Prior to blast cleaning all grease and oil contamination shall be removed by wiping or scrubbing the surface with rags or brushes wetted with solvent followed by a wipe down with clean dry cloths. Alternatively, proprietary emulsifying agents may be used and where this method of cleaning is employed the surface shall be thoroughly washed with clean water and then dried before proceeding.

Surface preparation shall achieve the required standards immediately prior to priming.

All blast cleaned surfaces shall be primed before visible re-rusting occurs or within four hours of the commencement of blasting. If more than the specified time elapses or visible re-rusting occurs the metal surfaces shall be lightly reblasted and where necessary washed to remove rust blooming and accumulation of soluble salts. Spent abrasive shall be completely removed from the prepared surface by either vacuum cleaning or stiff-brush sweeping.

When additional areas are blasted adjacent to newly primed areas, at least 25 mm of the previously primed area shall be reblasted, with the abrasive directed away from the coated surface.

Acid washes and other cleaning solutions or solvents including inhibitive washes intended to prevent rusting shall not be used on metal surfaces after they are blasted.

Only dry abrasive blast cleaning techniques shall be employed.

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N-PARAFFINS & LAB PLANT PROJECT PROTECTIVE PAINT AND COATINGS

STANDARDS

PROJECT SPECIFICATION

The abrasive used in installations such as wheel abators or manual blast cubicles in which the abrasive is recovered and re-used shall be a mixture of chilled iron or steel grit and steel shot able to produce the required surface profile. The abrasive mixture shall be replenished using new and worn abrasive so as to produce a consistent profile height and standard of surface cleanliness. The abrasive mixture shall be kept free of dust (including metallic particles) and debris. Abrasive blast cleaning employing sand shall not be permitted.

The amplitude of the profile of the blast-cleaned surface shall be 50-75 microns unless otherwise specified for a particular coating.

Abrasive material for blast cleaning, consisting solely of steel shot shall not be used. A mixture consisting of steel shot and at least 25% by weight steel grit is acceptable.

Expendable abrasive used for blast-cleaning shall be free of contaminants such as chlorides and other soluble salts and shall not contain metallic copper, nor more than 2% by weight of copper oxide. Expendable abrasives shall not be recycled. Sand shall not be used for blast-cleaning.

Abrasive size shall be selected to best suit the type of priming material and to satisfy the paint manufacturer’s recommendation, subject to the restriction in this standard.

Spent blast abrasive shall be completely removed from the

prepared

surface

by

either

vacuum

cleaning

or

stiff

brush

sweeping.

At the commencement of each project sample metal panels shall be prepared to demonstrate ability to comply with the specified level of cleanliness and, after approval, shall be used as the Project Standard for the remainder of the project work.

Purity and acceptability of abrasive blast cleaning quality shall be judged on the basis of visual examination using pictorial standards in accordance with BS 7079 Pt:A1/ISO 8501-1.

A non-metallic blast abrasive, i.e. aluminium oxide or garnet shall be used when abrading stainless steel surfaces. Sand shall not be used.

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STANDARDS

N-PARAFFINS & LAB PLANT PROJECT PROTECTIVE PAINT AND COATINGS

PROJECT SPECIFICATION

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5.2. Field Preparation

All the provisions for shop surface preparation shall be applicable for field preparation. If the specified requirements are impractical because of field conditions, CONTRACTOR shall submit full details of revised coating systems suitable for these field conditions for GULF FARABI review and approval prior to commencing work.

Shop prepared and primed surfaces shall be field repaired after erection of primed plant.

Over areas considered to be inaccessible after erection shop applied primer repairs, field applied primers, undercoats and finishing coats shall be applied, dried and cured before construction takes place. Care shall be taken to allow sufficient drying and curing time before moving, lifting or erecting newly painted surfaces.

Prior to mechanical preparation and application of priming paint the metal surface and feathered area of shop coating shall be solvent cleaned and thoroughly washed with clean water to remove all soluble salts and dried in a manner which will not re-deposit contaminants on to the cleaned surface.

Field surface preparation local to weld areas shall be carried out by vacuum blast method as far as is practicable within the field construction conditions. Where surface cleaning by abrasion blasting is prohibited, weld and other small areas shall be prepared by use of power tool cleaning or hand tool cleaning or a combination of these methods depending on the contour and position of the surface to be painted and a GULF FARABI approved primer material suitable for the cleaning method selected.

Surface preparation with power tool or hand tools shall be pursued to achieve a level of cleanliness in accordance with Grade C, St.3 of BS 7079: Pt. A1/ISO 8501-1.

The cleaning method(s) undertaken shall remove all weld flux, slag, weld heat oxides and weld metal spatter in addition to all loose mill scale or loose paint if present after welding and testing has been completed.

The use of Client approved grinding discs may be included to achieve the removal of tightly adhering weld splatter, but great care shall be taken to ensure that surfaces shall not be polished nor left with a detrimental roughness.

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STANDARDS

PROJECT SPECIFICATION

 

The final action of preparation prior to the application of priming paint shall be a thorough washing with clean, potable water (500ppm maximum chloride level) to remove all soluble salts from the metal surface followed by a method of drying that will not re-deposit contaminants on to the cleaned surfaces. Other surface preparation methods that meet the paint manufacturer’s requirements are acceptable, subject to GULF FARABI review and approval.

The initial coat of priming paint shall be carefully applied to ensure a thorough wetting of the prepared surfaces.

Shop applied paint shall be feathered back 50mm per coat at field welds etc. to allow the correct application and build up of required site applied paint coatings.

6.

APPLICATION CONDITIONS

6.1.

Weather and Surface Conditions

Surface preparation and painting shall not be undertaken in conditions which are favourable to surface condensation when temperatures are below 10ºC or the relative humidity is above

85%.

Surface preparation and painting shall not be undertaken when there is the likelihood of a change in weather conditions within four hours of the application which would result in air temperatures below those specified or the deposition of moisture upon the surface.

Paint materials shall not be applied over metal surfaces having temperatures less than 3ºC above the dew point or in excess of

38ºC.

Paint materials

shall not

be

applied to

steel when ambient

temperatures are expected to fall to 5ºC before the paint has dried.

Deviation from the limits specified is only permitted when backed up by the paint manufacturer and submitted for GULF FARABI review and approval.

Paint materials shall not be applied in rain, snow, fog or mist, nor to wet or damp surfaces. Paint shall not be applied to frosted or ice coated surfaces.

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STANDARDS

N-PARAFFINS & LAB PLANT PROJECT PROTECTIVE PAINT AND COATINGS

PROJECT SPECIFICATION

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Surface preparation and painting shall not be undertaken outside daylight hours at exterior locations.

6.2. Compressed Air

Compressed air supply used for blast cleaning shall be free from water and oil. Suitable air filters, separators and traps shall be provided and installed in the coolest part of the system, they shall be regularly emptied to prevent carry over of water and oil. Accumulations of oil and moisture shall be removed from the air receiver by regular purging. Air compressor shall not deliver air at excessive temperatures.

Nozzles shall be discarded and replaced when 50% worn, or when not achieving adequate anchor patterns or profiles.

Where air-operated equipment is used, the operator's hood or headgear shall be ventilated by clean cool air served through a regulator filter, to prevent blast cleaning residues from being inhaled.

6.3. Paint Mixing

Paint material shall be thoroughly mixed immediately prior to application. Mixing shall be by means of mechanical stirrers, paddle mixers, can vibrators or can shakers.

Constant mechanical agitation shall be maintained in the paint reservoir throughout paint spraying operations.

Paint component shall be mixed in the proper ratio as supplied by the paint manufacturer in proportional containers. Mixing of “guessed” quantities is not permitted. Where required, the paint manufacturer indicated induction time shall be observed. Mixed paint exceeding the pot life shall not be used.

Thinners shall only be added strictly in accordance with the paint manufacturers instructions.

The type of thinner shall comply with the paint manufacturer’s instructions.

When thinners are permissible, they shall be added during the paint mixing process.

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STANDARDS

 

PROJECT SPECIFICATION

 

6.4.

Film Thickness

 

The applied DFT over any square metre shall have average readings that are not less than nominal with 75% of the readings taken not less than nominal. No readings shall be less than 75% of the nominal.

The total dry film thickness for a multicoat system shall not be less than the added total specified dry film thicknesses.

Inadequate film thickness shall require the further application of an additional complete coat over the whole area until the dry film thickness is sufficient to meet the specified nominal. Excessive thick coats shall be removed completely by blast cleaning, and shall be re-coated according to this Project Standard.

The dry film thickness of each coating applied shall be checked by means of an elcometer or microtester dry film gauge.

Film

thickness

measuring

shall

not

include thickness of

pre-fabricating primers.

In the absence of pre-fabricating primer

film

thickness

records,

25

microns

shall

be

allowed

for

pre-fabrication

primers

whilst

checking

further

film

coat

thicknesses.

 

The dry film thickness of individual coats shall not exceed the manufacturers recommended maximum thickness and prove detrimental, i.e. wrinkling, mud cracking, general softness etc., to both the coating and/or the total system.

6.5.

Application

 

Paint materials shall only be applied by the paint manufacturer’s recommended method. Care shall be taken to select paint materials to suit the intended application method. Obtain coating manufacturer’s advise for special applications

Spray guns shall be held perpendicular to the surface being coated at a maximum distance of 300 mm from the surface and no closer than 200 mm to the surface.

Material and air pressure on the spray guns shall be regulated to achieve optimum atomization of the paint with the lowest possible pressures to avoid spray ricochet from the surface being painted.

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STANDARDS

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PROJECT SPECIFICATION

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Overlapping horizontal passes shall be made for each spray coat to obtain uniform application. Particular care shall be exercised to ensure that a uniform, complete wet coat is applied. Semi-dry spraying results in poor flow-out with excessive pinholing and shall be avoided.

Coats of paint shall be uniformly applied without sags, runs, spots, damage or contamination; such irregularities shall be removed and the affected area recoated.

Each coat of paint shall be in a proper state of cure or dryness before the application of the succeeding coat.

Equipment and/or piping shall not be painted until all approved heat treatment, non-destructive testing, and pressure testing has been completed.

Damage to each coat of paint, whether shop or field applied, shall be repaired by preparing the affected surface, in accordance with the preparation as specified and as originally carried out, cleaning and spot priming before succeeding coats of paint are applied. Surface preparation shall be carried out as stated in this standard. The extent of repair to the damaged area shall extend 50mm into sound paintwork. The sound paintwork shall be lightly prepared to etch the surface. No succeeding coat of paint shall be applied before preceding coat of paint is thoroughly dry.

Shop primed surfaces contaminated during transport and site storage shall be thoroughly washed down with fresh clean water and allowed to dry before the application of further paint coatings.

Coatings which have weathered for more than six months shall be thoroughly inspected prior to application of further coats to prevent intercoat adhesion problems.

To minimise intercoat contamination, succeeding coats shall be applied with a minimum time lapse consistent with proper drying time, work and erection schedules.

Interface adhesion problems shall be avoided by following the paint manufacturers’ recommendations and advice on preparation procedures i.e. removal of zinc salts, `mist’ coats, tie coats, etc. when commencing touch-up and/or overcoating paint work.

Roller application of the first primer coat is not acceptable. Rollers when used, shall be manufactured from good quality 'carpet pile' or lamb's wool.

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N-PARAFFINS & LAB PLANT PROJECT PROTECTIVE PAINT AND COATINGS

STANDARDS

PROJECT SPECIFICATION

When paints are applied by brushing, brushes shall be of a style and quality that will permit proper application of the material. Brushing shall be done so that a smooth coat as nearly uniform in thickness as possible, is obtained. There shall be no deep "detrimental" brush marks.

7. APPLICATION RESPONSIBILITY

7.1.

General

Certificates of release, confirming that successful completion of all appropriate tests and safety checks have been carried out to the released working areas, shall be obtained before the commencement of painting work.

All provisions of this Project Standard shall apply to both shop and field painting.

All paint application shall be carried out in a neat, thorough and workmanlike manner.

All cracks or crevices between structural components shall be filled with paint, if practicable. Cracks and crevices that are impracticable to fill with paint shall be filled with epoxy putty or an alternative material, subject to GULF FARABI review and approval.

CONTRACTOR shall ensure that wet paint is protected against damage.

All shipping tags, wires, strings and other means of temporary or shipping identification on surfaces to be painted shall be removed only after checking with and receiving authorisation from GULF FARABI.

CONTRACTOR shall be responsible for protection against damage to abutting property, vehicles, pedestrians and other portions of the structure, due to the painting operations.

CONTRACTOR shall ensure that all items in this standard are protected from paint splatter.

The working environment shall be maintained clean and neat during the paint application work.

Paints, thinners, solvents and rags, waste etc., soiled with these materials shall be kept in tightly closed containers whilst on the job site and not in use.

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STANDARDS

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PROJECT SPECIFICATION

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GULF FARABI shall have the right to stop the application of paint when in its opinion; conditions may result in damage to the applied coatings.

CONTRACTOR shall provide a temporary shelter for storage and mixing of paint materials. Storage conditions, i.e. temperatures, ventilation, etc. shall meet the paint manufacturer’s requirements.

During both application and drying, adequate ventilation shall be provided if the work area is enclosed.

7.2. Safety Requirements

CONTRACTOR shall be acquainted with safety and security requirements for equipment and materials for use on the project and, at all times, have available Safety Data Sheets for the coatings and ancillary products in use or stored at each site outside the CONTRACTORs premises.

CONTRACTOR shall observe and carry out all work in strict compliance with plant, local and national Health and Safety rules and shall obtain all necessary permits from the applicable authorities.

CONTRACTOR shall be responsible for earthing all its mechanical equipment to prevent build-up of static electricity.

The quantity of Volatile Organic Compound (VOC), in grammes per litre/pounds per gallon, shall be in compliance with the legal local, national and international values.

In general, all solvents are toxic. Skin contact and inhalation shall be avoided.

7.3. Inspection Requirements

GULF FARABI reserves the right to inspect all phases of shop and field cleaning, painting and galvanising operations to ensure that the CONTRACTOR is accurately following the recommendations and requirements of this Project Standard and the paint manufacturer's instructions. This inspection shall not be used as a substitute for adequate CONTRACTOR supervision and inspection nor the CONTRACTOR’s own quality assurance and quality control systems and procedures.

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STANDARDS

PROJECT SPECIFICATION

 

CONTRACTOR shall keep an accurate daily record of air temperatures and humidity conditions and the times of commencement and cessation of all phases of the cleaning, surface preparation and painting operations. The readings shall be registered at the start of work and at 3 hour time intervals till full curing of the last coat or repair-re-touch. These records which shall be certified accurate by the paint applicators painting supervisor shall be available for inspection by GULF FARABI at all times.

Surface preparation shall be checked using pictorial standards in accordance with BS 7079 Pt.A1/ISO 8501-1. Surface profile shall be compared visually with a surface roughness comparator or by replica tape in accordance with NACE Standard RP0287, at least four times per day, for each grade of preparation performed, and after each replenishment of abrasive.

Measurement of thickness of individual paint coatings and the total system shall be in accordance with the procedures of SSPC- PA2. Acceptable DFT shall be in accordance with Section 6.4.

Wet film thickness shall be measured at the start of application of each coat to ensure the correct dry film thickness is achieved.

The responsibility for the total cleaning, painting and galvanising operations remain entirely with the CONTRACTOR who shall fully guarantee material and workmanship for the entire protective system. Inspection, approval or comments by GULF FARABI shall not relieve the CONTRACTOR of this responsibility.

The first and succeeding field coats shall not be applied before the cleaned surface, or the preceding applied coats have been inspected and approved. Any damaged or defective coatings shall be repaired as specified and approved before preceding with any additional coats.

8.

GALVANISED ITEMS

8.1.

Requirements

Galvanised items shall be coated using the hot dipped process in accordance with the latest revision of BS 1461.

Articles to be galvanised shall be completely fabricated prior to the application of the hot dip galvanising process.

Items shall not be hot dipped before surface preparation has been carried out in a full and correct manner.

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Surfaces shall be free of old paint, oil, grease, weld, slag deposits and laminations; and rolling fabrication defects eliminated prior to hot dipping.

Coating weights shall comply with BS 1461, Table 1.

8.2.

Repairs

All loose or damaged coating shall be removed by means of power driven or hand-held wire brushes to leave a feathered edge on the existing coating. At welds, the cleaning method shall remove all weld flux, spatter, slag and heat tint.

Following removal of all unwanted surface deposits, the repair area and surrounding areas shall be washed with a suitable organic solvent in accordance with SSPC-SP1 and then bristle brush washed with clean water.

When thoroughly dry, a minimum of two coats of two-pack zinc- rich epoxy paint shall be applied by brush to provide a zinc coating of at least equal thickness to the galvanised layer in accordance with BS 1461, Appendix D.

The primer shall have a minimum of 80% metallic zinc in the dry film and all materials shall be applied strictly in accordance with the manufacturer’s recommendation. The primer shall overlap sound coating by at least 20mm and the DFT of primer shall not be less than 60 microns at any spot.

9.

VENDOR STANDARD SYSTEMS

9.1. General

On standard production equipment (i.e. motors, pumps, compressors, instruments, transformers and enclosures for switchgear) coated with VENDOR’S complete protective coating system, CONTRACTOR shall ensure that the VENDOR standard coating system is capable of providing protection from corrosion within the anticipated conditions of transportation, service life, operating temperatures and site without coating break-down. Details of the VENDOR’S standard protective coating system shall be forwarded to GULF FARABI for review and approval prior to commencement of painting.

Where VENDOR’S standard finish is used, information of the protective system shall be advised to GULF FARABI in sufficient detail for review and to enable coating repair, touch-up or over coating to be carried out without incompatibility problems arising.

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VENDORS providing only part coating system as their normal standard shall follow the requirements of this Project Standard for surface preparation and priming and identify to GULF FARABI the material of use, together with details of the material manufacturer(s).

Valves shall be supplied prime coated in accordance with the requirements of Table 2, Systems 6(A) or 6 (B).

10.

MATERIALS

10.1.

General

Coating materials shall be obtained from approved paint manufacturers using the full generic description given in Table 1.

All material shall be supplied in the paint manufacturer's original cans, durably and legibly marked with the description of the contents. This shall include the specification number, the colour reference number, the method of application for which it is intended, the batch number, date of manufacture and the paint manufacturer's name, initials, or recognised trademark. No intermixing of different brands or types of paints will be permitted.

CONTRACTOR shall supply data sheets for each type of paint which shall include the recommended minimum and maximum overcoating periods for the dry film thickness specified in this Project Standard.

Protective coating systems shall be from the same paint manufacturer to ensure compatibility unless otherwise approved by GULF FARABI.

All coating materials used shall conform to the following requirements. In meeting the composition clauses, the paint CONTRACTOR shall provide evidence of compliance and shall produce premium quality paint with the full performance required by this Project Standard.

Zinc rich primers shall be based on two pack epoxy media and shall contain a minimum of 80% metallic zinc by weight in the dry film.

Epoxy based paints, i.e. zinc rich epoxy, shall contain 40% minimum weight content of epoxy.

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Zinc silicate primer shall be based on inorganic or ethyl silicate media and shall contain not less than 85% metallic zinc by weight in the dry film.

Two-pack epoxy finishing paints shall be based on polyamide cured two-pack epoxy media and shall be pigmented with titanium dioxide and/or light fast coloured pigments to provide the necessary opacity, film build and weather resistance.

Micaceous iron oxide pigmented paint shall contain a minimum of 50% natural laminar micaceous iron oxide by weight in the dry film.

Aluminium silicone paint shall be based on a one-pack formulation comprising leafing aluminium pigment dispersed in silicone or modified silicone media. The paint shall be capable of withstanding continuous exposure to temperatures between 120 o C and 500 o C.

Mordant solution (T-wash) shall comprise a phosphoric solution incorporating copper salts in a solvent/water solution.

10.2. Material Storage

Storage of paint materials at the site of usage shall be the responsibility of the CONTRACTOR and the storage planning shall take into account the geographical and meteorological conditions and make provisions for any abnormality such as temperatures.

CONTRACTOR shall advise the coating manufacturer of the intended storage conditions and recommendations received in reply from the manufacturer shall be included in storage arrangement.

Records of paint material batch numbers together with dates of receipts of each batch shall be kept by the paint material applicator so that a sequence of storage can be arranged to ensure material is issued from store in the same sequence as received at painting venue. GULF FARABI reserves the right to inspect these records and check the issuing organisation at any time.

Storage shall take into account, and make provision for, governing local safety regulations, adequate fire prevention equipment and its maintenance and the elimination of ignition risks (e.g. no smoking, use of flame proof equipment etc.).

Purposeful spillage shall be prohibited, but sufficient inert absorbing material shall always be available for the immediate

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cleaning up of accidental spillage. The use of rags and wood dust for cleaning up of inflammable materials is not permitted.

The disposal of waste and empty containers shall be subject to regulations laid down by CONTRACTOR before the commencement of material deliveries. Empty and/or partially empty containers shall be collected and disposed of in accordance with the regulations.

Paint materials are potentially harmful to operatives and it shall be necessary to maintain a high standard of personnel hygiene. CONTRACTOR shall advise GULF FARABI of details of precautions being taken to protect all working personnel in the vicinity of paint storage and handling.

11.

DOCUMENTATION

CONTRACTOR shall ensure that detailed procedures and quality plans are submitted in accordance with this Project Standard, and covering all painting activities and shall include, but not be limited to, the following:

Safe storage and handling of materials, safe disposal of unwanted coatings and expended abrasive, etc.

Protective coating system to be used, together with current manufacturer’s data sheet

Initial preparation of welds (including dressing) and margins, removal of contamination and residues (e.g. adhesive tape)

Preliminary inspection and cleaning

Blast-cleaning method, abrasive and equipment including removal of oil and condensed water from the air stream, abrasive and replenishment

Blast-cleaning standard and surface profile, including measurement methods, and dust removal methods

Repair of damage to initial coatings including method of removal and testing of repairs

Inspection procedures to cover the requirements of paragraph 7.3, make and model of instruments, their calibration methods and frequency

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TABLE 1 - GENERIC PAINT DESCRIPTION

 

Generic Description of Required Product

Nominal DFT

Operating

(microns) (1)(2)

Service

Reference

Number

Temperature

Range (°C)

FP-101

Two pack, self curing, Zinc Silicate Coating (Ethyl Silicate based)

75

Minus 5 – 400

FP-102

Two pack, Zinc Rich Epoxy Primer

75

Minus 5 – 120

FP-103

Two pack Polyamide Cured Epoxy Primer

40

Minus 5 – 120

FP-104

Two pack, Epoxy Primer

50

Minus 5 – 120

TC-308

Two pack, Glass Flake Epoxy

400

Minus 5 - 120

UC-201

Two pack Micaceous Iron Oxide Pigmented Epoxy

125

Minus 5 - 120

TC-301

Two pack Acrylic Modified Polyurethane

50

Minus 5 - 120

TC-302

Silicone Acrylic

40

Minus 5 – 250

TC-303

Heat Resistant Silicone Aluminium

20

Minus 5 – 600

TC-304

Two pack Epoxy Phenolic

150

Minus 5 – 150

TC-305

Temperature Indicating Paint

40

(3)

TC-306

Air dried modified Silicone

50

Minus 5 – 350

TC-307

Two pack Coal Tar Epoxy

150

Minus 5 – 100

NOTES:

1) Coating manufacturer’s recommendations regarding the number of coats to achieve the specified individual dry film thickness shall be followed.

2) The dry film thickness of individual coats shall not exceed the manufacturer’s recommended maximum thickness and shall not prove detrimental to both coating and/or system

3) CONTRACTOR to define the temperature range

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PROJECT SPECIFICATION

TABLE 2 - PROTECTIVE COATING SYSTEMS

Nominal DFT for Total System (microns)

 

250

155

95

40

 

300

 

For Temperatures up to 150°C coat per System 2 (A) plus a topcoat of TC301.

For Temperatures greater than 150°C coat per System 1(B), 1(C), or 1(D) dependent on the operating temperature

115

Finishing Coats

 

TC301

mic.

By Shop

TC302

mic.

By Shop

TC303

mic.

By Shop

TC303

20mic.

By Shop

TC304

150 mic.

By Shop

TC305

mic.

By Shop

50

40

20

40

Undercoat

UC201

125 mic.

By Shop

TC302

40 mic.

By Shop

     

No paint required

 

Full

System

Primer

Non-insulated Carbon and Low Alloy Steel Towers, Drums, Exchangers, etc.

FP101

mic.

By Shop

FP101

mic.

By Shop

FP 101

mic.

By Shop

TC303

mic.

By shop

TC304

150 mic. By Shop

FP101

mic.

By Shop

75

75

75

20

Insulated Carbon and Low Alloy Steel Towers, Drums, Exchangers, etc.

75

Surface

Preparation

Sa 2½

By Shop

Sa 2½

By Shop

Sa 2½

By Shop

Sa3

By Shop

Sa 2½

By Shop

Sa 2½

By Shop

Specific Item

Operating temp. 120°C and below (including steam out conditions)

 

Operating temp. 121°C to 200°C

Operating temp. 201°C to 400°C

Operating temp. 401°C to 600°C

Items or parts of items in continuous service with operating temperatures between -4°C and 150°C (including steam out conditions)

Items in continuous service with operating Temp. 151°C and above.

Uninsulated portions of insulated items, i.e. nozzles, flanges, brackets, clips, etc.

Refractory lined reactors, etc. specified for temperature indicating Paint.

 

System

Code

1.

(A)

(B)

(C)

(D)

2.

(A)

(B)

(C)

3.

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TABLE 2 - PROTECTIVE COATING SYSTEMS (cont.)

Nominal DFT For Total System (microns)

 

300

100

 

300

250

 

250

155

95

40

Finishing Coats

 

TC304

mic.

By Shop

TC306

mic.

By Shop

TC304

mic.

By Shop

TC301

mic.

By Shop

TC301

mic.

By Shop

TC302

mic.

By Shop

TC303

mic.

By Shop

TC303

mic.

By Shop

150

50

150

50

50

40

20

20

Undercoat

     

UC201

125mic

By Shop

UC201

125 mic.

By Shop

TC302

40 mic.

By Shop

   

Full System

Primer

Insulated 300 Serious Stainless Steel Towers, Drums, Exchangers, etc. and Piping

TC304

mic.

By Shop

TC306

mic.

By Shop

TC304

mic.

By Shop

FP102

mic.

By Shop

FP101

mic.

By Shop

FP101

mic.

By Shop

FP101

mic.

By Shop

TC303

mic.

By Shop

150

50

150

75

75

75

75

20

Surface

Preparation

Sa 1

By Shop

Sa 1

By Shop

Sa2½

By Shop

Sa2½

By Shop

Non-insulated Carbon and Low Alloy Steel Piping and Fittings (1)

Sa2½

By shop

Sa2½

By Shop

Sa2½

By shop

Sa3

By Shop

Specific Item

Operating temp. 150°C and below (including steam out)

 

Operating temp 151°C to 350°C

Steel Skirts, Legs, Saddles, etc.

All Concrete Fireproofed supports

Non-fireproofed supports

Operating temp. 120°C to 200°C (including steam out conditions)

 

Operating temp. 121°C to 200°C

Operating temp. 201°C to 400°C

Operating temp. 401°C to 600°C

System Code

4.

(A)

(B)

5.

(A)

(B)

6.

(A)

(B)

(C)

(D)

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TABLE 2 - PROTECTIVE COATING SYSTEMS (cont.)

Nominal DFT For Total System (microns)

 

300

 

Coat per System 6(A), 6(B), 6(C) and 6(D), dependent on the operating temperature

 

-

Supplied by item manufacturer with temporary storage coating only.

Site coated per the requirements of either System 6(A), 6(B), 6(C), 6(D) or 7(A)

 

250

 

300

Finishing Coats

 

TC304

mic.

By Shop

 

Site coated per the requirements of either

system 6(A), 6(B), 6(C), 6(D) or 7(A)

 

TC301

50 mic.

By Shop

TC304

mic.

By Shop

150

150

Undercoat

 

No paint required

UC201

125 mic.

By Shop

 

Full System

Primer

TC304

mic.

By Shop

 

FP101

mic.

By Item

Manufacture

FP101

mic.

By Shop

TC304

mic.

By Shop

150

75

75

150

Surface

Preparation

Insulated Carbon and Low Alloy Steel Piping and Fittings (1)

Sa2½

By Shop

Sa2½

By Item

Manufacturer

 

Non-fireproofed Carbon Steel Structural Steel and Platforms

Sa2½

By Shop

Sa2½

By Shop

 

continuous

temperatures

between –4°C and 150°C (including steam

 

Items in continuous service with Operating Temps. 151°C and above.

Uninsulated portions of insulated piping, i.e. flanges, shoes, etc.

All Valves and specialty In-Line Components

All operating temperature. All items except socket weld items 2½” NB and below.

 

All operating temperatures. Socket weld items Sa2½” NB and below.

 

Fireproofed Carbon Steel Structural Steel

 

in

Specific Item

 

items

operating

of

Concrete Fireproofed

 
 

parts

with

out conditions)

or

All areas

 

Items

service

System Code

7.

(A)

(B)

(c)

8.

(A)

(B)

9.

(A)

10.

(A)

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TABLE 2 - PROTECTIVE COATING SYSTEMS (cont.)

Nominal DFT For Total System (microns)

 

Per BS 1461

Instruments and Electrical Equipment, Electrical Distribution and Control Boards, Boxes, Covers, Fittings, Switchgear, Transformers, etc.

Manufacturer’s standard Coatings and Finish (refer to Section 9) which shall be suitable for the expected operating temperatures and the site environment (Severe industrial/marine atmosphere). System shall be subject to review and approval by GULF FARABI

 

Manufacturer’s standard Coatings and Finish (see Section 9) which shall be suitable for the expected operating temperatures and the site environment (Industrial/Marine atmosphere). System shall be subject to review and approval by GULF FARABI

 

250

300

 

80

Finishing Coats

   

TC301

mic

By Shop

TC307

150 mic

TC301

mic

By Shop

Or Field

50

40

Undercoat

Handrails, Ladders, Ladder Cages, Gratings, Floor Plate and Light Standards and Fittings.

Hot dipped galvanised coating to BS 1461

Non-insulated Tankage, External Carbon Steel Surface, Operating Temperatures up to 120°C

UC201

125 mic

By Shop

 

Surfaces (when specified for colour coding only), operating temperature 120°C and below.Galvanized

 

Full System

Primer

FP102

mic

By Shop

TC307

150 mic

FP103

mic

By Shop

Or Field

Mechanical Equipment Motors, Turbines, Compressors, Pumps, Mixers, etc.

75

40

Surface

Preparation

 

Sa2½

By Shop

Sa2½

By Shop Or Field (2)

 

Specific Item

All areas

All areas

All operating Temps.

Shell Plates Fixed and Floating Roof Plates

Bottom Plates (Undersides)

All classes.

SYSTEM

CODE

11.

(A)

12.

(A)

13.

(A)

14

(A)

(B)

15.

(A)

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