ITP RevB With Attachments

Page 1 of 15

INSPECTION AND TEST PLAN

SURFACE PREPARATION AND PAINTING

Company: COMPANY:

GASCO

CONTRACTOR:

Agreement No:1352480 PLANT LOCATION: RUWAIS

ABU DHABI GAS INDUSTRIES

LTD. (GASCO) PROJECT: RUWAIS 4

th NGL TRAIN.

SUB-CONTRACTOR:

J1-197/07/008 PROJECT NO.5248 Doc.No.5248-00-AA-SEC-S-4001 REV.B

DOC.TYPE: SC09

DOC. CLASS : 02

B 17 MAY 11 15 Issued for Company Review Mykyta Pavlyk Mykyta Pavlyk Mahmoud Maleri

A 30 APR 11 10 Issued for Internal Review Mykyta Pavlyk Mykyta Pavlyk Mahmoud Maleri

Rev. Date Page Description Prepared Checked Approved

Page 2 of 15

REVISION RECORD SHEET

NOTES

i) Revisions after A are denoted by a vertical line in the left hand margin against the

revised text, with the revision number displayed next to the revision line as shown

by the example on the left.

ii) Revision Numbers are issued for Client approval. Implementation after Client

approval is Rev. A. Subsequent revisions shall be B, 0, 1, 2, 3 etc.

No. Date Description of Revision Status By App.

B May,17th

,2011 Issued for Company Review SCECO PETROFAC

A April, 30

th 2011

Issued for Internal Review SCECO PETROFAC

LEGENDS:

H-HOLD: A verification stage where inspection of work must be carried out

before work can proceed to the next stage. Advance notice shall be given to all parties. The Company / Contractor Inspector shall sign the testing record

W- WITNESS: A verification stage where the inspection, testing or performance of

a work activity is to be witnessed and for which advance notification shall be given to the parties. Work may proceed if the notified parties do not attend. SCECO QA/QC shall submit a report for the activity which the parties did not attend for records

R-REVIEW: The examination of inspection records and / or certificate applicable

to an inspection, test or activity. Notification not required for review point.

M-MONITOR: A verification method that permits the observance of inspections,

testing or the performance of a work activity at a frequency as deemed necessary to ensure work conformity. RFI not required.

ABU DHABI GAS INDUSTRIES LTD.(GASCO)

Ruwais 4th NGL Train. Painting works

INSPECTION AND TEST PLANINSPECTION AND TEST PLANINSPECTION AND TEST PLANINSPECTION AND TEST PLAN

Doc.No.5248-00-AA-SEC-S-4001 rev.B Activity : Surface Preparation and Painting

Sheet 3 of 15

Location: Mussafah, Abu Dhabi

Item Item Item Item No.No.No.No.

Description of Description of Description of Description of

activityactivityactivityactivity

ReferenceReferenceReferenceReference

DocumentsDocumentsDocumentsDocuments

Acceptance CriteriaAcceptance CriteriaAcceptance CriteriaAcceptance Criteria

Verifying Verifying Verifying Verifying

Documents Documents Documents Documents / / / /

QC RecordQC RecordQC RecordQC Record

SCECO SCECO SCECO SCECO

ResponsiResponsiResponsiResponsible ble ble ble

PersonPersonPersonPerson

Responsibilities Responsibilities Responsibilities Responsibilities / / / / Inspection Inspection Inspection Inspection

PointsPointsPointsPoints

SCECOSCECOSCECOSCECO PETROFACPETROFACPETROFACPETROFAC GASCOGASCOGASCOGASCO

1 Preliminaries

1.1 Approval of

painting

systems and

paint materials

DGS 6600 010

Rev.0 & 5248 -

PS-6600-

010/003 Rev.4

or as advised by

Client

As per Specs

Paint

Manufacturer

Certificate,

approved

MAR

Painting

Supervisor/

Inspector

H

H

H

2 Materials, Tools, Personnel

2.1

Tools &

Equipments

DGS 6600 010

Rev.0 &

5248-PS-6600-

010/003 Rev.4

Coating Equipment: spray

pressure, tip size and fan

angle to match paint supplier

recommendations

QC Equipment: Calibration of

DFT gauges at start of

production & then every

three hours (depending on

frequency of use)

Inspection

Certificates

Painting

Supervisor/

Inspector

H

H

M/R

2.2 Compressed Air

Quality (Blotter

Test)

DGS 6600 010

Rev.0 &

5248-PS-6600-

010/003 Rev.4

No indication of oil

discolouration and no

indication of water and

moisture contaminants

Daily Painting

Inspection

Report

Painting

Inspector

H

M/R

M/R

2.3 Check experience

of blasters,

painters,

inspector

According to

Client

requirements

SCECO should employ

personnel with adequate

knowledge and experience

Minutes of

Meeting,

Org.chart

Managing

Director H H R




Doc.No.5248-00-AA-SEC-S-4001 rev.B

Activity : Surface Preparation and Painting

Sheet 4 of 15







Page 5 of 15


Item Item Item Item No.No.No.No.



ReferenceReferenceReferenceReference DocumentsDocumentsDocumentsDocuments


Verifying Verifying Verifying Verifying Documents Documents Documents Documents / / / / QC RecordQC RecordQC RecordQC Record

SCECSCECSCECSCECO O O O





SCECOSCECOSCECOSCECO PetrofacPetrofacPetrofacPetrofac GASCOGASCOGASCOGASCO

2.4 Coating test

panel

preparation for

each system

DGS 6600 010

Rev.0 &

5248-PS-6600-

010/003 Rev.4

Paint system parameters for

each plate match

specification. Paint systems

numbers:2,3,4,8,9,32

PQT Status

report

Painting

Supervisor/

Inspector H H H

2.5

Abrasive (Type,

Size and

Condition)

DGS 6600 010

Rev.0 &

5248-PS-6600-

010/003 Rev.4

Shall conform with ISO 8504-

2

Daily Painting

Inspection

Report &

Test Certif.

Painting

Supervisor/

Inspector H M/R M/R

3. ENVIRONMENTAL CONDITIONS (Before and during surface preparation; before, during and after paint application)

3.1 Ambient Air

Temperature

DGS 6600 010

Rev.0

&

5248-PS-6600-

010/003 Rev.4

Minimum ambient air

temperature 4oC

Daily Painting

Inspection

Report

Painting

Inspector H M/R M/R

3.2 Metal

Temperature

DGS 6600 010

Rev.0

&

5248-PS-6600-

010/003 Rev.4

Maximum temperature shall

be as per Manufacturer

recommendations; Minimum

3°C above dew point

Daily Painting

Inspection

Report

Painting

Supervisor/

Inspector H M/R M/R






Page 6 of 15


IteIteIteItem m m m No.No.No.No.



ReferenceReferenceReferenceReference DocumentsDocumentsDocumentsDocuments






Responsible Responsible Responsible Responsible





3.3 Dew Point DGS 6600 010

Rev.0

&

5248-PS-6600-

010/003 Rev.4

As per specification;

Temperature at which no

condensation on substrate

Daily Painting

Inspection

Report

Painting

Supervisor/

Inspector H M/R M/R

3.4 Relative Humidity DGS 6600 010

Rev.0 & 5248-

PS-6600-

010/003 Rev .4

Maximum relative

humidity 85 percent

Daily Painting

Inspection

Report

Painting

Supervisor/

Inspector H M/R M/R

4. SURFACE PREPARATION

4.1

Preparation grades

of welds, cut edges

and other areas

with surface

imperfections

DGS 6600 010

Rev.0

&

5248-PS-6600-

010/003 Rev.4

Sharp edges, Fillets,

Corners and weld seams

shall be radiused to a

minimum of 3 mm

Daily

Painting

Inspection

Report

Painting

Supervisor/

Inspector

H

M

M

4.2

Check for grease,

dust and

contaminants

(soluble salts)

removal

DGS 6600 010

Rev.0

&

5248-PS-6600-

010/003

Rev 4

No contaminants and

foreign particles

Daily

Painting

Inspection

Report

Painting

Supervisor/

Inspector H W W/R






Page 7 of 15
















SCECOSCECOSCECOSCECO PPPPETROFACETROFACETROFACETROFAC GASCOGASCOGASCOGASCO

4.3

Surface

preparation and

roughness check

during blasting

DGS 6600 010

Rev.0 & 5248-

PS-6600-

010/003 Rev.4

Surface cleanliness for CS,

Sa 2.5 Surface Profile : 60-

75 microns for CS

Daily Painting

Inspection

Report

Painting

Supervisor/

Inspector H W W/R

4.4

Cleaning of surface

after blasting (salt

test)

DGS 6600 010

Rev.0 &

5248-PS-6600-

010/003 Rev.4

Dust on Substrate as per

rating 2, Salt level shall be

20mg/m2

Daily Painting

Inspection

Report

Painting

Supervisor/

Inspector H W W/R

5. PRIMER APPLICATION: 1st

COAT

5.1 Time after blasting DGS 6600 010

Rev.0

&

5248-PS-6600-

010/003 Rev.4

Blast cleaned surfaces

shall be primed within 4

hours. Note: 2hr if the

shift is changing

Daily Painting

Inspection

Report

Painting

Supervisor/

Inspector H W M/R

5.2

Application of

primer / First Coat

DGS 6600 010

Rev.0

&

5248-PS-6600-

010/003 Rev.4

As per paint data sheet Daily Painting

Inspection

Report

Painting

Supervisor/

Inspector H M/R M/R






Page 8 of 15









Documents Documents Documents Documents

/ / / / QC RecordQC RecordQC RecordQC Record






SCECOSCECOSCECOSCECO PetrofacPetrofacPetrofacPetrofac GASCOGASCOGASCOGASCO 5.3 Wet film

thickness

DGS 6600 010 Rev.0

&

5248-PS-6600-

010/003 Rev.4

As per paint data sheet Daily

Painting

Inspection

Report

Painting

Supervisor/

Inspector H M/R M/R

5.4 Dry film

thickness

DGS 6600 010 Rev.0

&

5248-PS-6600-

010/003 Rev.2

The max. And min.

values shall be as per

5248-6600-010/003

Rev.4

Daily

Painting

Inspection

Report

Painting

Inspector H H W/R

5.5 Visual

examination

DGS 6600 010 Rev.0

&

5248-PS-6600-

010/003 Rev.4

As per Specification

Requirements.

No defects

Daily

Painting

Inspection

Report

Painting

Inspector H W/R W/R

5.6 Rub test (only

for inorganic

zinc primer)

DGS 6600 010 Rev.0

&

5248-PS-6600-

010/003 Rev.4


Requirements

Daily

Painting

Inspection

Report

Painting

Inspector H W/R W/R

6.6.6.6. APPLICATION OF INTERMEDIATE / 2APPLICATION OF INTERMEDIATE / 2APPLICATION OF INTERMEDIATE / 2APPLICATION OF INTERMEDIATE / 2ndndndnd &&&& 3333rdrdrdrd/ COATS/ COATS/ COATS/ COATS

6.1 Time after

primer

application

DGS 6600 010 Rev.0

&

5248-PS-6600-

010/003 Rev.4

As per paint data sheet Daily

Painting

Inspection

Report

Painting

Supervisor/

Inspector H M/R M/R



INSPECTION INSPECTION INSPECTION INSPECTION AND TEST PLANAND TEST PLANAND TEST PLANAND TEST PLAN



Page 9 of 15














Responsibilities Responsibilities Responsibilities Responsibilities / / / /

Inspection PointsInspection PointsInspection PointsInspection Points


6.2 Cleaning of

surface before

painting

DGS 6600 010 Rev.0

&

5248-PS-6600-

010/003 Rev.4

As per paint data

sheet

Daily Painting

Inspection

Report

Painting

Supervisor/

Inspector H M/R M/R

6.3 Application of

intermediate

coat / 2nd

& 3rd

/

Coat

DGS 6600 010 Rev.0

& 5248- PS-6600-

010/003 Rev.4

As per paint data

sheet

Daily Painting

Inspection

Report

Painting

Supervisor/

Inspector H M/R M/R

6.4 Wet film

thickness

DGS 6600 010 Rev.0

& 5248- PS-6600-

010/003 Rev.4

As per paint data

sheet

Daily Painting

Inspection

Report

Painting

Supervisor/

Inspector

H M/R M/R

6.5 Dry film

thickness

DGS 6600 010 Rev.0

& 5248- PS-6600-

010/003 Rev.4

The max. And Min.

Values shall be as per

5248-6600010/003

Rev.2

Daily Painting

Inspection

Report

Painting

Inspector H H W/R

6.6 Visual

examination

DGS 6600 010 Rev.0

& 5248- PS-6600-

010/003 Rev.4


Requirements

No defects

Daily Painting

Inspection

Report

Painting

Inspector H W W/R

7777 APPLICATION OF 3APPLICATION OF 3APPLICATION OF 3APPLICATION OF 3RDRDRDRD/FINAL COAT/FINAL COAT/FINAL COAT/FINAL COAT

7.1 Check for

prescribed

colour code

DGS 6600 010 Rev.0

& 5248- PS-6600-

010/003 Rev.2

As per Approved

Paint System

Daily Painting

Inspection

Report

Painting

Supervisor/

Inspector

H H H






Acceptance Acceptance Acceptance Acceptance

CriteriaCriteriaCriteriaCriteria









SCECOSCECOSCECOSCECO Petrofac GASCO

7.2 Time after

previous coat

DGS 6600 010 Rev.0

& 5248- PS-6600-

010/003 Rev.2

As per paint data

sheet

Daily Painting

Inspection

Report

Painting

Supervisor/

Inspector

H M/R M/R

7.3 Cleaning of

surface before

painting

DGS 6600 010 Rev.0

& 5248- PS-6600-

010/003 Rev.2

As per paint data

sheet

Daily Painting

Inspection

Report

Painting

Supervisor/

Inspector

H M/R M/R

7.4 Application of

Top Coat / Final

Coat

DGS 6600 010 Rev.0

& 5248- PS-6600-

010/003 Rev.4

As per paint data

sheet

Daily Painting

Inspection

Report

Painting

Supervisor/

Inspector

H M/R M/R

7.5 Wet film

thickness

DGS 6600 010 Rev.0

& 5248- PS-6600-

010/003 Rev.4

As per paint data

sheet

Daily Painting

Inspection

Report

Painting

Supervisor/

Inspector H M/R M/R

7.6

Dry film

thickness

DGS 6600 010 Rev.0

& 5248- PS-6600-

010/003 Rev.4

The max. and min

values shall be as

per 5248- PS-6600-

010/003 Rev.4

Daily Painting

Inspection

Report

Painting

Inspector H H W/R

7.7

Visual

examination

DGS 6600 010 Rev.0

& 5248- PS-6600-

010/003 Rev.4

As per approved

paint system

No defects

Daily Painting

Inspection

Report

Painting

Inspector H W W/R






Page 10 of 15







Page 11 of 15







Acceptance Acceptance Acceptance Acceptance

CriteriaCriteriaCriteriaCriteria







Responsibilities Responsibilities Responsibilities Responsibilities / / / /

Inspection PointsInspection PointsInspection PointsInspection Points


8.1

Adhesion Test

(Pull-off/cross-

cut)

DGS 6600 010 Rev.0

& 5248- PS-6600-

010/003 Rev.4

Pull-off value should

be 15 kg/cm2 (ISO

4624) Cross-cut shall

be maximum grade

C2 (ISO 2409)

Paint

manufacturer

report (paint

system

qualification)

Painting

Inspector

H H H

8888 TESTINGTESTINGTESTINGTESTING

9999 REPAIRING (if any)REPAIRING (if any)REPAIRING (if any)REPAIRING (if any)

10101010 PAINT TOUCHPAINT TOUCHPAINT TOUCHPAINT TOUCH5555UP AND FINAL ACCEPTANCEUP AND FINAL ACCEPTANCEUP AND FINAL ACCEPTANCEUP AND FINAL ACCEPTANCE

10.1 Cleaning of

surface and

application of

paint

DGS 6600 010 Rev.0

&

5248-PS-6600-

010/003 Rev 4

As per paint data

sheet

Final Inspection

Report

Painting

Supervisor/

Inspector H W W/R

10.2 Completion of

painting for

final acceptance

and release

DGS 6600 010 Rev.0

&

5248-PS-6600-

010/003 Rev 4

No defects

DFT as per

requirement

Final Inspection

Report

Painting

Inspector H H W/R

Page 12 of 15

STEEL CONSTRUCTION ENGINEERING COMPANY, ABU DHABI

PROJECT: RUWAIS 4th

NGL TRAIN. PAINTING WORKS

DAILY PAINTING INSPECTION REPORT

Customer : Paint Spec. :

Contract No. : Location :

Job Title : Report NO. :

Job NO. : Date :

Item

ISO Line

No. :

DESCRIPTION OF ITEMS PAINTED

Working Conditions Internal / External Insp.Equipment Used Identificati

on No.

l. Hydrometer

Time (hrs) 2.DP / RH Calculator

Air Temp WB 3.Temperature Gauge

(O C) DB 4.Hypodermic Nle Gauge

Dew Point (O C) 5.Surface Profile Gauge

Relative Humidity % 6.WFT Gauge

Metal Temp (O C) 7.DFT Gauge

SURFACE PREPARATION:

From

To

PROFILE MEASUREMENT

TAPE:

Abrasive Blasting : Manual / Auto Pre-Blast Cleaning : Manual / Power

Abrasive Type : Blasting Degree(Grade) :

Blotter Test: Surface Finish :

Nozzle Preasure: Surface Profile : Microns

Dust level / High pressure water wash : Salt Contamination Test Result :

Last Adhesion test date: Adhesion test results:

PAINT APPLICATION

Time after previous coat:

From: ______________________________hrs

To:________________________________ hrs

Coating Manufacturer : Airless Spray Machine No :

Paint

Product/

Coat

Batch No. Mix Ratio Application

Methods Colour WFT. DFT. Total DFT

Overcoat

Time

Remarks:

Visual acceptance :

Prepared By SCECO Painting QC : Verified by Petrofac Representative : Approved by Gasco/TPI:

Name Name & Sign. Name & Sign.

Signature Position Position

Date Date Date

Page 13 of 15

STEEL CONSTRUCTION ENGINEERING CO

DFT REPORTDFT REPORTDFT REPORTDFT REPORT

Job Order / IPN No : Report No.:

Location : Client Name :

Paint System : Date :

Paint Manufacturer:

S.No Pipe # Item Code Heat No Size QTY DFT( µ ) Min in

( µ )

Max in

( µ )

Average

DFT( µ )

1

2

3

4

Remarks if any:

SCECOSCECOSCECOSCECO Painting InspectorPainting InspectorPainting InspectorPainting Inspector Petrofac GSPetrofac GSPetrofac GSPetrofac GS ---- JVJVJVJV GASCO / TPIGASCO / TPIGASCO / TPIGASCO / TPI

Name : Name : Name :

Position : Position : Position :

Signature : Signature : Signature :

Date : Date : Date :

Page 14 of 15

Steel Construction Engineering Co

FINAL INSPECTION REPORT PAINTING

Contract No: Date :

Job title: Test Panel Report No:

Location : Job Order:

Specification Reference :

Item(s):

Drawing No:

Piping ISO No :

Painting Specification: Surface preparation :

Paint System : Surface profile :

No. of coat applied : Total DFT:

Curing Test: Adhesion test:

Remarks : QC report attached

SCECO Painting QC Inspector Name &

Signature

Petrofac GS-JV Name & Signature Company/TPI Name & Signature

Page 15 of 15

STEEL CONSTRUCTION ENGINEERING CO

PULL-OFF ADHESION TEST REPORT

Date: time :

Report No.:

Job Order/ IPN No.:

Location : SCECO Painting Workshop ICAD , Mussaffah. Client Name : Petrofac /GASCO

Item Description :

PULL-OFF ADHESION TEST RESULTS

Client Paint System :

Location Of Test Coat Generic Value (psi)

Adhesion Failure (in %)

Cohesion Failure (in

%)

Glue Failure (in %) Location Of Failure

Primer

Mid Coat

Final Coat

LEGEND FOR LOCATION OF FAILURE

A = SUBSTRATE

B = PRIMER COAT

C= MID COAT

D- FINAL COAT

Y = ADHESIVE

Z = DOLLY

PAINT MANUFACTURER'S NAME : JOTUN

Remarks if any:

Paint Manufacturer

Signature and Date

QC Inspector

Signature and Date

Petrofac GS JV Stamp and Date

GASCO/TPI Signature and Date

Stamp and Date