PAINTING - iiiWe.com · - The purpose of this specification is to define material standard specification for painting in BANDAR ABBAS REFINERY GASOLINE PRODUCTION INCREASE PROJECT

شركت ملي مهندسي و ساختمان نفت ايران

1015: شماره پروژه

NATIONAL IRANIAN OIL ENGINEERING & CONSTRUCTION COMPANY

BANDAR ABBAS REFINERY GASOLINE PRODUCTION INCREASE PROJECT

(GENERAL)

NIOEC NO: PAGE/OF:

PIDEC PROJ. NO. 1197

UNIT/ITEM 00

PETROCHEMICAL INDUSTRIES DESIGN & ENGINEERING CO.

SPEC. NO. 00-GA-E-272000

SH/ OF

REV. 0 1 2

2 31.06.09 FINAL ISSUE (REVISED AS MARKED) AFC M.D H.G A.R

1 14.04.07 FINAL ISSUE AFC M.D H.G A.R

0 17.02.07 ISSUED FOR IMPLEMENTATION IFI A M.D H.G A.R

REV. DATE DESCRIPTION STATUSCODE

OWNER’S ACTION

PREPARED CHECKED APPROVED

Frame No. 6/0 FMT-GN-006/0 F:\1197\FORMAT\FORMAT SPEC.

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DOCUMENT TITLE:

MATERIAL STANDARD SPECIFICATION

FOR

PAINTING

ORIGINAL DOCUMENT NO: NIOEC-SP-80-02

TOTAL PAGES : 9 (EXCLUDING COVER SHEET & ATTACHMENTS)





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INTRODUCTION - The purpose of this specification is to define material standard specification for painting in BANDAR ABBAS REFINERY GASOLINE PRODUCTION INCREASE PROJECT. -Guidance for Use of this Addendum Where clauses in NIOEC-SP-80-02 are referred to in this Addendum, it means those clauses are amended by this Addendum. Other clauses in NIOEC-SP-80-02 shall remain valid based on NIOEC-SP-80-02. CONTENTS: (Page 1) Add the following sentence at the end of the list:

“APPENDIX C: SPLIT OF PAINTING WORKS” (Add)

2. REFERENCES - The following reference should be added: (Add) IPS-E-TP-100 “ENGINEERING STANDARD FOR PAINTS” IPS-C-TP-101 “CONSTRUCTION STANDARD FOR SURFACE PREPARATION” SSPC-PA2 “MEASUREMENT OF DRY FILM THICKNESS WITH MAGNET GAGES.” BS 3900-C5 “METHOD OF TEST FOR PAINT DETERMINATION OF FILM THICKNESS.” 4. GENERAL REQUIRMENT: 4.1: rubber, hoses, belts, flexible braided connectors, stainless steel (tubing, fittings and valves), gages and motor shafts. (Mod) 4.16: clause shall be deleted because this clause has repeated in 4.7 (Del) 5. SURFACE PREPARATION: - Following clause shall be added as 5.3, 5.4 and 5.5: (Add)

5.3 Manual cleaning

Manual cleaning using mechanical cleaning tools to remove mill scale and rust is the least satisfactory method of surface preparation and is used where blast cleaning is impractical or not economical. The surface produced shall be in accordance with IPS-C-TP-101 or SIS 055900 st3 or SSPC-SP 3. The manual cleaning methods shall not be used for the preparation of steel where high quality long-life systems are to be used. (Ref. to clause 8.2.3.2 of IPS-E-TP-100) 5.4 Chemical cleaning

a) Acid pickling: Pickling shall be carried out in the workshop. The surface produced shall be in accordance with IPS-C-TP-101 Section 6. The process normally comprises: - Immersion in a bath of warm dilute sulphuric acid or phosphoric acid both to remove mill scale and rust. - Washing in a bath of warm water to remove all traces of sulphuric acid. This water wash may be omitted when phosphoric acid pickling is used. - Immersion in a bath of hot dilute phosphoric acid to provide a passivated surface suitable for painting. The contents of the baths shall be discarded when the concentration is below that indicated specifically for the bath or if accumulation of sediment causes staining of the work.

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شركت ملي مهندسي و ساختمان نفت ايران & NATIONAL IRANIAN OIL ENGINEERING 1015: شماره پروژه

CONSTRUCTION COMPANY BANDAR ABBAS REFINERY GASOLINE

PRODUCTION INCREASE PROJECT

(GENERAL)

NIOEC NO:

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b) Solvent cleaning: Solvent cleaning should be used prior to the application of paint and in conjunction with surface preparation methods specified above for the removal of rust, mill scale or paint, etc. Petroleum solvents such as kerosene, mineral spirits, or chlorinated solvents such as trichloroethylene or 1.1.1 trichloroethene can be used to dissolve and remove soil. Chlorinated solvents are also effective in removing heavy oils, greases and waxes. (Ref. to clause 8.2.3.3 of IPS-E-TP-100)

5.5 Surface preparation for maintenance

Initially all areas of loosened paint and scale and all points of rusting should be located and treated in a manner essentially similar to the preparation detailed in the previous section. If such areas are sufficiently numerous as to make exact location and definition a difficult proposition, then whole paintwork should be prepared overall by sand-blasting, chipping, scraping and power wire brushing to the standards detailed in the previous section. All prepared areas shall then be degreased where necessary by solvent cleaning method. Surface preparation for maintenance shall be in accordance with IPS-C-TP-101 Section 13. (Ref. to clause 8.2.4 of IPS-E-TP-100)

8. PREPARATION OF PAINT BEFORE USE: 8.2.2.1: reference no. is 6.2.2.2 should be changed to 8.2.2.2. (Mod) APPENDIX A: PAINT SYSTEM -Page 23(Note:1)For insulated surfaces under insulation if metal skin operating temperature will be under 120°c min. 50 μm silicon modified shall be applied. (Mod) In paint system, it hasn’t considered any references and technical information for silicon aluminum and phenolic epoxy. So the following technical data shall be considered: (Add) -One coat of single pack pure silicon or silicon modified. Heat resisting paint (Aluminum).vehicle is Silicon resin-pure or suitably modified pigmented with aluminum, Volume solids 30-40% Minimum dry film thickness 25 microns (1 mil), Temperature resistance 400°C to 538°C. -Two pack epoxy phenolic with alkaline curing agent. Pigment titanium dioxide, zinc dust, inert, tinting colors and special abrasion resistance pigments.(6 mils) 150 microns dry film thickness, Volume solids percentage of 48-52.Curing in accordance with manufacturing recommendation .Temperature resistance 120°C. - For surface proofed with concrete, paint system shall be specified as following: (Add)

EXTERIOR SURFACE

TEMP.

RANGE °C

PAINT SYSTEM

DFT(DRY FILM THICKNESS)

IN MICRONS

PRIMER INTER. FINISH PC IC FC TOTAL SURFACE COAT COAT COAT PREP.NO.

SURFACE PROOFED

FIRE PROOFED WITH

CONCRETE

-

SA 2,1/2

ZINC RICH

EPOXY

-

-

75

-

-

75

2

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(GENERAL)

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- The following tables should be considered in spec. as attachments: (Add) ATTACHMENT 1

Inspection Requirements on Painting Work

NO. ITEM METHOD EXTENT CRITERIA 1. Application environmental condition 1)

2)

3)

Atmospheric Temperature Relative humidity Surface temperature to be applied

Measurement by thermometer Measurement by hygrometer Measurement by surface thermometer

Random (min.2 time/one day) Random (min.2 time/one day) Random (min.2 time/one day)

10ºC-43ºC Max. 85% (90% at field) 0ºC-50ºC & Dew point plus 3ºC over

2. Compressed air/Abrasive 1)

2)

Compressed air • Drying • Oil, etc.

Abrasive • Oil • Material

Visual with white cloth test Water test Certificate

Random (min.1 time/one day) Random (min.1 time/one day) Each batch

Not find Not find Not find

3. Surface Preparation 1)

2)

Surface cleanliness Surface Roughness only for blast surface

Visual : Comparison with standard photograph Note 1) Visual

All surfaces All surfaces

By paint system By paint system

4. Paints 1)

2)

3)

Kind of paint Condition of paint The Term of validity (Shelf life)

Check by label indication Visual or mixing by stirrer Check by label indication

All Random (min. 20%) All

The following shall not happen to a large degree : Gel, skinning, high viscosity, sedimentation within the term of validity Within the term of validity

5. Film thickness 1) Dry film thickness By dry film

thickness gage Note 2)

Random Refer to Attachment-4 for measuring procedure

More than 80% of the specified value at any point (Note 3)

6. Appearance of Paint Film - Color difference

- Mottling - Sagging - Blistering - Cracking - Flaking - Sticked foreign matter

Visual Random (min.20%) There is not a remarkable reference between color specimen and actual paint film.

NOTES: 1) Standard photograph in ISO 8501-1 or equivalent 2) The dry film thickness measure with an electro-magnetic coating thickness meter (e.g., inspector,

minitector, minitest, certotest, mikrotest)

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3) For each coat, the specified DFT shall be a target. Measurement shall be carried out three times at each measuring point. Average of three measurements shall be taken as the measured value. The minimum measured thickness shall be at least 80% of specific thickness and average measured thickness in the designated area or piece shall be more than 100% of specific thickness. The maximum dry film thickness shall be in accordance with the paint manufacturer's recommendations.

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ATTACHMENT 2

Procedure for Measurement of Dry Film Thickness

Dry film thickness shall be measured after finish coat application. Only one (1) measurement is made to each point.

1. Equipment

Painting Area Number of inspection required/each equipment

A<=3 sq.m Min. 3 points

3 sq.m <A=10 sq.m Min. 5 points

10 sq.m <A=30 sq.m 1 per 4 sq.m Min. 5 points

30 sq.m <A=100 sq.m 1 per 10 sq.m Min. 5 points

100 sq.m <A=300 sq.m 1 per 20 sq.m

300 sq.m 1 per 30 sq.m

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2. Piping

Table-1: Inspection Requirement for Painting DFT for pipe, fitting & valves at shop.

ITEM NOMINAL SIZE (Inch) LENGTH

No. of inspection

required for both end

Number of inspection

required for middle part

Number of pipes to be tested

PIPE D<=4" 5.5 m 1 0 1 per 20 Pipes Min. 1 Pipe in

Total

4<D<=10" 5.5 m 11 m

2 2

0 2

1 per 30 Pipes Min. 1 Pipe in

Total

10"<D<=24" 11 m 4 4 1 per 25 Pipes Min. 1 Pipe in

Total

FITTING D<=10" 2 0 1 per 30 Fittings Min. 1 Fitting in

Total

10"<D<=24" 4 0 1 per 25 Fittings Min. 1 Fitting in

Total

FLANGE D<=10" 2 - 1 per 30 Flanges Min. 1 Flange in

Total

10"<D<=24" 4 - 1 per 25 Flanges Min. 1 Flange in

Total

VALVE D<=10" 2 - 1 per 30 Valves Min. 1 Valve in

Total

10"<D<=24" 4 - 1 per 25 Valves Min. 1 Valve in

Total

Note: 1) Inspection shall be applied to prime and finish coats for each size of pipes.

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Table –2: Inspection requirement of painting DFT for pipe, fitting & valves at field.

ITEM NOMINAL SIZE (Inch) LENGTH

No. of inspection required

( Not Used) Number of pipes to be tested

PIPE D<=4" Every 40 m 1 Min 2 points in Total

4<D<=10" Every 40 m 1 Min 4 points in Total

10"<D<=24" Every 20 m 1 Min 8 points in Total

FITTING D<=10" 2 1 per 20 Fittings Min. 1 Fitting in

Total

10"<D<=24" 4 1 per 15 Fittings Min. 1 Fitting in

Total

FLANGE D<=10" 2 1 per 30 Flanges Min. 1 Flange in

Total

10"<D<=24" 4 1 per 25 Flanges Min. 1 Flange in

Total

VALVE D<=10" 2 1 per 20 Valves Min. 1 Valve in

Total

10"<D<=24" 4 1 per 15 Valves Min. 1 Valve in

Total Note: 1) Inspection shall be applied to prime and finish coats for each size of pipes.

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APPENDIX C (Addition)

SPLIT OF PAINTING WORKS

Item At Vendor Shop At Construction At Field Shop At Field

1. Structural Steel Primer & Intermediate Finish Coat Touch-up 2.Equipment /Heat Exchanger and Air Cooler, and Heater Boxes

External Primer ------- Intermediate & Finish Coat

Internal ------- ------- Complete Painting System

3. Tanks External ------- ------- Complete Painting

System

Internal ------- ------- Complete Painting System

4. Furnace Primer ------- Intermediate & Finish Coat

5.Ducts and Blow downs Stacks – Flare and Primer ------- Intermediate &

Finish Coat 6. Pumps, Drivers Compressors and Complete Painting

System ------- Touch-up

7. Piping Pipe, Flange Fitting, Rust Preventive Up to Primer Intermediate &

Finish Coat

Valves (Note 1) Up to Primer ------- Intermediate & Finish Coat

8. Electrical and Instrument Complete Painting System ------- Touch-up

9. Fire Equipment, Fire Hydrant, Hose Boxes etc.

Complete Painting System ------- Touch-up

Note 1: Primer for valves with operating temperature 400ºC and above shall be removed at field by power Tools, Complete Painting System shall be applied at Field.

2

NIOEC-SP-80-02(0) DOCUMENT CODE NO. OF PAGES: 39

PLAN/PRJ/SUB UNIT PHASE DISCIPLANE DOCUMENT TYPE SERIAL NO. REV. NO. DATE NIOEC 000 EG TP SP 8002 A0 JULY, 2005

NATIONAL IRANIAN OIL REFINING & DISTRIBUTION COMPANY

NATIONAL IRANIAN OIL ENGINEERING

& CONSTRUCTION COMPANY

NIOEC SPECIFICATION

FOR

PAINTING

FIRST EDITION

JULY,2005

THIS SPECIFICATION IS THE PROPERTY OF NATIONAL IRANIAN OIL ENGINEERING & CONSTRUCTION COMPANY. IT IS CONFIDENTIAL AND ALL RIGHTS RESERVED TO THE OWNER. NEITHER WHOLE NOR ANY PART OF THIS DOCUMENT MAY BE DISCLOSED TO ANY THIRD PARTY, REPRODUCTED, STORED IN ANY RETRIEVAL SYSTEM OR TRANSMITTED IN ANY FORM OR BY ANY MEANS WITHOUT THE PRIOR WRITTEN CONSENT OF THE NATIONAL IRANIAN OIL ENGINEERING & CONSTRUCTION COMPANY

JULY, 2005 NIOEC-SP-80-02(0)

REVISION INDEX

REV. PAGE

1 2 3 4 5 REV. PAGE

1 2 3 4 5 REV. PAGE

1 2 3 4 5 REV. PAGE

1 2 3 4 5

1 26 51 76

2 27 52 77

3 28 53 78

4 29 54 79

5 30 55 80

6 31 56 81

7 32 57 82

8 33 58 83

9 34 59 84

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11 36 61 86

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16 41 66 91

17 42 67 92

18 43 68 93

19 44 69 94

20 45 70 95

21 46 71 96

22 47 72 97

23 48 73 98

24 49 74 99

25 50 75 100

NOTES: 1) THIS SHEET IS A RECORD OF ALL REVISIONS TO THIS SPECIFICATION.

2) REMARKS RELATED TO EACH REVISION SHOW A BRIEF DESCRIPTION. THESE REMARKS SHALL BE INTERPRETED IN CONJUNCTION WITH THE REVISED TEXT MARKED BY REVISION NUMBERS.

3) WHEN APPROVED EACH REVISION SHALL BE CONSIDERED AS A PART OF THE ORIGINAL DOCUMENT.

4) NUMBER OF PAGES EXCLUDES THIS SHEET AND THE COVER SHEET.

5 4 3 2

JULY, 2005 NIOEC-SP-80-02(0)

1 0 JULY, 2005 M.TAVARI S.PAKDEL M.R.FARZAM M.A.A.SAJEDI

REV. DATE PREPARED CHECKED APPROVED AUTHORIZED

JULY, 2005 NIOEC-SP-80-02(0)

CONTENTS: PAGE NO. 1 SCOPE.........................................................................................................................................2 2. REFERENCES...........................................................................................................................2 3. UNITS..........................................................................................................................................3 4 GENERAL REQUIREMENTS ................................................................................................3

TABLE 1- DEW POINT DETERMINATION............................................................................6 5. SURFACE REPARATION .......................................................................................................6

5.1 Pre-blasting preparation..........................................................................................................6 5.2 Blast cleaning ............................................................................................................................7

6. PAINT MATERIALS ................................................................................................................9 6.1 Selection of Paint Materials.....................................................................................................9 6.2 Identification of Paint Materials.............................................................................................9 6.3 Storage of Paint Materials.......................................................................................................9

7. PAINTING SCHEDULES AND PAINT SYSTEM ................................................................9 8. PREPARATION OF PAINT BEFORE USE ........................................................................10

8.1 Storage and Appearance........................................................................................................10 8.2 Preparation of Paint for Application....................................................................................10

9. APPLICATION OF PAINT....................................................................................................13 9.1 General ....................................................................................................................................13 9.2 Priming of Ferrous Metals ....................................................................................................13 9.3 Shop Painting of Steel ............................................................................................................15 9.4 Field and Touch-Up Painting of Steel ..................................................................................15 9.5 Painting of Specific Surfaces .................................................................................................16

10. QUALITY CONTROL AND TESTING................................................................................18 APPENDIX A: PAINT SYSTEM ...................................................................................................23 APPENDIX B: PAINT COLOR SCHEDULE 28

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JULY, 2005 NIOEC-SP-80-02(0)

1 SCOPE

This NIOEC Specification covers the minimum requirements for the selection of coating materials, surface preparation, application procedure and inspection for protective coatings to be applied during construction and installation of equipment and associated facilities.

2. REFERENCES

Throughout this Specification the following dated and undated standards/ codes are referred to. These referenced documents shall, to the extent specified herein, form a part of this Specification. For undated references, the latest edition of the referenced document (including any supplements and amendments) applies. For dated references, the edition cited applies. The applicability of changes in dated references that occur after the cited date shall mutually be agreed upon by NIOEC and the Vendor/Contractor.

ASTM (AMERICAN SOCIETY FOR TESTING AND MATERIALS) ASTM D-3359"Standard Test Methodes for Measuring Adhesion by Tape Test" BSI (BRITISH STANDARDS INSTITUTION) BS 381C(1988) "Colors for Identification, Coding and Special Purposes" BS 6150(2002) "Painting of Building" IPS (IRANIAN PETROLEUM STANDARDS) IPS-M-TP-168 "Material and Equipment standard for Acrylic Silicone Finish Paint for

Temperature Applications Up to 230°C" IPS-M-TP-190 "Material and Equipment Standard for Coal Tar Epoxy Polyamide Paint as

Primer,Intermediate and Top Coat" IPS-M-TP-205 "Material and Equipment standard for Zinc Rich Epoxy Paint(Organic)as

Primer,Intermediate and Top Coat" IPS-M-TP-210 "Material and Equipment standard for Zinc Silicate(inorganic)Paints as

Primer,Intermediate and Top Coat" IPS-M-TP-215 "Material and Equipment standard for Epoxy Polyamide Primer" IPS-M-TP-220 "Material and Equipment standard for Epoxy Polyamide Intermediate

Paint" IPS-M-TP-225 "Material and Equipment standard for Epoxy Polyamide Paint as Top Coat" IPS-M-TP-235 "Material and Equipment standard for Two Pack Aliphatic Polyurethane

Paint as Top Coat" ISO (INTERNATIONAL ORGANIZATION FOR STANDARDIZATION) 12944(1998) “Paints and Varnishes-Corrosion Protection of Steel Structures by

Protective Paint System” 8501-1(1988) "Rust Levels of Steel Structure and Quality Levels for Preparation of Steel

Surfaces for Rust Protecting Surfaces" NIOEC-SP (NIOEC SPECIFICATION) NIOEC-SP-00-10 "NIOEC Specification for units"

2

JULY, 2005 NIOEC-SP-80-02(0)

SSPC (STEEL STRUCTURE PAINTING COUNCIL) SSPC-Vol. 1(1994)"Good Painting Practice" SSPE-Vol. 2(1994)"Systems and Specification"

3. UNITS

International system of units (SI) shall be used in accordance with NIOEC-SP-00-10, unless otherwise specified.

4 GENERAL REQUIREMENTS

4.1All surfaces shall receive an appropriate paint system as specified by the NIOEC with reference to Appendix A with the following exceptions: - any equipment furnished completely painted by the manufacturer unless it is specially

required to match a color scheme or to repair damage to the paint film;

- hot-dip galvanized steel, weathering steel, stainless steel and non-ferrous metals, monel, brass, copper, aluminum jacketing, unless it is specially required;

- nonmetallic surface; - nameplates, code stampings and push-buttons; - surfaces to be fireproofed; - concrete, brickwork, tile, glass and plastics, unless specially required; - machined surfaces; - insulation weatherproofing material or sheeting; - rubber, hoses, belts, flexible braided connectors, stainless steel tubing and fittings, gages,

valves, and motor shafts; - and any surface particularly indicated as not to be painted.

4.2 Paint systems are generally specified by dry film thickness of coat(s) and total dry film

thickness of primer, intermediate and topcoat rather than by the number of coats.

4.3 Unless otherwise stated in Appendix A, the total dry film thickness of paint system shall be 100 microns minimum. All paints and paint materials used shall comply with the specification given in relevant Material Specification and they shall be obtained from approved manufacturers only.

4.4 All materials shall be supplied in the manufacturer’s original containers, durably and legibly

marked according to relevant Material Specification.

4.5 Fabrication should preferably be complete before surface preparation begins.

3

JULY, 2005 NIOEC-SP-80-02(0)

4.6 All painting shall be carried out in full conformity with this Specification. Particular attention shall be paid to Manufacturer instructions on storage, mixing, thinning, pot life, application conditions, application technique and recommended time intervals between coats.

4.7 No paint shall be used in which the vehicle has set hard and which cannot readily be

reincorporated by correct mixing. Similarly, no paint shall be used which has jellified or which has thickened to such an extent that too much thinner is required to brushing consistency.

4.8 Paint shall not be applied under the following conditions:

- When the temperature of the surface is less than 3ºC above the dew point of the

surrounding air, and/ or the relative humidity is higher than 80%;

- When the temperature is below 4ºC;

- When the surface temperature is higher than 35ºC;

- When there is the likelihood of an unfavorable change in weather conditions within two hours after coating;

- When there is a deposition of moisture in the form of rain, condensation, frost, etc., on the

surface. This is likely to occur when the relative humidity is over 80% and the temperature is below 15ºC.

Each layer of paint shall be allowed to dry for a period of time within the limits prescribed by the paint manufacturer, before the next layer is applied.

4.9 Subsequent layers of a paint system shall have a difference in tint or color.

4.10 Particular attention shall be paid to the painting of corners, edges, welds, etc. especially

with respect to the specified minimum dry-film thickness.

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

4.12 All steel constructions or plates shall be provided with priming or coating system to protect the steel surfaces during the transport, storage, construction and joining stages, e.g. welding of the project.

4.13 All surface inaccessible after assembly shall be fully painted before assembly.

4.14 It shall be the responsibility of the contractor to coordinate work so that shop primed items

are primed and painted with compatible coating, as specified according to Appendix A.

4.15 Coatings shall be applied by conventional and/ or airless spray in exact accordance with this Specification and/ or the manufacturer’s instructions.

4.16 No paint shall be used in which the vehicle has set hard and which cannot readily be

reincorporated by correct mixing. Similarly, no paint shall be used which has jellified or

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which has thickened to such an extent that too much thinner is required to brushing consistency.

4.17 Two pack paints shall be carefully mixed in strict accordance with this Specification and/

or manufacturers instructions. The pot life of such paints shall be carefully noted and any mixed paint which has exceeded its pot life must be discarded irrespective of its apparent condition (see 8.2.1.14).

4.18 The application shall leave no sags, runs, marks or other defects.

4.19 Drying and application time between coats shall adhere to the coating manufacturer’s

recommendations with temperature and humidity conditions taken into account, and shall generally be kept to the minimum in order to prevent contamination between coats. Where contamination occurs between coats, this must be completely removed, generally be washed per manufacturer’s recommendation or otherwise with suitable detergent solution and rinsed with clean water. The paint surface shall be dry before over-coated application.

4.20 The greatest precaution shall be take in the spraying of inorganic zinc primers to ensure

proper cohesion and adhesion permitted care shall be take not to exceed the maximum film thickness .Inorganic zinc-rich paints shall be applied by airless spray. If the zinc powder is packaged separately, mix with the vehicle just before use. They shall be applied at a coverage rate recommended by Appendix A. Prior to top coating, a barrier or tie coat may be required for overcoating with certain generic coatings. The manufacturer’s recommendations shall be followed. Complete curing of the zinc-rich primer is necessary before top coating. Over spray shall be removed with a stiff bristle brush or wire screen. Popping will be eliminated by scrapping the painted surface with a soft sand paper before overcoating.

4.21 Any and all holes and surface imperfections shall be cleaned and filled in an approved

manner before painting. 4.22 Number of coats when specified shall be a minimum number of coats to achieve the

specified film thickness. Maximum dry film thick nesses should not exceed those specified by the client.

4.23 All equipment shall be maintained in good working order. Equipment shall be thoroughly

cleaned daily. Worn parts shall be replaced. Effective oil and water separators shall be used and serviced regularly.

4.24 All points of damage to paintwork incurred at any stage of the work including site welding

operations, shall be reprepared to the original standard and recoating with the specified priming coat and finish coat to restore the film thickness. In all such instances preparation shall extend 25 mm into the sound paintwork and a further 25 mm of sound paintwork shall be lightly blasted to etch the surface. Repainting shall then cover the prepared surface and the etched paintwork.

4.25 When painting insulating flanges with paints containing metallic pigments insulating

materials will be covered with protective striping to prevent breaking or “electrically shorting” the insulating barrier.

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4.26 Unless otherwise specified the minimum allowable time before application of intermediate or finish coat shall be three hours.

4.27 Maximum allowable time between application of intermediate and finish coat shall be as

recommended by the paint manufacturer but shall not be less than eight hours. 4.28 Any surfaces to be coated shall be rendered dust-free prior to the application of the prime coat. This shall be accomplished by blowing of the surface with clean dry air or by using an industrial vacuum cleaner.

TABLE 1- DEW POINT DETERMINATION

DEW POINTS (ºC) AT VARIOUS RELATIVE HUMIDITIES AIR TEMP. 30% 40% 50% 60% 70% 80% 90% 10

0%

-1 - - - - -6.5 -4 -2 -1 4 - -6.5 -4 -2 0.5 1.5 3.5 4.5 10 -6.5 -3.5 0.5 2 3.5 5.5 8.5 10

15.5 0 2 4 8 10 11.5 14 15.5

21 3 6.5 10 13 15 18 19.5 21

26.6 7 12 15.5 19 21 23.5 25 26.5

32 13 16.5 20.5 24 25.5 28.5 30.5 32 38 18 22 25.5 29 31 33.5 36 38

Note:

It is essential to ensure that no condensation occurs on blasted steel or between coats during painting.

Air at a given temperature can only contain a certain (maximum) amount of water vapor. This proportion is lower at lower temperatures.

The dew point is the temperature of a given air-water vapor mixture at which condensation starts, since at that temperature its maximum water content (saturation) is reached.

In practice, a safety margin must be kept, whereby the substrate temperature is at least 3ºC above dew point.

5. SURFACE REPARATION 5.1 Pre-blasting preparation

5.1.1 Sharp edges, fillets, corners, and welds shall be rounded or smoothened by grinding

(minimum radius 2 mm) 5.1.2 Hard surface layers (e.g. resulting from flame cutting) shall be removed by grinding prior

to blast cleaning.

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5.1.3 The surfaces shall be free from any foreign matter such as weld flux, residue, slivers, oil,

grease; salt etc. prior to blast cleaning. All surfaces should be washed with clean fresh water prior to blast cleaning.

5.1.4 Any oil and grease contamination shall be removed in accordance with SSPC/SSPM

Volume 2, grade SP1, prior to blast operations. 5.1.5 Any major surface defects, particularly surface laminations or scabs detrimental to the

protective coating system shall be removed by suitable dressing. Where such defects have been revealed during blast cleanings, and dressing has been performed, the dressed area shall be re-blasted to the specified standard. All welds shall be inspected and if necessary repaired prior to final blast cleaning of the area. Surface pores, cavities etc. shall be removed by suitable dressing or weld repair.

5.2 Blast cleaning

5.2.1 Blasting operations shall never be allowed in the vicinity of painting work or near to a wet

paint surface or any where that blast abrasive, grit or fall-out shall impinge on a freshly painted surface, or on any uncovered primed surface.

5.2.2 Blast cleaning operations shall not be conducted on surfaces that will be wet after blasting and before coating, when the surfaces temperature are less than 3ºC above the dew point, when the relative humidity of the air is greater than 85%, or when the ambient temperature is below 3ºC.

5.2.3 The maximum particle size of the abrasives used in blast cleaning shall not be larger than that passing through a 14-mesh screen B.S. Sieve Series. All abrasives shall be free from dust, moisture and salt. Blasting shall be continued till a uniform white metal surface is achieved.

5.2.4 Blast cleaning is permitted only during the day light.

5.2.5 Where rectification has been necessary on blast-cleaned surface, the particular area shall

be re-blasted to remove all rust and slag, and to provide adequate paint adhesion.

5.2.6 Blast cleaning shall overlap by a minimum of 25 mm into any adjacent coated areas. Any

steel work not primed and/or wetted by rain or moisture shall be re-blasted prior to being painted if rust develops.

5.2.7 Steel may be blast-cleaned either before or after fabrication. Sometimes it may be necessary both before and after.

Where steel is cleaned before fabrication it shall be protected with a suitable blast-primer to avoid rusting before fabrication is completed. During fabrication, the blast-primer will inevitably be destroyed or damaged in places, e.g. by welding. Such areas shall be cleaned and re-primed as soon as possible.

Where steel cleaned after fabrication it may still be necessary to apply a blast-primer, but often the first coat of the full protective system can be applied.

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5.2.8 The roughness of prepared surface results from primary roughness already present in the initial state and which is exposed by the mechanical preparation methods, in particular by blasting. The roughness parameters (the peak-to valley height) give some basis for determining the minimum coat thickness necessary for satisfactory embedment and covering of roughness peaks.

The surface roughness of steel work shall be within 0.1 mm to 0.03 ± 0.005 mm for painting, coating and lining.

5.2.9 Surface preparation specified in the schedule (Appendix A) shall be in accordance with the following Standard, ISO8501-1:

5.2.9.1 Hand Tool Cleaning ST2

5.2.9.2 Power Tool Cleaning and Power Tool touch up

of pre-blasted items ST3

5.2.9.3 Light Blast Cleaning (Sweep blast) SA1

5.2.9.4 Near White Metal Blast Cleaning SA2, ½

5.2.9.5 White Metal Blast Cleaning SA3

5.2.10 Standard level of cleanliness unless otherwise specified by the NIOEC, the level of cleanliness for prepared steel surface shall be Sa3 for zinc silicate and zinc rich epoxy primers and Sa2½ for other primers and organic coactions and for metal coatings, claddings and lining.

5.2.11 A qualified well trained operator shall be employed for the blast-cleaning job. The qualification of operator must be approved by NIOEC.

5.2.12 When sheets of less than 4 mm thickness are blasted, deformation may occur. This shall be avoided by:

a) Low air pressure, small grain sizes and the use of a blasting abrasive of low bulk density;

b) A low angle of blasting with sharp edged grain and a short duration of blasting. With

adhesive scale or fairly thick rusting it may be necessary to carry out preparatory work by some other methods, e.g. manual cleaning or pickling, before cleaning, measures a(and b) will result in less efficient blasting.

5.2.13 Residual shot, grit and dust shall be completely removed after blasting, preferably by

vacuum cleaning, but otherwise by oil and water free air blast or fiber brush.

5.2.14 All blasted steel surfaces shall be primed before visible re-rusting occurs or within 4 hours whichever is sooner.

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6. PAINT MATERIALS

6.1 Selection of Paint Materials

6.1.1 Only paint system which complies with Appendix A shall be used. 6.1.2 The paint materials supplied shall be certified by the manufacturer in accordance with

the requirements relevant IPS Material Specification for paint. The contractor shall obtain and retain all certificates and manufacturer’s data sheets.

6.2 Identification of Paint Materials

The contractor shall ensure that all materials supplied for painting operations are clearly marked according to IPS Material Specification for paints.

6.3 Storage of Paint Materials

All paint materials consigned to the coating site shall be properly stored in accordance with the manufacturer instructions at all times to prevent damage and deterioration prior to use. Materials shall be used in the order in which they are delivered.

7. PAINTING SCHEDULES AND PAINT SYSTEM

Unless otherwise noted, surface preparation and primer, intermediate and finish painting on Vessels, Exchangers, Equipment and Structural Steel will be done in the shop, and only touch-up will be required in the field.

Shop primer on piping for rust prevention will be done in the shop and primer, intermediate and finish will be required in the field.

All surfaces of tank plate shall receive one coat of Pre-fabrication primer (Inorganic Zinc Rich at 20 microns) at vendor shop and primer, intermediate and finish will be required in the field.

All surfaces shall receive an appropriate paint system and finish color as specified in Appendix A and B with exceptions which are noted in 4.1.

Temperatures listed in Appendix A refer to operating temperature of item, not design temperature.

For building painting see BS 6150 (Painting of Buildings).

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8. PREPARATION OF PAINT BEFORE USE 8.1 Storage and Appearance

8.1.1 Paint shall be stored in a well ventilated room, free from excessive heat or direct rays of the sun and maintained at a temperature between 4ºC and 27ºC. Open air storage shall be avoided particularly of heavy paints such as primers and undercoats.

8.1.2The maximum storage time for paints shall be as recommended by relevant Material Specification. Paints shall not be stored in open containers, even for a short time.

8.1.3All containers of paint shall remain unopened until required for use. Those containers which have been previously opened shall be used first. The label information shall be legible and shall be checked at the time of use.

8.1.4 The settlement of heavy paints such as red lead oxide primers, enamel undercoats, and wood priming paints shall be lessened by rolling the drums in which they are stored every six weeks. Touring the drums on their ends is not allowed. The normal finishing paints and drum paints do not require rolling during the storage period.

8.1.5 If paint has thickened to such as extent that more than 5% by volume (10% by volume for priming paints) of the correct thinners is required to bring it to brushing consistency.

8.1.6 Paint which has levered, gelled, or otherwise deteriorated during storage shall not be used; however thixotropic materials which can be stirred to attain normal consistency may be used.

8.1.7 The oldest paint of each kind shall be used first.

8.1.8 Temperature of paint may be excessively high or low depending on storage or shipping conditions. If so, warm or cool the paint to a temperature of 10-32ºC before mixing and use.

8.2 Preparation of Paint for Application

8.2.1 Mixing 8.2.1.1 Paints shall preferably be mixed by powered mixers and/or shakers. Only

small quantities are suitable for hand mixing, and then shall only be mixed by an efficient method such as boxing *. Avoid shaking partly full cans of latex paint, it cause foaming.

8.2.1.2 The paint shall be mixed in a manner which will insure the break-up of all lumps, complete dispersion of pigment and a uniform composition.

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8.2.1.3 The lumpy or stiff paste shall be broken up with a mechanical agitator. In some cases with a wide strong paddle made of wood or iron, stirred with a motion from container.

8.2.1.4 Where a skin has formed in the container, the skin shall be cut loose from the sides of the container, removed and discarded. If the volumes of such skins are more than 2% of the remaining paint, the paint shall not be used.

8.2.1.5 Mixing in open containers shall be done in a well ventilated area away from sparks or flames.

Paint shall not be mixed or kept in suspension by means of an air stream bubbling under the paint surface.

8.2.1.6 Dry pigments which are separately packaged shall be mixed into paints in such a manner that they are uniformly blended and all particles of the dry powder are wetted by the vehicle.

8.2.1.7 Pastes shall be made into paints in such a manner that the paste shall be uniformly blended and all lumps and particles broken up to form a homogeneous paint.

8.2.1.8 Tinting pastes or colors shall be wetted with a small amount of thinner, vehicle, or paint and thoroughly mixed. Next, the thinned mixture shall be strained.

Finally, it shall be added to the large container of paint and mixed until the color is uniform.

8.2.1.9 Paint which does not have a limited pot life (time interval) or does not deteriorate on standing may be mixed at any time before using, but if settling has occurred it must be remixed immediately before using.

8.2.1.10 Paint shall not remain in spray pots, painter’s buckets, etc. Overnight, but shall be stored in a covered container and remixed before use.

8.2.1.11 Catalysts, curing agents, or hardeners which are separately packaged shall be added to the base paint only after the latter has been thoroughly mixed. The proper volume of the catalyst shall then be slowly poured into the required volume of base with constant agitation. Do not pour off the liquid which has separated from the pigment and then add the catalyst to the settled pigment to aid mixing. The mixture shall be used within the pot life specified by the manufacture. (For example, more than 20 minutes and less than eight hours after mixing are the pot life limits for some chemically cured paints.) Therefore only enough paint shall be catalyzed for prompt use. Most mixed,

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catalyzed paints cannot be stored, and un-used portions of these shall be discarded at the end of each working day at the expense of the contractor. When specified, special continuous mixing equipment shall be used according to the manufacturer’s directions.

8.2.1.12The drum paints shall be rolled on its side for some minutes before opening. The entire paint content shall be poured into an empty clean drum or can, ensure that no heavy paste remains in the original container. If paste remains, some of paint shall be poured back and the mixture again stirred thoroughly and returned to the bulk.

8.2.1.13All pigmented paint shall be strained after mixing except where application equipment is providing with strainers. Strainers shall be of a type to remove only skins and undesirable matter but not to remove the pigment. Cheese-cloth

of fine metal gauze, approximately 0.15 mm (80 mesh) is recommended as strainer.

8.2.1.14When mixing two-component paints, check and remix each component individually. Then blend the two components at low speed until the mixture is completely uniform in color. Often, the two components are supplied in different colors so that a good mix can be readily determined. Do not mix more than a few liters at a time since the exotherm caused by the mixture may be so high as to make the paint solidify in the container.

8.2.1.15 Hand mixing of paints shall only be permitted for containers up to 5 liters. All larger containers shall be mixed by mechanical agitators and brought to a uniform consistency. Where pigment separation readily occurs such as heavy or metallic pigments, prevention shall be made for continuous mixing during application.

8.2.2 Thinning 8.2.2.1 Do not thin the paint unless recommended by supplier or needed for spray

application or in case of thickening of paint as in 6.2.2.2.

8.2.2.2 If thickening of paint prevents proper application by brush, not more than 5% by volume of the correct thinner may be added; for oil-based primers containing red lead, up to 10% by volume is acceptable. For enamels which are applied by spraying, special enamel thinners shall be used. For drum paints and for priming paints, white spirit (mineral turpentine) shall be used as thinner. Emulsion paints normally require thinning up to 12% by volume of clean fresh water. The addition of more water than is necessary to obtain a satisfactory brushing consistency is not allowed.

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8.2.2.3 When thinning the paint, first be sure that it is well mixed before adding the thinner. Then thinner shall be added slowly to paint during the mixing process.

8.2.2.4 If the paint is cold, do not add thinner to make application easier. Instead, bring the paint to 10-32ºC. Paint heaters can be used to reduce viscosity for spray application, thus avoiding the addition of thinners. Do not apply warm paint to cold steel. Results are best if both are similar in temperature.

9. APPLICATION OF PAINT 9.1 General

9.1.1 Paints shall be applied in accordance with this Specification and good industrial practice. Manufacture instruction shall also be considered.

9.1.2 Paint shall not be applied under the conditions described in 5.10. The paint film shall not be exposed to moisture and contamination before it has dried. Priming and painting under controlled condition in the shop is preferred.

9.1.3 The degree of cleanliness of surface will be determined by the requirements in respect

of paint system (Appendix A).

9.1.4 The number of coats applied after priming and the total dry film thickness of paint will be determined by the requirement in respect to paint system and conditions with reference to Appendix A. By no means shall the total dry film thickness of paint not be less than 125 microns for moderate exterior environments; severe environment needs higher film thickness.

9.2 Priming of Ferrous Metals

9.2.1 General

9.2.1.1 Prepared surfaces should be primed generally within four hours or before visible re-rusting occurs.

9.2.1.2 Blast cleaned surfaces may be protected for short periods by thin coat of pre-treatment primer. Such primers shall be applied as a continuous coating in an even manner to achieve a minimum film thickness of 20 microns. Such primers do not replace the full thickness of permanent primer.

9.2.1.3 The priming coat or coats on steel shall be as specified by Appendix A but in

no case shall have a total dry film thickness less than 50 microns. When applied in two coats, a shade contrast between coats is recommended.

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9.2.1.4 In order to minimize contamination between successive coats of paint, over coating of the preceding coat shall be done within the period of time recommended by the manufacturer and shall not delayed beyond the period specified. When delays are unavoidable, the painted surface shall be thoroughly cleaned and dried to the satisfaction of the NIOEC before over coating may take place.

9.2.1.5The primer is applied by spray, except when the NIOEC prefers another method of application or required by the job and/or material.

9.2.1.6 Primed steelwork, especially if it has been exposed for a lengthy period, shall be examined carefully before further coats of paint are applied. If the primer has been deteriorated, e.g. is perished, eroded or poorly adhering, or has been

damaged, so allowing corrosion to develop, the affected areas shall be re-prepared and primed. If there is evidence of widespread corrosion beneath the primer, it shall be removed and the surface again prepared and primed.

9.2.1.7 Removal of salt deposits by washing from surfaces primed with zinc-rich primers is especially important as the corrosion products formed by reaction between the salts and the zinc can affect the performance of subsequent coats.

9.2.1.8 With a single coat of primer, it is difficult to obtain films of uniform thickness and free from pinholes, the points at which corrosion starts. In all but ‘mild’ interior environments, application of two coats of primer is suitable. If application of two coats cannot extend to the whole of the surface, a second coat shall be applied to vulnerable points, e.g. along external angles and to bolts and rivet heads.

9.2.1.9 Surface primed with red-lead primer shall not be exposed to the weather for more than one month.

9.2.2 Priming of steel prepared by blasting

9.2.2.1 Blast cleaned steel prepared to SIS Grade Sa 3 or Sa 2½ shall frequently be coated either in the shop or on site with a pre-treatment or pre-fabrication primer or with original primer.

9.2.2.2 For further priming over the pre-fabrication primers or for direct application to blast cleaned steel, the priming paint shall be in accordance with relevant Material Specification for paints.

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9.2.2.3 Unless otherwise specified by the NIOEC with reference to Appendix A, it is essential that the total film thickness of the priming coats (blast or pre-fabrication primer plus second primer) shall meet the prescribed thickness of 75 micron minimum in all area.

9.3 Shop Painting of Steel

9.3.1 Full protection applies in the shop immediately after fabrication normally results in a longer life of the protective system. However, damage during transportation and erection may subsequently necessitate widespread repair or touch-up of coating, so the structural steelwork, surface pipework, towers, vessels, heat-exchanger shells and similar containers which will not be lagged can be treated in the shop, subject to mutual agreement.

9.3.2 The shop treatments will be determined by requirements in respect to paint system and conditions such as type of environment transportation, economic, etc.

9.3.3 Handling and storage of shop treated items shall be so that to prevent damage to the treated surfaces.

9.3.4 Damage resulting from handling in the shop following painting, such as during storage or loading, is to be repaired as a part of the field painting operations. If the shop coat is damaged in fabrication, it shall be repaired before leaving the shop.

9.3.5 Contact surfaces shall be painted or left unpainted as specified in the procurement documents. When painted, at least the first coat shall be applied in the shop, with subsequent coats being applied in the field while the surfaces are still accessible, unless otherwise specified.

9.3.6 If the paint specified is harmful to the welding operator or is detrimental to the welding operation or the finished welds, the steel shall not be painted within 100 mm of the areas to be welded.

9.4 Field and Touch-Up Painting of Steel

9.4.1 Previously applied shop coating must be dry and free of dirt, oil, or other contaminates. The manufacturer’s instructions shall be followed if special surface preparation procedures are required before application of the field coats.

9.4.2 All shop coated items which have deteriorated as a result of transshipment to the extent that either crumbling or white staining of the coating is evident shall receive. A superficial sweep blast cleaning sufficient to remove the degradation and to re-prepare exposed degraded metal substrate and dust.

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9.4.3 Shop coated steel members shall preferably be field painted after erection of such members is completed. Steel members may be field painted on the ground before erection, provided such painting is touched-up where damaged with the same number of coats and kinds of paints after erection. However, the last complete coat of paint shall be applied after erection.

9.4.4 The first field coat of paint shall be applied within a reasonable period after the shop coat(s), and in any event before the weathering (and required touch-up) of the shop coat becomes excessive.

9.4.5 When the type of paint for field coats is not specified, it shall be determined that the paint to be used is compatible with the shop applied coats(s). Paint used in the first field coat over shop painted surfaces shall not cause wrinkling, lifting, or other damage to the underlying paint.

9.4.6 Contact surfaces shall be painted or left unpainted as specified in the procurement documents or required by the job.

9.4.7 Surfaces (other than contact surfaces) of fabricated assemblies those are accessible before erection but which will not be accessible after erection shall receive all field coats of paint before erection.

9.4.8 All cracks and crevices shall be filled with paint if practical.

9.4.9 Wet paint shall be protected against damage from dust or other detrimental foreign matter as much as is practical.

9.4.10 Steel stored pending erection shall be kept free from contact with the ground and so positioned as to minimize water-holding pockets, soiling, contamination, and deterioration of the paint film. Such steel shall be cleaned and repainted or touched-up with the specified paint whenever it becomes necessary to maintain the integrity of the film.

9.4.11 All field welds and all areas within 100 mm of welds shall be cleaned before painting, using surface preparation methods at least as effective as those specified for the structure itself; all welds shall either be blast cleaned, thoroughly power wire brushed, chemically scrubbed, or water scrubbed of all detrimental welding deposits as required.

9.5 Painting of Specific Surfaces

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9.5.1 Contact surfaces Unless otherwise specified by the NIOEC, the following practice shall be followed regarding painting of contact surfaces:

9.5.1.1 The areas of steel surfaces to be encased or embedded in concrete shall not be painted.

9.5.1.2 Steel to be completely enclosed in brick or other masonry shall be given at least one coat of shop paint.

9.5.1.3 The areas of steel surfaces to be in contact with wood shall be painted as indicated in 9.5.1.5

9.5.1.4 Surfaces to be in contact only after field erection shall be painted as provided in 9.5.1.5, except where the paint interferes with assembly or where indicated in 9.5.1.7.

9.5.1.5 Steel surfaces not in direct bonded contact, but inaccessible after assembly shall receive the full specified paint system before assembly.

9.5.1.6 Bearing-type joints may be painted as required in 9.5.1.5.

9.5.1.7 Contact surfaces of members to be joined by high strength bolts in friction-type joints are a special case. Unless specifically authorized to the contrary, they shall be left unpainted and free of oil, grease, and coatings.

9.5.2 Edges

All sharp edges shall be coated to the same film thickness as the adjacent steelwork to prevent premature breakdown from this area. Corners, services, bolt heads and rivet heads require similar attention. Where there is any doubt that these areas have received adequate film thickness the NIOEC may direct that an additional strip coat of paint, be applied to ensure the full film thickness, without any additional cost to the NIOEC.

9.5.3 Welds

As rolled steel may be blast-cleaned and protected with blast primer before fabrication and welding. This prevents the serious development of rust, which would be difficult to remove after fabrication. The use of steel that has rusted heavily during storage

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should be avoided for the same reason. When welding metal coated or zinc-dust painted steel, it is necessary to remove the coating near the weld area, or mask-off the weld area before coating. Most painted steel can be cut and welded satisfactory provided that the coating thickness is less than 25 microns. After welding, scale and heat-damaged coating shall be removed by local blast-cleaning and the area renovated by repainting the original coating.

10. QUALITY CONTROL AND TESTING

10.1 Manufactures of all materials shall supply test certificates of all tests performed and a certificate of compliance stating that the material meets the requirements of the applicable specifications.

10.2 Test shall ensure that the quality of the surface coating is in accordance with that specified

and shall include, but shall not be limited to, thickness testing, adhesion testing, holiday testing , abrasion testing, solvent testing, etc.

10.3 Requested tests should be carried out in accordance with ASTM standards as specified in

SSPC (good painting practice) volume 1 page 217 & 218. 10.4.HUMIDITY CHECK

The air’s relative humidity shall be measured with a psychrometer. Surface preparation and/or paint application operations shall not commence until relative humidity is less than the limits set in paragraphs 8.3. Relative humidity shall be measured and recorded a minimum of six (6) times a day whence two (2) times before commencement of work. Moisture on the surface being prepared or painted shall be measured every day with a surface moisture indicator before beginning surface preparation operations or applying a coat of paint.

10.5.ROUGHNESS CHECK

A Rugotest or Keane-Tator comparator shall be used in determining anchor pattern of sand blasted surfaces, when a fixed anchor pattern rang is required by a specific painting system.

10.6THICKNESS CHECK

Dry paint thickness shall be measured with a magnetic probe, such as Micro test or Elcometer or equivalent. It is imperative that the magnetic probe be calibrated for each thickness of coating steel support with a non-magnetic block whose thickness is as close as possible to the coating being checked. Each coat’s thickness and total thickness shall be checked. Make five (5) separate spot measurements spaced evenly over each section of the structure 10 square meters in area

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(divide the entire surface in 10 square meter areas). On each spot, make 3 readings by moving the probe a short distance for each new gage reading. Discard any unusually high or low gage reading that cannot be repeated consistently; Take the average of the three (3) gage readings as spot measurement. INORGANIC ZINC SILICATE: Before over coating it shall be checked, with the solvent recommended by the paint manufacturer, that the hydrolysis is complete by soaking the surface with a rag impregnated with the recommended solvent. Thickness checking shall be made after the application of the zinc silicate coat. Thickness shall be in the range 50 to 90 microns. For each successive coat, the minimal allowable thickness shall be least 80% of the specified thickness; the maximum thickness shall not exceed 150% of the specified thickness. For the total system, the minimal allowable thickness shall be at least 80% of the specified thickness, the maximum thickness shall not exceed 150% of the specified thickness unless the paint remained soft or shows mud crack or orange skin or wrinkling pinhole and intercoat delamination which cause rejection of the paint.

Surfaces with coat thickness out of tolerance shall: - Be sand blasted if too thick and repainted. - Receive and additional paint coat to obtain specified thickness.

10.7.In order to achieve the specified dry film thickness, frequent checks of wet film thickness

shall be carried out during the paint application with film thickness gauges such as the elcometer wheel or comb type.

10.8.In the event of the film thickness not meeting the specified requirements, additional coat

(s) of the paint concerned shall be applied in compliance with the specified requirements.

10.9.The degree of curing of epoxy resin based paint systems shall be checked by the determination of the resistance of the coating to methyl ethyl ketone (MEK). After rubbing the coating for one minute with a rag soaked in MEK, the coating shall not be softened and shall resist scraping with a fingernail.

10.10.POROSITY CHECK (FOR INTERNAL LINNIG ONLY)

Coating integrity shall be checked with a direct current holiday detector. The electrode shall consist of an eighty (80) cm 2 cellulose sponge soaked in a 1% detergent solution in potable water.

The instrument shall be calibrated and checked every hour to indicate a coating porosity of 80 000 ohms under a voltage of 67.5 volts between the ground and wet sponge a resistance of 90 000 ohms indicates no porosity. Sponge displacement speed on the surface shall not exceed 0.3 meters per second (18

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meters per minute). The sponge shall be moved back and forth so that is passes over the same area twice. The measurement is taken on the second pass. A minimum of ten percent of the painted surface shall be examined. If there is any porosity, the inspector or the NIOEC representative shall have the entire painted surface inspected. An alternating current holiday detector should preferably be used. In this case, the voltage between the painted steel surface and the test electrode shall be 5 volts micron of paint coat thickness. The inspector shall mark defective areas for repair. Any porous area shall be repaired when the number of pores is greater than 3 per square meter, the entire area shall be blast cleaned and repainted as per this specification.

10.11.ADHERENCE CHECK Paint adherence shall be checked as per ASTM method D3359. Method A (Xcut) shall be used for paint film thicker than 125 microns, method B (lattice pattern) shall be used for paint films up to 125 microns.

Test method A: An X-cut is made in the film to the substrate; pressure-sensitive tape is applied over the cut and then removed. Acceptable rating are 5A (No peeling or removal) or 4A (Trace peeling or removal along incisions or at their intersections).

Test method B: A lattice pattern with either six or eleven cuts in each direction) cross is made in the film to the substrate, pressure-sensitive tape is applied over the lattice and then removed, and adhesion is evaluated by comparison with descriptions and illustrations. Spacing between the cut lines shall be 1 mm for film thickness up to 50 microns and 2mm for film thickness from 50 to 125 microns. Acceptable results are rate 5B (the edges of the cuts are completely smooth, none of the squares of the lattice is detached) or 4B (Small flakes of the coating are derached at intersections, if the test is unsatisfactory, the entire surface shall be blast cleaned and repainted. Recoating after this destructive test is at the Applicator’s expense. Coating film should be inspected visually after each application and before application of the next coat in order to verify that the whole surface is free of defects as:

- Mud-cracking - Inclusion and cleanliness - Holidays - Bubble - Mechanical damage - Runs/sags - Over spray

10.12.EXTENT OF INSPECTION

In view of the final acceptance, the extension of the inspection shall be as hereinafter indicated and shall be referred to the following steps of work: Primed surfaces

Complete painted surfaces.

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Paint application shall not be started before previous coat/preparation is inspected and approved.

10.13.INSPECTION RESULTS

All quality control results shall be written up into reports. All reports shall be submitted to the NIOEC during provisional acceptance of the paint.

10.14.REPAIR OF DEFECTS OR DAMAGE

Any defect or damage that may occur shall be repaired before the application of further coats and where necessary the particular surface (s) made paint free. Remedial work shall be carried out prior to packing for shipment. Areas where due to inadequately prepared surfaces, solvent entrapment, excessive application of prime and/or finish coats, etc, the tested paint system consistently fails to meet the required test standards for adhesion/ cohesion, the contractor shall remove the affected area by blast cleaning and shall reapply the full paint system to meet the required standard. Areas which are to be overcoated shall be thoroughly cleaned free from grease, oil and other foreign matter and shall be dry. The surfaces shall then be prepared to the standard as originally specified (for large damaged areas), or prepared to the highest possible standard using mechanically operated tools (for small local damaged spots up to 1 m2. Subsequently additional compatible coats shall be applies, until they meet the specification. These additional coats shall blend in with the final coating on adjoining area. During the agreed maintenance period, any observed defective coatings, rusted areas or failures developing in the paint systems, shall be repaired to the satisfaction of the NIOEC inspector. When factory painted or painted surfaces have been marked in handling, the damaged paint and non-adherent paint shall be removed and the surface thoroughly cleaned. The edges on the damaged area shall be smoothed. Surface preparation shall extend approximately 5 cm into the sound coat. The primer and finishing coats shall be applied in accordance with Article 9. Where touch up of a shop applied inorganic zinc silicate primer is involved, the type of paint employed for touch up shall be two pack zinc rich polyamide cured epoxy primer for temperatures up to 150°C and ethyl silicate based inorganic zinc primer for temperatures in excess of 150°C.

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Note: If sand blasting is not applicable for any reason to be agreed upon by NIOEC or inspector, zinc silicate primer shall not be used for touch up repairs. Zinc rich 2 components epoxy primer or an approved epoxy primer formulated for application on hand or mechanically brushed surfaces should be used instead. The touch up primer shall be compatible with the paint system.

10.15.Manufacturer’s shop or field applicator shall submit check certified for the following

point:

a) Surface profile check b) Verification of paint documentation c) Environmental conditions during application d) Curing check e) Appearance film check f) Adhesiveness cross-out check

Note: 1) Acceptable surface profile shall be in accordance to the technical date sheet of the

product. 2) Adhesion degree of each product shall be as for ASTM D-3359 and shall be specified

by the paint manufacturer and approved by Owner. After the test, the surface shall be restored in accordance with the system applied.

10.16.Contractor reserves the right to witnessed at manufacture’s shop in spot for type/lot the

following inspections and test.

1) Blasting and primer system: a) Surface profile b) Verification of primer documentation c) Verification of paints maturity d) Appearance film check e) Adhesiveness cross-cut check

2) Painting complete system

a) Verification of paint documentation b) Verification of paint maturity c) Appearance film check

10.17.If during the above mentioned inspection, painting defects (such as dripping, blistering,

mud- cracking, over thickness and dry spray) or conditions of preparation, thickness, bond etc, should be found not to be conforming to the requirements, the manufacturer’s shop or field applicator at his own expense restore the faulty surfaces to an acceptable degree.

JULY, 2005 NIOEC-SP-80-02(0)

APPENDIX A: PAINT SYSTEM

PAINT SYSTEM DFT

(DRY FILM THICKNESS) IN MICRON SERVICE TEMP.

RANGE SURFACE

PREPRATION PRIMER COAT INTERMEDIATE COAT FINISH COAT PC IC FC TOTAL

UP TO 120ºC SA 2,1/2

ZINC-RICH

EPOXY IPS-M-TP-205

EPOXY POLYAMIDE IPS-M-TP-220

TWO-PACK POLYURETHANE

IPS-M-TP-235 75 150 50 275

121ºC TO 200ºC SA 3

ZINC-SILICATE PAINT

IPS-M-TP-210

SILICON ACRYLIC

IPS-M-TP-168

SILICON ACRYLIC

IPS-M-TP-168 75 25 25 125

201ºC TO 400ºC SA 3

ZINC-SILICATE PAINT

IPS-M-TP-210

SILICON ALUMINUM

SILICON ALUMINUM 75 25 25 125

BOLTING, FLOOR GRATING, LADDERS, STAIR TREAD, HANDRAILING, ELECTRICAL FIXTURES, STRUCTURAL STEELWORK, FABRICATED STEELWORK, COLUMNS, VESSELS, TANKS, HEAT TRANSFER EQUIPMENT, STEEL STACKS, PIPING, ETC. (EXTERNAL SURFACE & UNINSTULATED)

401ºC TO 600ºC SA 2,1/2 SILICON

ALUMINUM SILICON

ALUMINUM 25 25 50

MISCELLANEOUS MECHANICAL & ELECTRICAL EQUIPMENT, FIREFIGHTING AND FIRST AID EQUIPMENT, MACHINERY, PUMP, MOTOR, SWITCH TRANSFORMER,, ETC.

TO THE MANUFACTURER'S STANDARDS, UNLESS OTHERWISED SPECIFIED

INSTRUMENTS, INSTRUMENT PANELS, CONSOLES AND CABIENTS. TO THE MANUFACTURER'S STANDARDS, BUT WITH SPECIFIED COLOR IF APPLICABLE

NOTE 1) FOR INSULATED SURFACES UNDER INSULATION IF METAL SKIN ORERATING TEMPRATURE WILL BE UNDER 120°C MIN. 200 µm COAL TAR-EPOXY SHALL BE APPLIED. NOTE 2) FOR SOIL ENVIRONMENT (BURIED PIPING AND STRUCTURES) SEE NIOEC-SP-50-17.

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PAINT SYSTEM (CONT’D)

PAINT SYSTEM DFT


RANGE SURFACE PREPRATION PRIMER COAT INTERMEDIATE

COAT FINISH COAT PC IC FC TOTAL

CRUDE OIL STORAGE TANKS (INTERNAL PAINTING)

1) BOTTOM PLATES SA 2,1/2 COAL TAR EPOXY IPS-M-TP-190

COAL TAR EPOXY IPS-M-TP-190

COAL TAR EPOXY IPS-M-TP-190 150 150 150 450

2) SHELL PLATES

2.1) BOTTOM COURSE SA 2, 1/2 COAL TAR EPOXY IPS-M-TP-190



2.2) TOP COURSE (1500 mm)

I) FIXED ROOF TANKS SA 2, 1/2 COAL TAR EPOXY IPS-M-TP-190



II) FLOATING ROOF TANKS SA 2, 1/2 ZINC-RICH

EPOXY IPS-M-TP-205



IPS-M-TP-235 75 150 50 275

2.3) REST OF SHELL SHOP PRIMED ONLY (NO TREATMENT AT SITE)

3) INSIDE ROOF

I) FIXED ROOF TANKS SA 2, 1/2 COAL TAR EPOXY IPS-M-TP-190



II) FLOATING ROOF TANKS SHOP PRIMED ONLY (NO TREATMENT AT SITE)

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PAINT SYSTEM DFT


RANGE SURFACE


REFORMATE, HCG, OLEFIN GASOLINE, REGULAR GASOLINE

(INTERNAL PAINTING)

1) BOTTOM PLATES SA 2,1/2 EPOXY

POLYAMIDE IPS-M-TP-215



100 100 100 300

2) SHELL PLATES

2.1) BOTTOM COURSE SA 2, 1/2 EPOXY




100 100 100 300


I) FIXED ROOF TANKS SA 2, 1/2 EPOXY




100 100 100 300


EPOXY IPS-M-TP-205



IPS-M-TP-235 75 150 50 275


3) INSIDE ROOF

I) FIXED ROOF TANKS SA 2, 1/2 EPOXY




100 100 100 300


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PAINT SYSTEM DFT


RANGE SURFACE


CONDENSATE, NAPHTA, JET FUEL, KEROSENE, DIESEL

(INTERNAL PAINTING)

1) BOTTOM PLATES SA 2,1/2 PHENOLIC EPOXY PHENOLIC EPOXY PHENOLIC EPOXY 150 150 150 450

2) SHELL PLATES

2.1) BOTTOM COURSE SA 2, 1/2 PHENOLIC EPOXY PHENOLIC EPOXY PHENOLIC EPOXY 150 150 150 450


I) FIXED ROOF TANKS SA 2, 1/2 PHENOLIC EPOXY PHENOLIC EPOXY PHENOLIC EPOXY 150 150 150 450


EPOXY IPS-M-TP-205



IPS-M-TP-235 75 150 50 275


3) INSIDE ROOF

I) FIXED ROOF TANKS SA 2, 1/2 PHENOLIC EPOXY PHENOLIC EPOXY PHENOLIC EPOXY 150 150 150 450


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PAINT SYSTEM DFT


RANGE SURFACE


INDUSTRIAL WATER TANK, BALAST WATER, SLOPE &

DEMINERALLIZED WATER (INTERNAL PAINTING)

1) BOTTOM PLATES SA 2,1/2 COAL TAR EPOXY IPS-M-TP-190

COAL TAR EPOXY IPS-M-TP-190 150 150 300

2) SHELL PLATES SA 2, 1/2 COAL TAR EPOXY IPS-M-TP-190

COAL TAR EPOXY IPS-M-TP-190 150 150 300

3) INSIDE ROOF SA 2, 1/2 COAL TAR EPOXY

IPS-M-TP-190 COAL TAR EPOXY

IPS-M-TP-190 150 150 300

NOTE ) FOR INTERNAL PAINTING OF DRINKING WATER TANKS EPOXY POLYAMINE (IPS-M-TP-226) AS PRIMER AND INTERMEDIATE AND EPOXY POLYAMIDE (IPS-M-TP-225) AS FINISH COAT EACH COAT 125 µm (TOTAL 375 µm) SHALL BE APPLIED.

JULY, 2005 NIOEC-SP-80-02(0)

APPENDIX B

PAINT COLOR SCHEDULE

B.1.1.This Appendix is prepared to define color coding, marking and identification of equipment, piping, vessels and structural steel.

B.1.2.Colours and letters are used to identify the service of insulated and uninsulated

piping and equipments. The style and extent of colour coding shall be according to the following. For piping, lines shall be labeled by identification bands colour. Bands shall be located on one side of each valve and every 50m. of pipe run. All equipment shall be identified with labels, label shall consist of item number.

B.2.PREPARATION OF SURFACES

B.2.1.The color coding, marking and identification paint shall be applied to dry, clean, adequately prepared surfaces, under favorable conditions, and in accordance with manufacturer’s instructions.

B.2.2.Surfaces shall be free of oil, grease, dirt and other surface contaminants which

would otherwise be detrimental to the adhesion of the paint used for color coding and marking.

B.2.3.All surfaces to receive paint shall be thoroughly washed with solvent and wiped dry

with clean rags.

B.2.4.Bare and rusted steel shall be cleaned by hand or power wire brushing, sanding, chipping, scraping or any combination of these methods in accordance with the steel structures painting council specifications SSPC-SP-2 or SSPC-SP-3.

B.3.COLOUR CODING

B.3.1.Finish Colour This requirement shall not apply to galvanized equipment or stainless steels, aluminium or other non-ferrous metals.

B.3.1.1.Steel structures Steel structures shall have the following colours: - Main steel structures and piperacks Brown beige RAL 1011 - Piping supports Light beige RAL 1001 or Aluminium RAL 9006 - Handrails (excluding toe plate and midrail) Black RAL 9005 -Handrails (toe plate and midrail) Orange RAL 2003

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- Stair way (excluding toe plate and midrail) Black RAL 9005 - Stair way (toe plate and midrail) Orange RAL 2003 - Safety gates Orange RAL 2003 - Platforms lower edges and toe plates, midrails and safety platforms Orange RAL 2003 - Upper ladders and round platforms and top rails Black RAL 9005 NOTE: Structural steel, platform ladders, handrail etc. including pipe supports

shall be color finished in accordance with the reference drawings attached to this Appendix.

B.3.1.2.Various equipment

Vessel and similar equipment shall have the following colours: - Vessels up to 148ºC Light ivory RAL 1015 - Vessels over 148ºC Aluminium RAL 9006 - Exchangers and air cooler header boxed up to 148ºC White RAL 9010 - Exchangers and air cooler header boxes over 148ºC Aluminium RAL 9006 - Tanks:(Conform to Employer) AV-gas,MO-gas,Naphta,Pentane White RAL 9010 Kerosene White RAL 9010 Gas oil Light ivory RAL 1015 Diesel Light ivory RAL 1015 Fuel oil,Crude oil Brown beige RAL 1011 Water Aluminium RAL 9006 - Ducts Aluminium RAL 9006 - Furnaces/boiler W.H. boiler radiant and convection Aluminium RAL 9006 - Steam turbine generator Manufacturer standard - Gas turbine generator Manufacturer standard - Ejectors Same as piping - Flame arrestors Same as piping - Forced draft fans Manufacturer standard

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- Cooling tower fans Manufacturer standard - Mono rail/hoist Same as crane - Strainers Same as piping - Silencers Same as equipment - Tank mixers Manufacturer standard

B.3.1.3.Machinery

Machinery shall have the following colours: - Pumps, compressors and drivers Manufacturer standard

B.3.1.4.Electrical & Instrument Equipment

- Conduit and Fittings Manufacturer standard - Switches, starters, etc. Manufacturer standard - Fuse boxes, electric distribution boards, motor switches, electric cable metallic joints Blue RAL 5010 - Control panels Manufacturer standard

B.3.1.5.Piping

Piping shall have the following colours: - Piping up to 93ºC Light ivory RAL 1015 - Piping over 93ºC Aluminium RAL 9006 - Firewater,Foam line Red RAL 3000 -Dangerous, chemicals and gases Yellow RAL 1006 (e.g. Caustic soda, H2SO4)

B.4.Marking by Lettering and colour Bands

B.4.1.The paint shall be applied in adequate coats to readily identify the applicable color.

B.4.1.1To alleviate color bleed through when using primary and secondary color striping, it may be necessary to use templates in applying each color. Templates should be designed in such a manner that one color will not be applied over another color.

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B.4.1.2.Piping spools shall be color coded as follows:

A 6” wide color band shall be applied around the circumference of the pipe. The

color band shall be a solid primary color or primary color with secondary color as designated in the following schedule. Unless otherwise agreed, colour bands shall be arranged at significant points for plant operation (e.g. where pipes start and end or at branches or at valves).

- Finish colour: see B.3.1.5 colours - Primary colour: Band, 150 mm wide - Process piping White RAL 9010 - Service piping Green RAL 6010 - Secondary colour: Band, 50 mm wide - Liquid Hydrocarbons DK Brown RAL 8014 - Gaseous Hydrocarbons DK Beige RAL 1011 - Hydrogen Orange RAL 2003 - Asphalt Black RAL 9005 - Amine Yellow RAL 1006 - Sulphur Green RAL 6010 - Caustic and acid -- -- - Inert gas and air Orange RAL 2003 - Steam White RAL 9010 - Water DK Brown RAL 8014 - Drinking water Blue RAL 5010

B.4.1.3.Equipment shall be additionally marked with lettering (e.g. vessel No.). Style

and extent of these markings are indicated herebelow. Lettering for equipment shall be placed once on each item of equipment at a clearly visible location. The letters should have the following height: - for equipment with dimensions of ≤ 1 m to 5 m : 80 mm - for equipment with dimensions of > 5 m to 15 m : 300 mm - for equipment with dimensions of > 15 m to 50 m : 600 mm

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- for equipment with dimensions of > 50 : 900 mm The blank space between the letters should be 10% of the letter height. The type of letters shall be determined on size. The color of letters shall be blank color RAL 9005. Lettering for tanks shall be placed at a height of approx 4/5 of the shell height. Lettering for horizontal vessels and spherical vessels, shall be placed at the height of the centerline.

B.5.IDENTIFICATION COLORS DETAILS

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Documents

PAINTING - iiiWe.com · - The purpose of this specification is to define material standard specification for painting in BANDAR ABBAS REFINERY GASOLINE PRODUCTION INCREASE PROJECT