Blasting and Painting Procedure

SHELL PETROLEUM DEVELOPMENT COMPANY OF NIGERIA Classification Status: Restricted -

OCTOBER, 2012 DOCUMENT NUMBER: FYP-NG01009296-YOKA1-RA-6068-00003

PROJECT: COMPLETION AND COMMISSIONING OF YOKRI FLOWSTATION

CONTRACT No.: NG01009296

DOCUMENT TITLE: BLASTING AND PAINTING PROCEDURE

APPROVAL Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Limited

Revision

A01

Date

24-10-2012

NATONY LIMITED RC. 105963 Km 5 NPA Expressway, Ekpan-Warri, Delta State.

Description

Issued for Approval

NATONY

SPDC

Originator

Checker

Approved By

Reviewed By

Approved By

Joseph Chinedu

Wickliffe Oladeinde

Femi Alao

Nnameka Anyachor /N.V.L.N. Rao

AMOBI A. R.

COMPLETION AND COMMISIONING OF YOKRI FLOWSTATION NATONY LIMITED

BLASTING AND PAINTING PROCEDURE FYP-NG01009296-YOKA1-RA-6068-00003

RC. 105963

A01

ADDITIONAL AGREEMENT/APPROVAL RECORD

Party

Ref Ind.

Name

Sign

Date

Revision Philosophy         

Revisions for review will be issued at R01, with subsequent R02, R03, etc as required. All revisions approved for issue or design will be issued at A01, with subsequent A02, A03, etc as required. Documents approved for Construction will be issued at C01, C02, C03, etc as required Documents or drawings revised as “As built” will be issued as Z01, Z02 Z03 etc as required Narrative sections revised from previous approved issues are to be noted in the table below and/or highlighted in the RH margin (using the appropriate revision status) thus: A02 Previous revision highlighting to be removed at subsequent issues. Drawings/diagrams revised from previous approved issues are highlighted by 'clouding' the affected areas and by the use of a triangle containing the revision status. If a document is cancelled the document will be issued at the next sequential number and suffixed with a X. For example if R02 is the current revision then X03 will be the Cancelled revision All revisions to this document must be approved by the relevant Technical authority

Revision History Revision No.

Date of issue

Document ID/Reason for change

A01

24-10-2012

Issued for Approval

R03

08-09-2012

Issued for Review

R02

28-08-2012

Issued For Review

R01

10-07-2012

Issued For Review

Blasting and Painting Procedure FYP-NG01009296-YOKA1-IN-6070-00003

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COMPLETION AND COMMISIONING OF YOKRI FLOWSTATION NATONY LIMITED

RC. 105963

BLASTING AND PAINTING PROCEDURE FYP-NG01009296-YOKA1-RA-6068-00003

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CONTENTS 1.0

SCOPE…………………………………………………………………………………….4

2.0

PURPOSE………………………………………………………………………………...4

3.0

DEFINITION OF TERMS/ABREVIATIONS…………………………………………...4

4.0

REFERENCE DOCUMENT…………………………………………………………….4

5.0

RESPONSIBILITIES……………………………………………………………………..4

6.0

WORK PROCEDURE.............................................................................................5

6.1

MATERIALS............................................................................................................5

6.2

GRIT BLASTING.....................................................................................................6

6.3

PRIMING AND PAINTING.......................................................................................7

6.4

INSPECTION AND TESTING..................................................................................8

6.5

INSPECTION RECORDS AND REPORTING.........................................................8

6.6

PAINTING INSPECTION REPORT FORM.............................................................9

Blasting and Painting Procedure FYP-NG01009296-YOKA1-IN-6070-00003

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COMPLETION AND COMMISIONING OF YOKRI FLOWSTATION NATONY LIMITED

RC. 105963

BLASTING AND PAINTING PROCEDURE FYP-NG01009296-YOKA1-RA-6068-00003

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1.0 SCOPE This procedure is applied to the painting of all piping, structural steel, bends and pipe fittings, valves, machinery and other steel equipments subjected to corrosion by atmospheric environment in this project. This procedure is to be applied in conjunction with other applicable project specification, procedure, drawing and manufacturer’s instruction The method statement shall describe the method of blasting of pipes and painting of pipes, structural skids, vessels and tanks in accordance with applicable codes and standards for Forcados Yokri Integrated Completion Project onshore.

2.0 PURPOSE The purpose of this procedure is to provide requirement and responsibilities for painting activities which should be followed till the end of this project.

3.0 DEFINITION OF TERMS/ABBREVIATIONS. COMPANY:

Shell Petroleum Development Company Limited (SPDC)

CONTRACTOR:

An entity (Natony Limited) assigned to perform the WORK described in the contract.

PROJECT SITE:

FYIP Onshore Completion Works For Yokri Flow station. Location where work is to be performed.

4.0 REFERENCE DOCUMENTS a) b)

DEP 30.48.00.31 - General: Blasting and Painting S-22: SPDC Standard Construction Specification

5.0. RESPONSIBILITIES Project Manager The Project Manager ensures adequate provision of all the resources needed for the successful execution of the work scope. He ensures that experienced and skilled persons are involved in the execution of the work scope. He is responsible for managing HSE for these operations. QA/QC Engineer

Blasting and Painting Procedure FYP-NG01009296-YOKA1-IN-6070-00003

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COMPLETION AND COMMISIONING OF YOKRI FLOWSTATION NATONY LIMITED

RC. 105963

BLASTING AND PAINTING PROCEDURE FYP-NG01009296-YOKA1-RA-6068-00003

A01

QA/QC Engineer shall be responsible for control and verification of the implementation of this method statement. He shall be responsible for all quality control and quality assurance functions. Site Engineer He ensures that the job is carried out in a professional manner and on schedule. He manages and coordinates the resources provided. Safety Officer He is responsible for validity and re-validity of Permit-to-Work (PTW) before commencement of work and makes it readily available on site for sighting of Shell Representative(s) and NATONY LIMITED QA/ QC team. He assists the Site Engineer to ensure that all personnel adhere strictly to the safety rules and regulations.

6.0 WORK PROCEDURE 6.1 MATERIALS a)

PAINTS All paints and paint materials to be used shall be obtained from manufacturers approved by SPDC. All material shall be supplied in the manufacturers original containers, durably and legibly marked with the description of the contents. This shall include the specification number, the colour reference number, the method of application for which it is intended, the batch number, date of manufacture, the shelf-life expiry date and the manufacturers name or recognized trade mark. The storage and preparation of paints and other coating materials shall be in accordance with the manufacturer’s instructions.

b)

ABRASIVES Abrasives to be used in blast cleaning all pipes, plates etc shall be as specified in ISO 8504-2. Suitable abrasive are: Chilled iron grit or shot . Steel and malleable iron grit or shot. Non-metallic abrasive (aluminium oxide, copper, slag, garnet, etc). Blasting and Painting Procedure

FYP-NG01009296-YOKA1-IN-6070-00003

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COMPLETION AND COMMISIONING OF YOKRI FLOWSTATION NATONY LIMITED

RC. 105963

BLASTING AND PAINTING PROCEDURE FYP-NG01009296-YOKA1-RA-6068-00003

A01

Sand or other materials producing silica dust shall not be used. The abrasives shall be free from oil, grease, moisture etc, Re-used abrasive shall be clean, sharp and free from contaminants. 6.2

GRIT BLASTING At the construction yard, all pipes shall be grit blasted using the following procedures: a) Align pipes at open field area, laying the pipes side by side on racks. b) Fill grit-pot with grits via pot sieve. c) Connect compressor unit and blasting gun via hoses to grit pot. d) Put on compressor unit with valves in closed position. e) Prior to blasting, grit blaster and operator shall kit-up with their safety gears, which includes blasting hoods, blasting aprons, coveralls, safety boots, hand gloves, ear muff and eye goggles. f) During blasting operation, blasting area shall be completely free of other personnel. g) The operator shall gradually open the compressor valves and then the grit pot valves until the required pressure is obtained for blasting to S.A 2 1/2 (Near white according to SPDC specification SSPC-SP10). h) The grit blaster shall grit blast the pipes one after the other, making sure all exposed surfaces are blasted. i) The operator shall close all valves and put off compressor unit after blasting one by one all exposed surface of pipes, and turn pipes through 180 0 to expose the under sides. j) Repeat steps (d) to (i), to grit blast the remaining side of pipes. k) The hose shall be carbon imprignated to avoid static shock to the operator. During site grit blasting the following procedures shall be used: For height above two (2) meter, erect scaffolds to form platforms for grit blasters. Fill grit pot with grit via sieve. Connect compressor unit and two blasting guns via hoses to two grit pots. Put on compressor unit with valves in closed position. Operators and grit blasters shall kit-up with their safety gears, which includes blasting aprons, coveralls, safety boots, hand gloves, ear muff and eye goggles, prior to blasting operation. Blasting area shall be free of other personnel during blasting operations. The operators shall gradually open the valves until the required pressure is obtained for blasting to S.A. 2 ½. It is the responsibility of the operator to ensure that the compressed air supply is free from water and oil and shall not be allowed to deliver air at temperature above 110 degree centrigrade. Note:

Blasting and Painting Procedure FYP-NG01009296-YOKA1-IN-6070-00003

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COMPLETION AND COMMISIONING OF YOKRI FLOWSTATION NATONY LIMITED

RC. 105963

BLASTING AND PAINTING PROCEDURE FYP-NG01009296-YOKA1-RA-6068-00003

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Dead manhandle to be connected along with blasting hose to the blaster for safely operation. 6.3

PRIMING AND PAINTING

6.3.1 PAINT APPLICATION REQUIREMENTS After grit blasting of pipes, and structures they shall be primed with the appropriate primer within 4 hours of abrasive cleaner application. The paint shall be applied in accordance with the manufacturer’s product data sheet, which shall include the mix ratio, the method of application, the use of thinners and over coating times. Areas with inadequate coating thickness shall be thoroughly cleaned, and if necessary, abraded, and additional compatible coats shall be applied until they meet the required film thickness. Painting shall not be performed when the temperature of the surface is less than 3 oC above the dew point of the surrounding air or when the relative humidity of the air is greater than 85% unless local conditions dictate otherwise and SPDC is in agreement. In addition, paints shall not be applied under the following conditions: - When the surface temperature is greater than 40 oC (unless a higher temperature is agreed by the paint manufacturer) - When the air temperature is less than approximately 4 oC, (Depending on local conditions) - When there is the likelihood of an unfavourable change in weather conditions within two hours after painting. If condensation, rain, dust or other foreign materials contaminate the surface of a paint coating, which is not dry to the touch, the paint shall be removed, the surface re-cleaned and fresh paint applied in accordance to DEP 30.48.00.31. At our yard the following procedures shall be adhered to: a) Fill spray pot with zinc phosphate primer. b) Connect compressor to spray pot via hoses. c) Spray painter shall be fully geared in P.P.E, which must include nose mask, protective clothing, safety boots, hand gloves and eye goggles. d) Check spray nozzle and remove pigments with solvent. As specified by Paint Manufactures e) Prime the pipes as specified by Paint Manufactures (they are aligned during grit blasting). f) The spray painter shall prime the pipes one after the other to a d.f.t of 30 to 40 microns. The pipes shall then be rotated through 180 o to show unprimed surfaces, which shall then be primed one by one to a d.f.t of 30 to 40 microns. Blasting and Painting Procedure FYP-NG01009296-YOKA1-IN-6070-00003

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COMPLETION AND COMMISIONING OF YOKRI FLOWSTATION NATONY LIMITED

g) h) i)

RC. 105963

BLASTING AND PAINTING PROCEDURE FYP-NG01009296-YOKA1-RA-6068-00003

A01

At site, painting of all pipe spools, vessels and skids shall commence after the completion of all installation works. The recommended coating system shall be as per DEP 30.48.00.31-GEN, jan’09 table 7 for new structures made of carbon steel and table 12 for maintenance coating system. Spray painters shall be fully kitted with their safety gears, which include nose masks, protective clothing, safety boots, hand gloves and eye goggles prior to painting operation.

Note: All surfaces shall be cleaned and dried before application of paint. Wet film thickness shall be determined using wet comb, while dry film thickness shall be determined using Electrometer. 6.4

INSPECTION AND TESTING Before painting activities commence, Natony Limited shall submit an inspection procedure report indicating inspections and tests to be conducted during preparation and application of the paint system for approval by SPDC. The following coating inspections and tests shall be applied.

6.4.1 SURFACE CONTAMINATION This test shall indicate the extent of substrate contamination as a result of iron, chlorides and dust as specified in ISO 8502-1, ISO 8502-2 and ISO 8502-3 respectively. 6.4.2 WET FILM THICKNESS, WFT Spot checks shall be carried out during the course of the painting operation to ensure that film thickness is being maintained. Spot checks shall be in accordance with ISO 2808, method No.7B. 6.4.2 DRY FILM THICKNESS, DFT Dry film thickness test shall be carried out in accordance with ISO 2808, method No.6 6.4.3 ADHESION The adhesion of the primer to the steel substrate and the inter coat adhesion of the subsequent coat(s) after curing shall be determined by the application of either a crosscut test in accordance with ISO 2409 or a pull-off test in accordance with ISO 4624. 6.5

INSPECTION RECORDS AND REPORTS SPDC shall have the right to inspect the paintwork at all stages of preparation and to reject any tool, instrument, material, equipment or work, which do not conform to specifications. Prior to final acceptance of the paintwork, an inspection shall be made and Natony Limited and SPDC shall both be represented and they shall sign an agreed inspection report. A sample of this inspection report is attached to this document.

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COMPLETION AND COMMISIONING OF YOKRI FLOWSTATION NATONY LIMITED

RC. 105963

BLASTING AND PAINTING PROCEDURE FYP-NG01009296-YOKA1-RA-6068-00003

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6.6. PAINTING INSPECTION REPORT FORM REPORT No.: _____________________DATE: _______________ PROJECT:

LOCATION:

CLIENT:

DATE OF WORK:

ITEM DESCRIPTION: MATERIAL CONDITION: EQUIPMENT / TOOLS USED:

INSTRUMENT USED: WEATHER CONDITION: PAINTING PERIOD: SURFACE CONDITION: CONDITION AFTER SURFACE PREPARATION: PAINT APPLICATION TECHNIQUE (S): TYPE OF QUALITY CONTROL CHECKS: 1. WFT 2. DFT

3. SURFACE CONTAMINATION 4. ADHESION

RESULT / COMMENT:

NAME OF INSPECTOR: ___________________

SIGNATURE: _____________

DATE: __________ NAME OF NATONY LTD REP: ___________________

SIGNATURE: ____________

DATE : __________

Blasting and Painting Procedure FYP-NG01009296-YOKA1-IN-6070-00003

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