Blasting and Painting
Short Description
Blasting and Painting...
Description
PROJECT:
PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
Petrofac
CLIENT:
PEDIL REV:
D1
SHEETS INDEX AND REVISIONS Rev.
Section
Revision Description
Note: Revision Table to be used on Post-AFD Issues
HOLDS Hold No.
Section
Description
DOCUMENT NUMBER:
SFBE-0000-00-PI-SPE-0006 DATE:
08-02-2011
PAGE NO:
2 of 64
PROJECT:
PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
Petrofac
CLIENT:
PEDIL REV:
D1
DOCUMENT NUMBER:
SFBE-0000-00-PI-SPE-0006 DATE:
08-02-2011
PAGE NO:
3 of 64
ABBREVIATIONS
Abbreviation
Description
ABS
Acrylonitrile Butadiene Styrene
ASTM
ASTM International (former American Society for Testing & Materials)
CP
Cathodic Protection
DFT
Dry Film Thickness
Fe3O4
Iron Oxide ( magnetite)
FPSO
Floating Production Storage and Offloading vessel
FROSIO
Norwegian Professional Council for Education and Certification of Inspectors for Surface Treatment
ISO
International Standards Organisation
ITP
Inspection Test Plan
J
Joule
Kv
Kilovolt
m2
Square metre
mm
millimetre
mg/m2
Milligram per metre squared
MDFT
Minimum Dry Film Thickness
MEK
Methyl Ethyl Ketone
MIO
Micaceous Iron Oxide
MPa
Megapascal
MSDS
Material Safety Data Sheets published by Manufacturer
NACE
NACE International (former National Association of Corrosion Engineers)
PROJECT:
PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
Petrofac
CLIENT:
PEDIL REV:
D1
DOCUMENT NUMBER:
SFBE-0000-00-PI-SPE-0006 DATE:
08-02-2011
PAGE NO:
4 of 64
NaCl
Sodium Chloride
NDFT
Nominal Dry Film Thickness is the dry film thickness specified for each coat or for the complete paint system
NORSOK
Norwegian Standards Organization
PFP
Passive Fire Protection
pH
Measurement of acidity
ppm
Parts per Million
RAL
Colour definition according to RAL standard of Institute fϋr Gϋtesicherung und Kennzeichnung e.V.
SSPC
Steel Structures Painting Council
tba
To be advised
TLV
Threshold Limit Value
TSA
Thermally Sprayed Aluminium
UV
Ultra Violet
v/cm
Volts per centimetre
VOC
Volatile Organic Compounds
WFT
Wet Film Thickness
µs/cm
Microseimens per centimetre
µm
micron
PROJECT:
PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
Petrofac
CLIENT:
PEDIL REV:
D1
DOCUMENT NUMBER:
SFBE-0000-00-PI-SPE-0006 DATE:
08-02-2011
PAGE NO:
5 of 64
CONTENTS
SHEETS INDEX AND REVISIONS........................................................................... 2 HOLDS........................................................................................................ 2 ABBREVIATIONS ............................................................................................ 3 CONTENTS................................................................................................... 5 1
INTRODUCTION ...................................................................................... 8
1.1
General ............................................................................................... 8
1.2
Scope.................................................................................................. 8
1.3
DEFINITIONS ......................................................................................... 9
2
REFERENCE DOCUMENTS .........................................................................11
2.1
Codes and Standards ..............................................................................11
2.2
Reference Project Documents ..................................................................13
3
HEALTH, SAFETY AND ENVIRONMENTAL REQUIREMENTS ..................................14
3.1
Environmental Conditions .......................................................................14
3.2 CONTRACTOR’s Responsibilities towards Health, Safety and Environmental Regulations ................................................................................................14 4
WARRANTY REQUIREMENTS......................................................................15
4.1
General ..............................................................................................15
4.2
Warranty inspection ..............................................................................16
5
GENERAL REQUIREMENTS ........................................................................17
5.1
General ..............................................................................................17
5.2
Documentation.....................................................................................18
5.3
Coating Procedures ...............................................................................19
5.4
Personnel ...........................................................................................19
5.5
Reporting............................................................................................20
5.6
Surfaces Not Requiring Coating .................................................................20
PROJECT:
PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
Petrofac
CLIENT:
PEDIL REV:
D1
DOCUMENT NUMBER:
SFBE-0000-00-PI-SPE-0006 DATE:
08-02-2011
PAGE NO:
6 of 64
5.7
Coating System SUPPLIERs Representative ...................................................20
5.8
Audits ................................................................................................20
6
MATERIAL REQUIREMENT.........................................................................21
7
SURFACE PREPARATION ..........................................................................23
7.1
General ..............................................................................................23
7.2
Pre-cleaning ........................................................................................24
7.3
Blast Cleaning ......................................................................................25
7.4
Access................................................................................................28
7.5
Environmental Conditions .......................................................................28
7.6
Additional Preparation ...........................................................................28
7.7
Other Cleaning Procedures ......................................................................29
8
COATING APPLICATION ...........................................................................31
8.1
General ..............................................................................................31
8.2
Mixing and thinning ...............................................................................32
8.3
Compatibility with existing coating systems .................................................32
8.4
Application Method................................................................................32
8.5
Overcoating Method...............................................................................33
8.6
Environmental Conditions .......................................................................33
8.7
Holding Primers ....................................................................................34
8.8
Coating thickness ..................................................................................34
8.9
Multi coat systems.................................................................................35
8.10 Weld areas ..........................................................................................35 8.11 Carbon/stainless steel joints ....................................................................36 8.12 Protection of applied coatings ..................................................................36 8.13 Protection of coated contact points ...........................................................36 8.14 Internal Coating Of Tanks, Vessels And Equipment .........................................36 9
REPAIRS..............................................................................................37
9.1
General ..............................................................................................37
PROJECT:
PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
Petrofac
CLIENT:
PEDIL REV:
D1
DOCUMENT NUMBER:
SFBE-0000-00-PI-SPE-0006 DATE:
08-02-2011
PAGE NO:
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9.2
Insufficient Thickness ............................................................................37
9.3
Excess Thickness ..................................................................................37
9.4
Film Defects ........................................................................................37
9.5
Repairs To Zinc Coated Surfaces ...............................................................38
9.6
Coating Under Intumescent Fireproofing .....................................................38
10
INSPECTION AND TESTING........................................................................40
10.1 General ..............................................................................................40 10.2 Inspection Of Prepared Surfaces ...............................................................40 10.3 Visual Inspection Of Coated Surfaces ..........................................................41 10.4 Coating Thickness Measurement (DFT) ........................................................41 10.5 Holiday Testing.....................................................................................43 10.6 Additional Tests....................................................................................43 11
QUALITY CONTROL ................................................................................45
11.1 General ..............................................................................................45 11.2 Final Inspection ....................................................................................45 11.3 Rejected Work and Equipment .................................................................46 11.4 Quality Plan.........................................................................................46 11.5 Reporting............................................................................................47 11.6 Inspection Personnel and Equipment ..........................................................47 12
DOCUMENTATION ..................................................................................48
ANNEX A.
EXTERNAL COATING SYSTEMS ...........................................................49
A.1 COATING SYSTEMS SUMMARY SHEETS..........................................................50 ANNEX B.
OLOUR CODING .............................................................................59
B.1
COLOUR SCHEDULES FOR OFFSHORE EQUIPMENT ...........................................59
B.2
COLOUR CODING OF PIPING......................................................................60
ANNEX C.
INSPECTION & TESTING (FOR ITP) FOR COATING WORK ............................62
PROJECT:
PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
1
INTRODUCTION
1.1
General
Petrofac
CLIENT:
PEDIL REV:
D1
DOCUMENT NUMBER:
SFBE-0000-00-PI-SPE-0006 DATE:
08-02-2011
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The Project is an offshore green-field development in Malaysia which currently consists of a Wellhead Platform (WHP) and adjacent Floating Production & Storage Unit (FPSO) linked by subsea flowlines with gas export to a third party platform. This specification covers the minimum technical requirements for surface preparation, method of application, inspection and materials to be used for all external coating of equipment, steel structures and piping. 1.2
Scope This document is applicable to the Topsides and Substructure Structural steel, piping and equipment for the FPSO and the WHP on the Project X Development. The following items and areas are not to be coated unless otherwise specified on datasheets or on COMPANY drawings:
Equipment supplied finish coated with an approved system (touch-up of damaged areas is required);
Equipment chrome plating or nickel plated, copper, brass, plastic and other similar surfaces;
Acoustic or textured ceiling materials;
Galvanized steel surfaces for interior service except where required for safety or identification purpose or for architectural or decorative treatment, unless the surface has been damaged;
Exposed threads, threaded bolt holes and flange mating surfaces;
Stainless steel surfaces except as defined in System 4, Annex A of this Specification;
Sacrificial and impressed current anodes and reference electrodes;
Moving parts such as valve spindles, delicate machinery and machined surfaces;
Push buttons and switches;
Instrument and electrical items such as glass faced pressure gauges, light fittings, cables, instrument panels etc.;
Name plates, tag plates, and code stampings;
PROJECT:
PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
Concrete and masonry work;
Fibre reinforced plastic items.
Petrofac
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PEDIL REV:
D1
DOCUMENT NUMBER:
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Vendor package equipment which will be delivered to the jobsite coated with a shop applied system shall be coated in accordance with this Specification unless Vendor’s specification has been agreed in writing by COMPANY. Other exclusions from the scope of this specification and covered elsewhere by alternative project specifications are as given below:
1.3
Fireproofing, however surface preparation and application of coating required under the PFP is covered in this specification (Ref. 49);
Specific requirements for Thermally Sprayed Aluminium (TSA) coating systems (Ref.50);
Thermal and Acoustic Insulation (Ref. 51);
Internal lining of pressure vessels and storage tanks (Ref. 52);
Coating of Pipelines (Ref. 47).
DEFINITIONS Within this Requisition the following definitions shall apply: COMPANY
shall mean
Petrofac Energy Development International Limited, its staff, employees, and any authorised agents
CONTRACTOR
shall mean
The organisation responsible execution of this scope of work
DOCUMENT
shall mean
Any drawings, data sheets, specifications, certification, or reports required to be generated by this Requisition for any purpose
SUB-SUPPLIER
shall mean
Any party contracted by the SUPPLIER to supply part of the materials or services required by this Requisition
SUPPLIER
shall mean
The COMPANY responsible for the manufacture or supply of equipment or
for
the
PROJECT:
PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
Petrofac
CLIENT:
PEDIL REV:
D1
DOCUMENT NUMBER:
SFBE-0000-00-PI-SPE-0006 DATE:
PAGE NO:
08-02-2011
10 of 64
materials shall
shall indicate
a mandatory requirement
should
shall indicate
a recommendation
PROJECT:
PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
2
REFERENCE DOCUMENTS
2.1
Codes and Standards Ref no
Document Number
(1)
ISO 12944-2
(2)
ISO 12944-7
(3)
ISO 12944-8
(4)
ISO 9001
(5)
ISO 4628-3
(6)
NACE 52302
(7)
ISO 17024
(8)
ASTM G 8
(9)
ASTM G 42
(10)
SSPC-SP 1
(11)
ISO 8504 Part 2
(12)
ISO 8502 Part 3
(13)
ISO 8503 Part 1
(14)
ISO 8501 Part 1
(15)
NACE RP0287
(16)
ISO 8502 Part 6
(17)
ISO 8502 Part 9
(18)
ASTM A 380
(19)
ASTM D 4285
Petrofac
CLIENT:
PEDIL REV:
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DOCUMENT NUMBER:
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Description Paints and varnishes. Corrosion protection of steel structures by protective paint systems. Part 2: Classification of Environments Paints and varnishes. Corrosion protection of steel structures by protective paint systems. Part 7: - Execution & Supervision of Paint Work Paints and varnishes. Corrosion protection of steel structures by protective paint systems. Part 8: Development of Specifications for New Work & Maintenance Quality Management Systems Paints and varnishes - Evaluation of degradation of coatings Designation of quantity and size of defects, and of intensity of uniform changes in appearance - Part 3: Assessment of Degree of Rusting Guide to Qualification of Tradesman Industrial Maintenance Painters; NACE; 1988 Conformity assessment - General requirements for bodies operating certification of persons Standard test methods for cathodic disbonding of pipeline coatings Standard test method for cathodic disbonding of pipeline coatings subjected to elevated temperatures Solvent Cleaning Preparation of steel substrates before application of paints and related products. Surface preparation methods. Part 2: Abrasive blast cleaning Preparation of steel substrates before application of paints and related products. Tests for the assessment of surface cleanliness. Part 3: Assessment of dust on steel surfaces prepared for painting (pressures sensitive tape method) Preparation of steel substrates before application of paints and related products. Surface roughness characteristics of blastcleaned steel substrates. Part 1: Specification and definitions for ISO surface profile comparators for the assessment of abrasive blast- cleaned surfaces Preparation of steel substrates before application of paints and related products. Visual assessment of surface cleanliness – Part 1: Rust grades and preparation grades of uncoated steel substrates and of steel substrates after removal of previous coatings Field Measurement of Surface Profile of Abrasive Blast Cleaning Steel Surfaces Using a Replica Tape Preparation of steel substrates before application of paints and related products. Tests for the assessment of surface cleanliness. Part 6: Sampling of soluble impurities on surfaces to be painted – The Bresle method Preparation of steel substrates before application of paints and related products. Tests for the assessment of surface cleanliness. Part 9: Field method for the conduct metric determination of water soluble salts Standard Practice for Cleaning, Descaling, and Passivation of Stainless Steel Parts, Equipment, and Systems Standard test method for indication oil or water in compressed air
PROJECT:
PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
(20)
ISO 11127 Parts 1-7
(21)
ISO 11124-2
(22)
ISO 11124-3
(23)
ISO 11126-9
(24)
ISO 11126-10
(25)
ISO 11126-4
(26)
ISO 11126-7
(27)
ISO 8504 Part 3
(28)
ISO 8504 Part 1
(29)
ASTM D 5064
(30)
SSPC - SP 11
(31)
ISO 8502 Part 4
(32)
ASTM E 337
(33) (34)
SSPC-PA 2 ISO 2808
(35)
ISO 17025
(36)
ISO 19840
(37)
ASTM 4541
(38)
ISO 2409
(39)
ASTM 4752
(40)
NACE RP0188
(41)
ISO 3549
(42)
DIN 8566-2
(43)
CAP 437
(44) (45)
NORSOK M 501 DNV-RP-401
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Preparation of steel substrates before application of paints and related products – Test methods for non-metallic blast cleaning abrasives Preparation of steel substrates before application of paints and related products. Specifications for metallic blast-cleaning abrasives. Part 2: chilled-iron grit Preparation of steel substrates before application of paints and related products. Specifications for metallic blast-cleaning abrasives. Part 3: high-carbon cast-steel shot and grit Preparation of steel substrates before application of paints and related products - Specifications for non-metallic blast-cleaning abrasives - Part 9 : staurolite Preparation of steel substrates before application of paints and related products - Specifications for non-metallic blast-cleaning abrasives - Part 10: almandite garnet Preparation of steel substrates before application of paints and related products. Specifications for non-metallic blast-cleaning abrasives. Part 4: coal furnace slag Preparation of steel substrates before application of paints and related products. Specifications for non-metallic blast-cleaning abrasives. Part 7: fused aluminium oxide Preparation of steel substrates before application of paints and related products. Surface preparation methods. Part 3: Hand and power tool cleaning Preparation of steel substrates before application of paints and related products. Surface preparation methods. Part 1: General principles Standard Practice for Conducting a Patch Test to Assess Coating Compatibility Power Tool Cleaning to Bare Metal Preparation of steel substrates before application of paints and related products. Tests for the assessment of surface cleanliness. Part 4: Guidance on the estimation of the probability of condensation prior to paint application Standard Test Method for Measuring Humidity with a Psychrometer (the Measurement of Wet- and Dry-Bulb Temperatures) Measurement of dry coating thickness with magnetic gauges Paints and Varnishes - Determination of Film Thickness General requirements for the competence of testing and calibration laboratories Paints and varnishes Corrosion protection of steel structures by protective paint systems Measurement of, and acceptance criteria for, the thickness of dry films on rough surfaces Standard Test Method for Pull-Off Strength of Coatings Using Portable Adhesion Testers Paints and Varnishes - Cross-Cut Test Standard Test Method for Measuring MEK Resistance of Ethyl Silicate (Inorganic) Zinc-Rich Primers by Solvent Rub Recommended practice for discontinuity (holiday) testing of protective coatings Zinc dust pigment for paints. Specifications and test methods Filler Metals for Thermal Spraying - Solid Wires for Arc Spraying Technical Delivery Conditions Civil aviation authority standard for helideck “offshore helicopter landing areas: a guide to criteria, recommended minimum standards, and best practice” Surface Preparation and Protective Coatings Recommended Practice Cathodic Protection
PROJECT:
PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
2.2
Petrofac
CLIENT:
PEDIL REV:
D1
DOCUMENT NUMBER:
SFBE-0000-00-PI-SPE-0006 DATE:
PAGE NO:
08-02-2011
13 of 64
Reference Project Documents Ref no (46) (47) (48) (49) (50) (51) (52)
Document Number SFBE-0000-00-PR-BOD-0001 SFBE-5000-00-PL-SPE-0006 SFBE-0000-00-PI-SPE-0010 SFBE-0000-00-PI-SPE-0014 SFBE-0000-00-PI-SPE-0015 SFBE-0000-00-PI-SPE-0016 SFBE-0000-00-PI-SPE-0017
Description Basis of Design 3LPE Anti-Corrosion Coating Specification Cathodic Protection Specification Specification for Fireproofing of Structural Steel and Facilities Specification for Thermally Sprayed Aluminium Specification for Thermal and Acoustic Insulation Specification for the Internal Lining of Vessels and Tanks
PROJECT:
PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
Petrofac
CLIENT:
PEDIL REV:
D1
3
HEALTH, SAFETY AND ENVIRONMENTAL REQUIREMENTS
3.1
Environmental Conditions
DOCUMENT NUMBER:
SFBE-0000-00-PI-SPE-0006 DATE:
PAGE NO:
08-02-2011
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Equipment shall be suitable for long term, continuous operation in the site environmental and service conditions as stated in project document SFBE-00-0000-PR-BOD-0001 Basis of Design (Ref. 46). 3.2
CONTRACTOR’s Responsibilities towards Health, Safety and Environmental Regulations The Manufacturer shall be responsible for ensuring that the goods and services supplied meet all applicable regulations on health, safety and environmental issues. The CONTRACTOR shall be responsible for all aspects of safety and personal protection in the execution of the work. Local and statutory Environmental rules and regulations shall be adhered to. The Manufacturers safety data sheets shall be obtained and shall be made continuously available at the work place. Manufactures instruction on handling and storage shall be followed at all times. Flammable products, thinners, etc. are to be stored in accordance with current local regulations, away from combustible materials and all precautions taken to avoid creating a fire hazard. All personnel shall be provided with approved personnel protection, e.g. protective clothing, safety glasses, safety shoes, hard hats, goggles, respirators, earplugs and any other necessary safety equipment. All safety equipment shall be maintained to a good working condition. Adequate warning signs shall be prominently displayed at all access points to areas where abrasive blasting and painting is in progress. Handling and disposal of hazardous waste resulting from the CONTRACTOR's painting activities shall be in accordance with regulations and specific contract requirements.
PROJECT:
PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
4
WARRANTY REQUIREMENTS
4.1
General
Petrofac
CLIENT:
PEDIL REV:
D1
DOCUMENT NUMBER:
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08-02-2011
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CONTRACTORs undertaking painting and/or coating work which is to be carried out in accordance with this specification shall guarantee the quality of their coating work. Before any painting or coating work shall commence, the warranty period and associated coating condition shall be agreed with the COMPANY. The coating systems to be used in accordance with this specification shall be suitable for a marine environment (C5-M as specified in ISO 12944-2, Ref. 1). The use of coating systems as described in this specification and approved by the COMPANY shall not affect the warranties to be agreed by the contract parties involved. If reference areas are proposed and agreed, they shall be in accordance with requirements as specified in ISO 12944-7 Clause 7 (Ref. 2) and ISO 12944-8 Table 1, No. 1.13 (Ref. 3). Surfaces that have deteriorated beyond the specified level of breakdown within the warranty period shall be repaired by the CONTRACTOR and he/she shall bear the cost of materials, equipment and labour for the repair. Only surfaces that have suffered from mechanical damage or chemical spillage as a result of operational activities fall outside this warranty. In case of a dispute on the condition of the coating work that has been inspected, and agreed, an independent expertise body shall conduct a review inspection at the CONTRACTOR’s cost. Both the COMPANY and the CONTRACTOR shall accept the findings of the inspection by this independent consultant. Skid-mounted assemblies and packaged equipment, and all major items such as vessels and pumps etc., will normally be delivered in the fully coated condition. The CONTRACTOR shall carry out any necessary repairs to these coatings in addition to providing coating systems on items within CONTRACTOR’s own scope. During preparation and coating, the CONTRACTOR shall be responsible for the protection of all structure and equipment surfaces from mechanical damage or coating over-spray and droppings. The coating systems listed in Annex A shall be applied. Only Manufacturer’s with a proven track record of supply of equivalent products to the offshore industry with quality systems certified to ISO 9001 (Ref. 4), and with experienced locally
PROJECT:
PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
Petrofac
CLIENT:
PEDIL REV:
D1
DOCUMENT NUMBER:
SFBE-0000-00-PI-SPE-0006 DATE:
PAGE NO:
08-02-2011
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available technical representatives will be acceptable. The Manufacturer shall be able to provide supporting data from exposure tests and/or cyclic weathering testing to confirm the suitability of the materials proposed for the operating and prevailing environmental conditions. The final colour schedule for equipment, piping and structures, and the identification marking of piping, shall be in accordance with Annex B of this Specification. 4.2
Warranty inspection Ten (10) years after the acceptance date of the completed coating work: 1.
The degree of rusting shall be in accordance with ISO 4628-3 (Ref. 5) and shall not be worse than Ri 2 (0.5 % rusting) for new construction. This degree of rusting shall only be allowed in localised areas and not be scattered over the total surface area coated;
2.
Visual cracking, mud-cracking or flaking of the coating systems is not allowed. Full attention shall be given to areas such as corners where overlaps are difficult to avoid;
5.
Blistering is not allowed;
6.
No conspicuous discolouration or excessive loss of gloss shall be observed in the topcoats specified for the atmospheric zone. The topcoat on steel floors is not included but the topside of the helideck shall be included.
PROJECT:
PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
5
GENERAL REQUIREMENTS
5.1
General
Petrofac
CLIENT:
PEDIL REV:
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DOCUMENT NUMBER:
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The CONTRACTOR is responsible for all Quality Assurance and Control activities and shall be fully responsible for the quality of the work which shall be performed in strict accordance with this Specification and all other relevant documents. Unless specifically excluded in the contract, CONTRACTOR’s scope of supply shall include the provision of all facilities, equipment, consumables, labour and documentation necessary to complete the work in accordance with the requirements detailed herein. Skid-mounted assemblies and packaged equipment, and all major items such as vessels and pumps etc., will normally be delivered in the fully coated condition. The CONTRACTOR shall carry out any necessary repairs to these coatings in addition to providing coating systems on items within CONTRACTOR’s own scope. During preparation and coating, the CONTRACTOR shall be responsible for the protection of all structure and equipment surfaces from mechanical damage or coating over-spray and droppings. The coating systems listed in Annex A shall be applied. The specific coating products and the paint Manufacturer shall require approval of COMPANY. Only Manufacturers with a proven track record of supply of equivalent products to the offshore/onshore petrochemical industry over at least 10 years, with quality systems certified to ISO 9001 (Ref. 4), and with experienced locally available technical representatives will be acceptable. The paint Manufacturer shall be able to provide supporting data from exposure tests and/or cyclic weathering testing to confirm the suitability of the materials proposed for the operating and prevailing environmental conditions. The final colour schedule for equipment, piping and structures, and the identification marking of piping, shall be in accordance with Annex B of this Specification. The CONTRACTOR shall schedule a pre-job meeting to ensure that job and quality requirements are fully understood. Attendees shall include a representative of the COMPANY the CONTRACTOR’s job superintendent and coating supervisor and the coating inspector, and should also include the Manufacturer’s representative.
PROJECT:
PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
Petrofac
CLIENT:
PEDIL REV:
D1
DOCUMENT NUMBER:
SFBE-0000-00-PI-SPE-0006 DATE:
PAGE NO:
08-02-2011
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For all coatings work, the CONTRACTOR shall submit appropriate work plans and a quality plan for implementing the requirements of this specification for review by the COMPANY. Full details of Inspection and Testing requirements are included in Section 10 of this specification and details of Quality Control activities which will be carried out by COMPANY are included in Section 11 of this specification. 5.2
Documentation Prior to the commencement of work the CONTRACTOR shall obtain full details of all coatings materials to be used from the selected Manufacturer(s) including product data sheets and safety sheets. The following properties of the cured coating systems shall be reported using standardized and approved laboratory test methods:
Adhesion;
Resistance to sea water and marine atmosphere as appropriate;
Service temperature, maximum limits;
Resistance to ageing (UV/salt spray);
Resistance to mechanical damage, e.g. impact resistance, elongation, tensile strength, abrasion;
Resistance to biological attack, for coating exposed to sea water;
Resistance to cathodic disbondment when coating is used in combination with cathodic protection;
Compatibility of different coatings when such are combined;
Repairability during construction, installation and service.
Pre-qualification tests on coating materials shall be performed in accordance with NORSOK M 501 (Ref. 44). The Manufacturer’s up to date technical and application data sheets shall be obtained by the CONTRACTOR for all components of each coating system. Certificate of Conformity for each product and batch to be used shall be issued with the material. CONTRACTOR shall ensure before commencing any painting, that coating materials are within their shelf life. The CONTRACTOR shall, at no additional cost to the COMPANY, provide material samples and test panels of the prepared coated surfaces if required by COMPANY. The test shall be performed at the shop or field location where
PROJECT:
PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
CLIENT:
PEDIL REV:
Petrofac
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production coating will take place. COMPANY may witness these tests and conduct testing as seen fit. 5.3
Coating Procedures Prior to the commencement of work, CONTRACTOR’s coating procedures shall be submitted to COMPANY for approval. The detailed procedures shall include, but not necessarily be limited to the following:
5.4
Method and equipment for surface preparation;
Method and equipment for coating application;
Coating materials data (Manufacturer’s product data sheets and application notes);
Ranges of temperature and relative humidity control methods for surface preparation and coating work;
Time restrictions between surface preparation and first coat and subsequent coats;
Number of coats and minimum total dry film thickness;
Procedure for repair of damaged coating;
Methods of inspection and testing;
Frequency of monitoring, inspection and testing;
Surface preparation and coating record sheets, see Annex C;
Finish colours.
Personnel Only professional skilled blasters and painters shall be used. A certified foreman shall supervise the blasters and painters. Painters and painting supervisors shall be trained in accordance with an internationally recognized standard such as NACE “Guide to Qualification of Tradesman Industrial Maintenance Painters” (Ref. 6). Painting inspectors shall be trained and certified to NACE level I, Frosio, or equivalent. Before any work is commenced the certificates should be submitted to the COMPANY for review. Certifying bodies shall comply with ISO 17024 (Ref. 7). If not certified, the skill of all proposed blasting and painting personnel shall be verified before commencing any painting or coating works.
PROJECT:
PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
5.5
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Reporting A full reporting/recording system, as given in Annex C, shall be maintained by CONTRACTOR who shall log daily the following data:
5.6
Air and substrate temperatures;
Relative humidity and ambient conditions;
Coating progress;
Type and grade of blast cleaning abrasive;
Surface cleanliness;
Surface profiles;
Measured coating film thickness;
Visual inspection;
Coating material batch number;
Any other information pertinent to the work.
Surfaces Not Requiring Coating The items described in Section 1.2 are not to be coated unless otherwise specified on datasheets or on COMPANY drawings. Note that jacket surfaces below splash zone, piles and conductors will be protected by sacrificial anodes as defined in Project CP specification (Ref. 48). However in order to reduce the number of anodes required on the jacket structure, a partial painting system in accordance with DNV-RP-B401 Category II (Ref. 45) will be applied to at least 90% of the submerged structure. See System 8.
5.7
Coating System SUPPLIERs Representative The selected Coating Material SUPPLIER(s) shall have available at short notice a technical representative on the site for provision of advice, instruction and assistance to the CONTRACTOR. The technical representative shall be fully familiar with the requirements of this specification and with application characteristics of the coating systems(s) under consideration.
5.8
Audits COMPANY reserves the right to conduct quality, safety or environmental audits at the coating work place prior to or during the work.
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PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
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ORIGINATOR:
Painting & Coating of External Surfaces Specification
6
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MATERIAL REQUIREMENT CONTRACTOR is responsible for ensuring suitable control of materials and to ensure the Manufacturer’s recommendation on shelf life and storage is adhered to. The material shall be delivered to the site in the original containers with labels intact and seals unbroken. Manufacturer’s instructions in respect of storage, shelf life, mixing and thinning, as well as method of application and recommended time limits between coats shall be followed by CONTRACTOR. Coating materials which have gelled or otherwise deteriorated during storage shall not be used. All coating materials shall be premixed by mechanical agitators for a sufficient time to thoroughly mix pigment and vehicle and bring material to a uniform consistency. Zinc silicate primer shall be based on two pack inorganic or ethyl silicate media and shall contain not less than 85 % metallic zinc by weight in the dry film. Zinc rich epoxy primers shall be based on two pack epoxy media, containing minimum 90% metallic zinc by weight in the dry film. Epoxy-acrylic or urethane-acrylic topcoats shall be two-pack products formulated to provide either high gloss or sheen finish. They shall be suitable for recoating after extended periods of exposure to marine conditions without requiring surface roughening. Epoxy based paint shall be two pack products formulated to provide the specified film build without sagging or running. They shall contain polyamide or amine adduct curing agents. Any coating system that will be used in combination with cathodic protection shall possess excellent cathodic disbondment properties. This applies specifically to the jacket splash zone coating system. All such coating systems shall be tested in accordance with ASTM G8 (Ref. 8). The extent of disbondment at any point from the periphery of the intended holiday shall not exceed 10 mm after 28 days at ambient temperature. For the submerged jacket partial coating system the requirement for a disbondment test will be considered, based on existing paint manufacturers data. If the coating system will be subject to elevated temperatures the coating system shall be tested in accordance with
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PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
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ORIGINATOR:
Painting & Coating of External Surfaces Specification
Petrofac
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ASTM G42 (Ref. 9) at the maximum operating temperature. The acceptable criteria shall be as per the ambient temperature test. Zinc silicate primers and zinc rich epoxy primers shall not be used in combination with cathodic protection.
PROJECT:
PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
7
SURFACE PREPARATION
7.1
General
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Prior to any surface preparation, all sharp edges shall be profiled to a minimum radius of 2 mm by grinding and all rough cutting and weld profiles shall be made smooth. Flame cut areas and weld spatter shall have been ground flush. All oil, grease, and dirt shall be completely removed in accordance with SSPC SP-1 (Ref. 10). Wiping with rags soaked in thinners will not be accepted. Preparation methods and procedures for surfaces to be coated shall remove all foreign matter, surface irregularities and contaminants to bring the surface to the specified standard of cleanliness prior to the application of coatings. Metallic surfaces shall be prepared prior to coating by dry abrasive blast cleaning as outlined in ISO 8504-2 (Ref. 11). The surface profile and the anchor pattern shall be in accordance with the standard specified for the appropriate coating system in Annex A. All surfaces to be coated shall be rendered dust free to ISO 8502-3 (Ref. 12) rating 1 prior to the application of each coat by blowing the surface with clean dry air or by using an industrial vacuum cleaner. Prior to commencing blasting work on the project, blast cleaned steel panels shall be prepared in compliance with the surface preparation requirements above. The surface profile shall be measured by microscopic assessment of replicas taken from the surface or by other direct methods as approved by COMPANY. If the surface has been exposed to salt laden atmosphere, any salts shall be removed by high pressure washing with clean fresh water prior to blasting or mechanical cleaning. CONTRACTOR shall be required to demonstrate by surface testing that the salt level is not detrimental to the applied coating, see Section 7.3.1. Prefabrication primers are allowed. However, after assembly these primers shall be removed by blasting and the surface shall be blasted to the initial specified surface cleanliness unless otherwise agreed with the COMPANY. Alternative surface cleaning is only acceptable after written approval of the COMPANY. Stainless steel surfaces shall not be treated with carbon steel cleaning tools or any tools previously used on carbon steel.
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PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
7.2
Pre-cleaning
7.2.1
Carbon and low alloy steels
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Surfaces to be coated shall be free of any contamination and any excessive rust scale shall be removed. All welded areas and appurtenances shall be given special attention for removal of welding flux in crevices. Welding spatter, slivers, laminations and underlying mill scale not removed during fabrication and exposed before and during blast cleaning operations shall be removed by mechanical means. Edges shall be ground smooth as stated in Section 7.1. Excessive salt contamination of parts that have been stored in and exposed to the open air should be removed prior to blast cleaning. Salt contamination shall be assessed as specified in Section 7.3.1. All bolt holes and other regions which could be contaminated with oil or grease shall be solvent cleaned prior to the commencement of blast cleaning. Solvent cleaning shall be carried out in accordance with SSPC-SP1 (Ref. 10). When emulsion or detergent type degreasers are used, this treatment shall be followed by copious rinsing using fresh and clean potable water or pressure water/steam wash. All degreasers shall be biologically degradable. Where rectification has been necessary on blast-cleaned surfaces, the dressed areas shall be pre-cleaned as initially specified. 7.2.2
Stainless Steels, Galvanized or Non Ferrous materials If stainless steel, galvanised or non-ferrous metal surfaces are to be painted then blast cleaning shall be carried out by smooth sweep blasting, using a fine non-iron containing abrasive (e.g. aluminium oxide). On galvanised surfaces, the zinc layer shall not be damaged, but zinc corrosion products (white rust) and/or ferrous rust shall be removed; a smooth uniform surface roughness shall be achieved. No defects such as break through or crisping of the zinc layer shall occur. Surface roughness shall be in the range of 20 m to 30 m or as agreed with the Manufacturer. Alternative preparation methods include abrading with sandpaper or light grinding with a suitable (flexible) disc where sweep blasting is impossible, is acceptable subject to COMPANY approval. When aluminium components have to be painted, any loose aluminium oxide shall be removed. Detergents with a pH > 9 shall not be used with aluminium substrates.
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PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
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Painting & Coating of External Surfaces Specification
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Petrofac
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For the treatment of stainless steels, attention shall be given to the level of free halides in cleaning materials to be used. If un-coated stainless steels have to be hot-water cleaned, the temperature of the water shall be not higher than 60 °C. 7.3
Blast Cleaning Blast cleaning shall employ only sharp angular abrasive, which must be free from dust, salts and other impurities. The abrasive shall be selected to achieve the specified surface amplitude and shall be regularly checked and sieved to remove fines and impurities. Blast abrasives used on open sites or in facilities not specifically controlled to preserve the cleanliness of spent abrasive shall not be recycled. Expendable abrasive shall not be recycled. Abrasives based on metallic slag shall not contain any free metals. Only aluminium oxide or non-metallic abrasives shall be used for stainless steel and other noble metallic surfaces. Blast abrasives shall be free from oil, grease, or moisture. The maximum permissible chloride content shall be 25 ppm. Sand or silica producing abrasives shall not be used. Blast cleaning shall not be done in areas close to coating operations and/or wet coated surfaces in order to prevent dust or grit contamination. Spent abrasive shall be completely removed from the prepared surface by either vacuum cleaning and/or stiff brushing. Blast cleaned surfaces shall be prepared to the required quality of cleanliness by reference to the visual illustrations in ISO 8501-1 (Ref. 14). Surface profiles shall be continuously checked against surface comparators in accordance with ISO 8503-1 (Ref. 13) and verified using Testex surface profile tape per NACE RP 0287 (Ref. 15) or equal at the frequency given in section 10.2. The surface profile shall be in accordance with the coating system sheets given in Annex A. For carbon steel, low alloy steels and stainless steels to be coated with Thermally Sprayed Aluminium, the surface profile shall be between 70 m and 110 m. Blasted surfaces shall be examined for traces of oil, grease or other contamination and tested for the presence of soluble salts. If present, contaminants shall be removed by solvent washing or for salts, by water washing or steam cleaning, and the affected areas re-blasted.
PROJECT:
PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
7.3.1
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Residual Salt Contamination The maximum content of soluble impurities on the blasted surface before coating application shall not exceed a conductivity corresponding to a NaCl content of 20 mg/m2. Sampling and measurement shall be in accordance with ISO 8502-6 (Ref. 16) and ISO 8502-9 (Ref. 17) accordingly. Other suitable methods to measure the chloride ion content or the total salt level may be used, subject to COMPANY agreement. Testing of the level of salts shall be carried out at each work area and at least once per 100 m². The tests shall be carried out a minimum of three times per day or shift during the progress of the work. Special attention shall be given to areas where water has been trapped and dried out. No acid washes, cleaning solutions, solvents, chemical treatments, or inhibitor washes (intended to prevent rusting), shall be used on steel surfaces after they have been dry blast cleaned.
7.3.2
Surface Dust The dust level on the blast-cleaned surface at the time of coating shall not exceed quantity-rating 2 in accordance with ISO 8502-3 (Ref. 12). Checks on dust levels shall be made at least once on each component and once per 100 m2 of prepared surface and a minimum of three checks per day during the progress of the work.
7.3.3
Presence of Millscale Sa 2½ blast-cleaned carbon steel surfaces to be used for new construction or modifications shall be tested to ensure they are free of mill scale. The cleaned surfaces shall be examined using magnifying instruments or chemical tests, such as a copper sulphate test as outlined in ASTM A380 (Ref. 18). Checks on the presence of mill scale shall be made on each component and at least once per 100 m² of prepared surface and a minimum of three checks per day during the progress of the work.
7.3.4
Blast Cleaning Equipment The CONTRACTOR shall demonstrate that blasting and spraying equipment to be used is in good condition and well maintained. Blasting and painting equipment shall fully comply with any local and/or regional regulation. a. The compressed air shall be free of water and oil. Adequate separators and traps shall be provided, installed in the coolest part of the system. The presence of oil and water shall be determined on a white blotter as per
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PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
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ORIGINATOR:
Painting & Coating of External Surfaces Specification
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PEDIL REV:
Petrofac
D1
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ASTM D 4285 (Ref. 19) at least twice per twelve hours and following every compressor start-up. In no case shall the temperature of the compressed air be allowed to exceed 110 °C. b. Blasting nozzles shall be discarded and replaced when the nozzle diameter has increased through wear by more than 50 % of the original diameter. Blasting equipment, its operators and the equipment being blasted shall be properly earthed to prevent the occurrence of electrostatic discharges. Abrasive blast cleaning equipment shall be an intrinsically safe construction and equipped with a remote shut-off valve triggered by the release of a dead man's handle at the blasting nozzle. 7.3.5
Abrasives Abrasives for use in blast cleaning steels shall be in accordance with ISO 8504-2 (Ref. 11) and Table 7.1. Test methods shall be in accordance with the tests specified in ISO 11127 (Ref. 20). Each batch of abrasive should be tested to check that the abrasive meets the requirements as specified in the relevant ISO standard. The conductivity of abrasives to be used for stainless steels shall be a maximum of 150 µS/cm. The COMPANY shall approve the use of alternative abrasive materials. Table 7.1 ABRASIVE SPECIFICATION Type
Metallic
Natural Mineral
Synthetic Mineral
7.3.5.1
Generic Name
Characteristics
Iron Grit
> 1.7 % Carbon
ISO 11124-2 (Ref. 21)
Steel Grit
0.8 % to 1.2 % Carbon
ISO 11124-3 (Ref. 22)
Staurolite
Iron / Aluminium Silicate
ISO 11126-9 (Ref. 23)
Specular Haematite
Crystalline Fe2O3
Garnet
Calcium Iron Silicate
ISO 11126-10 (Ref. 24)
Coal Slag
Aluminium Silicate
ISO 11126-4 (Ref. 25)
Aluminum Oxide
Crystalline Corundum
ISO 11126-7 (Ref. 26)
Standard
Selection of abrasives There is a wide variation in performance between the products within a given generic class of abrasives. Surface anchor profile is directly proportional to the abrasive particle size (the larger the abrasive particle size, the deeper the profile). Cleaning rate is inversely proportional to the abrasive particle size (the larger the abrasive particle size, the slower the cleaning rate). A balanced
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PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
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Painting & Coating of External Surfaces Specification
Petrofac
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mixture of particle sizes will produce the optimum level of cleanliness, cleaning rate and surface profile. Steel or iron grit is commonly used as recyclable abrasives. In general, when steel shot is used, it shall be used together with steel grit and approved by the COMPANY. The abrasives shall be free from oil, grease, moisture, chloride contamination etc. 7.3.6
Grades of surface finish The recognized surface finish grades are summarized in Table 7.2 below; Table 7.2 SURFACE FINISH GRADES Surface Finish Grade
ISO 8501-1 (Ref. 14)
SSPC
NACE
Sa 3
SP-5
1
Sa 2½
SP-10
2
Sa 1
SP-7
4
-
SP-1
-
St 3
SP-3
Power Tool Cleaning To Bare Metal
-
SP-11
-
Water Jetting
-
SP-12
5
Wet Abrasive Blasting
-
TR 2
6G198
White Metal Near-White Metal Sweep Blast Cleaning Solvent Cleaning Power Tool Cleaning
7.4
Access Access for coating work should be constructed so as to provide easy and sufficient access for surface preparation, painting and inspection of all surfaces. Scaffolding shall be constructed in accordance with local regulations and the requirements of the COMPANY or as otherwise agreed with the COMPANY.
7.5
Environmental Conditions Surface preparation shall not take place when the ambient air temperature is below 5 °C, when the relative humidity is greater than 85 %, or when the metal surface temperature is less than 3 °C above the ambient dew point. Prepared surfaces shall be kept free from any contamination and shall be completely free from blast residues, dust or grit.
7.6
Additional Preparation Intended weld areas shall be masked to a distance of 50 mm to either side of the weld area after blast cleaning and before priming.
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PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
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ORIGINATOR:
Painting & Coating of External Surfaces Specification
Petrofac
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A 300 mm wide strip of uncoated blast cleaned surface shall be left between primed and unblasted surfaces to prevent damage to the newly dried coating when additional blasting is done. When blast cleaning is resumed, the 300 mm strip of previously blasted surface shall require only a light brush blast to remove any rust that might remain. When rectification has been necessary on blast cleaned or previously coated surfaces, the dressed areas shall be reblasted to remove all dust and contaminants and to provide adequate paint key. Blast cleaning shall overlap a minimum of 25 mm into the adjoining coated surface. 7.7
Other Cleaning Procedures In case of metal surfaces for which abrasive blast cleaning is specified but which, because of their location cannot be so treated, reference shall be made to the appropriate procedure as specified in the referenced standards and as summarised below.
7.7.1
General Alternative surface cleaning shall only be acceptable by written approval of the COMPANY. Restrictions specified in section 7.1 shall be adhered to. Alternative primers such as surface tolerant primers may be required for alternative methods of surface cleaning. These shall be in accordance with the Manufacturer’s recommendations. Alternative primers need the approval of the COMPANY.
7.7.2
Power Tool Cleaning Power Tool Cleaning using power wire brushes shall only be carried out where blast cleaning is impractical and shall be performed in accordance with ISO 8504-3 (Ref. 27) to achieve the required surface cleanliness in accordance with ISO 8501-1 (Ref. 14). Prior to power tool cleaning, all oil, grease etc. shall be removed by solvent cleaning in accordance with ISO 8504-1 (Ref. 28). Power tool cleaning to bare metal shall be in accordance with SPC-SP 11 (Ref. 30). Proper care is to be exercised in the use of power tools to prevent excessive roughening of the surface and the formation of ridges and burrs or conversely, burnishing of the work surface. If the surface being prepared lies adjacent to a coated surface, the power tool cleaning shall overlap the coated surface by at least 25 mm and the coated surface shall be feathered. Power tool cleaning should be confined to minor areas.
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PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
7.7.3
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Hand Tool Cleaning Hand Tool Cleaning, where specifically approved by COMPANY, shall be carried out in accordance with ISO 8504-3 (Ref. 27) to achieve the required surface cleanliness in accordance with ISO 8501-1 (Ref. 14). Prior to hand tool cleaning, oil, grease and salts shall be removed by solvent cleaning in accordance with referenced standards. Only stainless steel wire brushes shall be used to abrade stainless steel surfaces. Brushes used to abrade carbon steel shall not subsequently be used to abrade stainless steel or other high alloy materials where ferritic contamination would be detrimental.
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PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
8
COATING APPLICATION
8.1
General
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In general the requirements for the coating systems in this specification cover their application to surfaces prepared by dry blast cleaning. All application procedures and equipment shall be available for review by the COMPANY. The Manufacturer’s product data sheets and specifications for mixing, application and curing shall be considered an integral part of this Specification. The CONTRACTOR shall be responsible for obtaining the product and safety data sheets of each material from the Manufacturer. All coating systems shall be applied in accordance with this specification and the Manufacturer’s instructions and data sheets. Any conflicting requirements shall be brought to the attention of the COMPANY. Each coat shall be of a contrasting colour to the previous coat unless otherwise approved by COMPANY. All paints in any one particular paint system, whether shop or site applied, shall originate from a single Manufacturer. To ensure that only correctly blasted surfaces are coated, a minimum of 100 mm around the edges of prepared areas shall be left uncoated, unless adjoining a coated surface. If they adjoin a coated surface, the connection to the existing paint film shall be made as described in this section. In cases where the COMPANY has delivered an object to the CONTRACTOR in order to be painted, the COMPANY will inform the CONTRACTOR about the layers of coating which have already been applied. The CONTRACTOR shall complete the required system in accordance with this specification. No coating shall be applied within 50 mm to areas that need to be welded later. The specified primer coating / first coat shall be applied as soon as practicable after completion of blast cleaning (or other approved preparation) of that area. In no case shall the coating be applied to cleaned surfaces showing evidence of fresh rusting or contamination (including condensation). Blast cleaned surfaces shall be coated within a maximum of 4 hours after blast cleaning of carbon steel and within 1 hour after sweep blasting of stainless steel/duplex stainless. Zinc rich primers shall be applied over abrasive blast cleaned carbon and low alloy steel surfaces only. When using an Inorganic zinc rich ethyl silicate coating, a surface profile with angular amplitude must be achieved.
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PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
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ORIGINATOR:
Painting & Coating of External Surfaces Specification
Petrofac
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PEDIL REV:
D1
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Paints containing metallic zinc shall never be applied, or dripped onto stainless steel components. 8.2
Mixing and thinning All paint spraying equipment including mixers shall be thoroughly cleaned before the mixing of new materials. All coating materials shall be mixed and thoroughly stirred in accordance with Manufacturer’s instructions. Sufficient agitation to maintain good mixing shall be applied until the product is used. If air is entrapped in the product during mixing/stirring, sufficient time should be allowed for the air bubbles to escape before application. Only thinners specified by the Manufacturer shall be used.
8.3
Compatibility with existing coating systems Before any painting work is commenced, the compatibility with any existing coating systems or layers shall be checked. The Manufacturer shall be consulted. If there is any doubt about compatibility, patch testing in accordance with ASTM D 5064 (Ref. 29) shall be conducted to evaluate the interfacial adhesion. Over-coating shall only be carried out with products made by the same Manufacturer.
8.4
Application Method Coating application shall be airless spray unless otherwise specified. Spraying is the preferred method of application. Lines and spray equipment shall be thoroughly cleaned with the Manufacturer's recommended cleaner before the addition of new coating materials. The painting CONTRACTOR shall supply a complete range of tips with varying spray angles and sizes, as recommended by the Manufacturer. The spray pressure shall be uniform and the spray pattern smooth. Spray method including overlap, gun adjustment and direction of spray shall be in accordance with the Manufacturer’s recommendations. The spray equipment and nozzle sizes shall meet the recommendations set forth by the Manufacturer for each specific coating material. Lines and pots shall be thoroughly cleaned before adding new materials. Only the Manufacturer’s recommended cleaning agents shall be used. Coatings shall be applied in a uniform manner to the specified film thickness without runs, sags or other blemishes and with strict observance of the recommended time intervals between coats.
PROJECT:
PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
Petrofac
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PEDIL REV:
D1
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Brush application ("stripe coating") shall be used to ensure adequate film thickness at corners, edges, bolts, nuts and welds. Roller application shall only be allowed on steel floors and panels inside climate controlled areas. Rollers shall be of good quality to ensure uniformity of the applied coating. 8.5
Overcoating Method Coatings shall be dried and cured in accordance with the Manufacturer’s recommendations prior to over-coating. Over-runs, drips and smears shall be removed and any coating damage or imperfection shall be repaired before overcoating. If the DFT does not meet the requirements of this specification, corrective action shall be taken. Where zinc rich primers are applied they shall be over-coated as soon as possible but only after sufficient cure if the primer is an inorganic zinc primer. The Manufacturer’s maximum over-coating times shall not be exceeded. Zinc salts (white rust) that have formed during the intervening period shall be removed in accordance with the Manufacturer's instructions prior to overcoating.
8.6
Environmental Conditions Coating work shall not take place during the following conditions:
Under adverse weather conditions, e.g. rain, fog, snow or when such conditions are likely before the coating has become dry;
When the ambient temperature is below 10 °C, unless approved by COMPANY;
When the ambient temperature is above 40 °C;
When the relative humidity is > 85 %;
When metal surface temperature is < 3 °C above the ambient dew point (< 5 °C for sprayed aluminium);
Outside daylight hours on exterior locations.
Unless otherwise agreed, the CONTRACTOR shall supply all the weather protection, scaffolding and any other equipment necessary to ensure that the work is carried out in accordance with this specification and the agreed programme. This includes, for example, heating and air-drying equipment. Dew point determination shall be done in accordance with ISO 8502-4 (Ref. 31) and humidity measurement shall be made in accordance with ASTM E 337
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PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
Petrofac
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PEDIL REV:
D1
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(Ref. 32). Higher substrate temperatures shall only be accepted if the Manufacturer has confirmed in writing that this application will not affect the performance of the coating work. 8.7
Holding Primers A holding or temporary protective primer may be applied to prepared metal surfaces to facilitate shop or site handling procedures. Such primers shall in no way replace the function or film thickness of any part of the specified coating system. Overcoating of zinc epoxy or acrylic based holding primers will not be permitted by the COMPANY. These primers shall be completely removed by blast cleaning prior to application of specified primer / first coat. Sweep blasting of inorganic zinc shop primers may be allowed where CONTRACTOR can demonstrate to COMPANY'S satisfaction, by submission of supporting test data based on long term cyclic testing, that there is no reduction in system adhesion or performance. CONTRACTOR shall also demonstrate that sufficient controls are in place to ensure adequate cleanliness and condition of the aged primer before overcoating. Alternative surface cleaning is only acceptable after written approval of the COMPANY. In all cases, areas of localised breakdown, and weld areas or damaged areas shall be cleaned to the full specified standard. In areas where cathodic protection will be applied, the full coating system including the holding primer shall be tested for cathodic disbondment in accordance with ASTM G8 (Ref. 8) or ASTM G42 (Ref. 9).
8.8
Coating thickness The coating systems are detailed in Annex A "Coating Systems Summary Sheets" and the nominal dry film thickness (DFT) is given for each coat. The DFT of any coat shall not be greater than 40 % above nor 10 % below the nominal value specified. The exception to this is for Thermally Sprayed Aluminium (TSA) where the minimum overall thickness shall be 200 μm. The DFT shall be measured in accordance with SSPC-PA 2 (Ref. 33). The minimum dry film thickness (MDFT) is the acceptance thickness for the total applied coating system, based on a 95 % probability of this value being exceeded by any individual measurement. In practice, this requires statistical records to be maintained of thickness measurements. Spot checks shall be carried out during the course of the painting operation to ensure that film wet film thickness (WFT) is being maintained. These shall be
PROJECT:
PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
Petrofac
CLIENT:
PEDIL REV:
D1
DOCUMENT NUMBER:
SFBE-0000-00-PI-SPE-0006 DATE:
PAGE NO:
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performed according to the procedure described in ISO 2808, Method No. 1A comb gauge (Ref. 34). 8.9
Multi coat systems Sequential coats shall be contrasting colours so that each stage of the work can be readily identified and their film thickness determined. Intervals between coats shall be kept to the minimum complying with the coating SUPPLIER’s recommendations at the prevailing temperature in order to avoid contamination between coats. Any contamination between coats shall be removed. Zinc silicate and zinc rich epoxy primers shall be tie-coated or over-coated within a maximum of seven (7) days unless specific approval has been given by the COMPANY to extend this period. In the event of specified maximum recoating intervals being exceeded, or for the application of additional coats to existing weathered coatings, the COMPANY shall be informed and the Manufacturer’s recommendations for surface preparation shall be fully described. This may involve sweep blasting, or water or solvent washing before top coating or such other measure as approved by the COMPANY.
8.10
Weld areas No coating, except "weldable" grades of zinc based holding primers, shall be applied within a minimum of 50 mm or edges / areas prepared for welding. The zinc based holding primer shall be a grade which is approved by a certifying authority such as Lloyds Register or equivalent as not being detrimental to the resultant weld. The following procedure shall be followed with regard to welding, where zinc silicate or zinc rich epoxy and tie coat are used:
Intended weld area shall be masked after blast cleaning and before priming, as stated in Section 6.6;
After the application and curing of the primer, an additional 50 mm on each side of the primed surface, immediately adjoining the weld area, shall be masked. The tie coat shall be applied within the stipulated 7 days;
When ready to weld, the first tape shall be removed from the base steel exposing the weld area;
On completion of welding, the area shall be mechanically cleaned to remove weld contamination and debris; thereafter the remaining masking
PROJECT:
PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
CLIENT:
PEDIL REV:
Petrofac
D1
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tape shall be removed and the weld area pencil blasted, extending this to sweep blast the 50 mm of primed surface before proceeding with priming and coating; 8.11
Any masking tape used shall be removed as soon as possible to avoid damage to the surface underneath.
Carbon/stainless steel joints Where carbon steel is welded to stainless steel, the joint shall be coated with the coating system specified for the stainless steel with a minimum overlap of 50 mm onto the carbon steel. However, the nominal dry film thickness (NDFT) requirements for the connected carbon steel shall be applicable.
8.12
Protection of applied coatings Applied coatings shall be adequately protected and the temperature and humidity controlled in accordance with Manufacturer’s recommendations to ensure that all coatings are correctly dried and cured.
8.13
Protection of coated contact points At contact points such as where piping rests directly on a support (e.g. a saddle or beam), there is a potential for severe corrosion. Therefore coated surfaces which will be in contact with other surfaces shall be protected with nonmetallic inserts or shims such as Teflon straps or preformed self-adhesive shims, usually made from fibre reinforced plastic. Shims should have a limited contact area and high impact strength, and retain their properties over sustained load and offshore exposure conditions. A corrosion resistant U-bolt coated with a protective non-metallic material should complete the pipe clamps. Where clamps are not used, shims made from creep resistant plastic materials such as acrylonitrile butadiene styrene (ABS) are available. These can be adhesive bonded to the underside of the pipe. The selected system for protection shall be agreed with the COMPANY. Such protection shall be applied when coatings are fully cured.
8.14
Internal Coating Of Tanks, Vessels And Equipment Internal lining requirements are given in Specification for the Internal Lining of Vessels and Tanks, (Ref. 52).
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PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
9
REPAIRS
9.1
General
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Repair of defective areas shall be accomplished in the same manner as the original coating in regard to surface preparation prior to recoating, unless alternative and equivalent methods are defined within this specification, or agreed by the COMPANY. Epoxy coatings which have aged to the point where further application may give rise to intercoat adhesion problems, shall be sweep blasted after cleaning prior to further coating. Approval for this work shall be obtained from the COMPANY. 9.2
Insufficient Thickness In the event that a completely coated surface is found to have insufficient coating thickness, this surface may, subject to specific COMPANY approval, receive an additional coat or coats until the specific thickness is achieved. The COMPANY may alternatively require the surface to be blast cleaned and recoated. Surfaces to receive additional coating shall be properly cleaned of all foreign matter or contaminants and prepared as recommended by the Manufacturer.
9.3
Excess Thickness In the event that a coated surface is found to have excessive thickness, it shall be brought to COMPANY's attention who will decide on the appropriate action to be taken. Acceptance by COMPANY of excessive thickness will be considered only if the measured thickness is confirmed by the Manufacturer in writing as not being detrimental to the satisfactory service life and performance of the coating system and if testing demonstrates that there is no loss in system or intercoat adhesion.
9.4
Film Defects Defects such as misses, incorrect colour, gloss level and poor hiding power shall be repaired by applying additional coating as required. Defects such as poor finish, texture, sagging, runs, dry spray and over-spray shall be removed by abrading the film to remove the defect and then applying additional coating as required. Defects such as poor adhesion, pinholes, holidays and cracking shall be completely removed by blast cleaning to substrate and reapplying the complete system.
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PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
Petrofac
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PEDIL REV:
D1
DOCUMENT NUMBER:
SFBE-0000-00-PI-SPE-0006 DATE:
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Damaged areas, defects in the coating system such as over-runs, drips and smears that have to be removed or areas with inadequate DFT shall be recleaned. The re-cleaning shall carry over on to the secure surrounding coating for not less than 250 mm all round and the edges shall be feathered (over a width of at least 70 mm). After surface cleaning the specified coating system or the required layers of the specified coating shall be re-applied. Any additional coats shall blend in with the final coating on adjoining areas. Manufacturers shall be consulted if the existing coating requires abrading before over-coating to obtain good bonding. 9.5
Repairs To Zinc Coated Surfaces Where repairs are required to zinc rich epoxy primer or galvanized surfaces, either with or without topcoats, the following procedure shall be followed:
Blast clean surface using grit to preparation grade Sa 2½ in accordance with ISO 8504-2 (Ref. 11);
Apply 70 µm DFT zinc-rich two-pack epoxy primer in two coats;
Apply topcoats as required to achieve original system thickness.
Overcoating may be permitted before complete curing of the zinc rich epoxy provided that all volatile material has evaporated. It shall be noted that the above procedure is for repairs only. Under no circumstances shall this procedure be used in place of original priming to specification or galvanized surfaces. Surface preparation by any other method than blast cleaning shall only be permitted with the written approval of the COMPANY. COMPANY may require that CONTRACTOR completely removes and re-apply the full coating system where the extent of repairs is considered to be excessive. Inorganic zinc silicate shall not be overcoated by itself. Insufficient coating thickness shall be reblasted and recoated. Repair to damaged galvanizing when the extent of damage exceeds 40 mm2, shall be subject to COMPANY approval. 9.6
Coating Under Intumescent Fireproofing All coating which is applied under fireproofing shall be approved by the intumescent fireproofing material SUPPLIER prior to application. All steel to be fireproofed, plus a continuous band of steel of minimum width 300 mm away from it, shall be primed and over-coated with a system which has
PROJECT:
PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
Petrofac
CLIENT:
PEDIL REV:
D1
DOCUMENT NUMBER:
SFBE-0000-00-PI-SPE-0006 DATE:
PAGE NO:
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been agreed between the SUPPLIER of the fireproof material and the SUPPLIER as being compatible with the fireproofing system and materials. Approval for the use of a specific type of fireproofing shall be obtained in writing from the COMPANY.
PROJECT:
PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
10
INSPECTION AND TESTING
10.1
General
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D1
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CONTRACTOR shall monitor all work and shall conform to the requirements of this specification against a project specific Inspection Report, detailed in Annex C. The CONTRACTOR shall protect all equipment, structures and any other areas from mechanical damage, environmental damage, blockage or obstruction, damage caused by over blasting, dripping paint, paint splashes and overspray. The CONTRACTOR shall be responsible for all inspection and quality control functions necessary to achieve coating standards in accordance with this specification. All testing and inspection equipment shall be kept accurately calibrated at all times and shall be covered by current calibration certificates issued by the equipment SUPPLIER or a test laboratory accredited to ISO 17025 (Ref. 35) or equivalent for conducting such work. It is the CONTRACTOR’s responsibility to ensure that monitoring and testing work is carried out to show that the coatings comply with this specification. The COMPANY reserves the right to carry out any additional tests at random to ensure compliance and the CONTRACTOR shall have suitable calibrated test equipment available for COMPANY use. All personnel and paint products applied under fireproofing shall be approved by the intumescent fireproofing material SUPPLIER, and the COMPANY. 10.2
Inspection Of Prepared Surfaces All blast cleaned or otherwise prepared surfaces shall be visually inspected for conformance to the specified standard of cleanliness immediately prior to application of the first coat in accordance with ISO 8502-3 (Ref. 12). Random measurements of blast profile shall be made at a minimum frequency of five per shift per location, using Testex tape or other approved method per NACE RP 0287 (Ref. 15). Inspection of soluble salts on the blasted surface shall be in accordance with ISO 8502-6 (Ref. 16) and ISO 8502-9 (Ref. 17). Testing of the level of salts shall be carried out on each component and at least once per 100 m². Tests shall be carried out a minimum of three times per day or shift during the progress of the work. Special attention shall be given to areas where water has been trapped and dried out.
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PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
10.3
Petrofac
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D1
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Visual Inspection of Coated Surfaces The completed coating shall be of good visual appearance. All coated surfaces shall be visually examined after application of each coat for deleterious film defects, e.g. bubbles, blisters, pinholes, dry spray, orange peel, runs, sagging, wrinkling, grit, dust inclusions, or other deleterious anomalies. All such defects shall be repaired in accordance with this Specification. The topcoat shall completely cover the colour of the underlying layers. If antiskid systems are applied, the anti-skid material shall be uniformly dispersed on the surface of the coating.
10.4
Coating Thickness Measurement (DFT) Wet film thickness (WFT) measurements shall be made throughout the course of application of each coat in order to ascertain the adequacy and uniformity of thickness. These shall be performed according to the procedure described in ISO 2808, (Ref. 34), Method No. 1A – comb gauge. Coating dry film thickness (DFT) measurements shall be in accordance with ISO 2808. Digital magnetic induction type gauges are preferred for magnetic substrates and eddy current type gauges for non-magnetic substrates. The magnetic ‘banana’ type gauges shall not be used. Calibration shall be done in accordance with SSPC-PA 2 (Ref. 33). Measurements shall be randomly and evenly taken and the number shall be in accordance with Table 3. The number of measurements shall be increased for areas having a difficult configuration with regard to paint application or limitations in accessibility. Special attention shall be given to areas such as welds, edges, corners and parts where coatings are brush applied (these are referred to as "areas requiring special consideration" in ISO 19840, (Ref. 36).
PROJECT:
PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
CLIENT:
DOCUMENT NUMBER:
PEDIL
SFBE-0000-00-PI-SPE-0006
REV:
Petrofac
D1
DATE:
PAGE NO:
08-02-2011
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Table 10.1 - SAMPLING PLAN Area / Length of Inspection Area (m² or m)
Minimum Number of Measurements
Up to 1
5
Above 1 to 3
10
Above 3 to 10
15
Above 10 to 30
20
Above 30 to 100
30
Above 100
For additional ranges (m2 or m), the corresponding number of measurements shall be added.
Note: Areas above 1,000 m2 should be divided into smaller inspection areas
DFT shall be taken covering each coat prior to application of the following coat. The minimum measurement location frequency shall be one (1) per two (2) square metres of flat surface, with additional measurements taken at changes in section, corners or edges. Minimum, maximum and average shall be recorded for each coated item on the inspection record sheets. Acceptance criteria for the completed coating system, based on the NFDT are stated in Section 8.8, and Annex A. 10.4.1
Adhesion Tests Adhesion testing shall be carried out during all coating system qualification trials and as a routine test for atmospheric exposed organic coatings. The quality of adhesion between the coating system and the steel substrate, and of the adhesion between the coating layers, shall be measured using either: a)
A self-aligning adhesion tester in accordance with ASTM D 4541 (Ref. 37). The minimum pull-off force for coating systems with a NDFT greater than 150 m shall be: -
5 MPa for zinc primed coating systems;
-
7 MPa for non-zinc primed coatings systems.
Or: b)
A crosscut test in accordance with ISO 2409 (Ref. 38), Class 0 for coating systems with a maximum total NDFT of 150 m.
Testing shall be done on fully cured systems only, i.e. not less than 14 days after the application of the final layer. The adhesion requirements for TSA are specified in Specification for Thermal Sprayed Aluminium (Ref. 50).
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PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
Petrofac
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PEDIL REV:
D1
DOCUMENT NUMBER:
SFBE-0000-00-PI-SPE-0006 DATE:
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Adhesion testing shall be carried out on each component and at least once per 100 m² of coated surface. Spots damaged by the adhesion tests shall be repaired in accordance with this specification. Acceptance criteria for adhesion testing shall depend upon coating type and available test data for equivalent systems. As a minimum, adhesion/cohesion levels of 5 MPa for standard organic coatings and 7 MPa for glass flake epoxy. Lower individual values shall require further investigation and remedial action. Antiskid system for helidecks and walk ways: Unless otherwise specified by the COMPANY, the surface friction coefficient (µ) of anti skid coating systems applied to helidecks shall be = 0.8. The test method to be used shall be approved by the COMPANY. 10.4.2
Inorganic zinc primers A solvent rub test using MEK in accordance with ASTM D 4752 (Ref. 39) shall be carried out to ensure inorganic zinc primers are fully cured before overcoating.
10.5
Holiday Testing 100% holiday detection in accordance with NACE RP 0188 (Ref. 40) shall be carried out on all coatings used for partial immersion or total immersion service except for thermally sprayed coating systems. The coatings shall be free of pores and holidays. The high voltage technique shall be used; nominally set at 5 V/μm based on NDFT, or as agreed with the Manufacturer but not exceeding 25 kV in total. For coatings that are < 500 μm DFT, the wet sponge technique may be used if approved by the COMPANY. Defects found shall be marked, repaired and retested in accordance with this Specification. The CONTRACTOR shall provide the necessary equipment for calibrating the holiday detector.
10.6
Additional Tests COMPANY reserves the option to require CONTRACTOR to perform such testing of coating materials as may be necessary to prove that the quality is in accordance with the Manufacturer’s specifications and data sheets and is fully suitable, without reduction in performance or other detrimental effects, under the prevailing application condition. Qualities to be tested may include, but not be limited to, the following:
Volume Solids;
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PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
Petrofac
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PEDIL REV:
D1
DOCUMENT NUMBER:
SFBE-0000-00-PI-SPE-0006 DATE:
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Viscosity;
Pigment Dispersion;
Adhesion to Substrate;
Drying Time;
Cure Time;
Percentage Zinc in Dry Film (zinc-rich primers only);
Percentage Glass flake in Dry Film (glass flake containing coatings only);
Percentage of epoxy resin in the dry film.
Test methods shall generally be in accordance with COMPANY approved methods, and shall be carried out under conditions that reflect the prevailing environmental and application conditions. Any batch of materials found inferior in any way to the standards and specifications of the Manufacturer’s approved data sheets shall not be used and the COMPANY will require further testing of materials by the coating CONTRACTOR until confidence in the materials is restored to the COMPANY. Certain coatings shall be tested for adequacy of cure. The test method and frequency shall be submitted by coating CONTRACTOR for COMPANY approval and may involve solvent wiping, pencil hardness testing or other chemical or mechanical methods.
PROJECT:
PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
11
QUALITY CONTROL
11.1
General
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The COMPANY or its Representative shall have the right to inspect, check or review, at all times, any or all of the activities, equipment, inspection equipment, or products designated for the work. All parts of the work shall be accessible for this purpose. On behalf of the COMPANY, regular quality checks will be carried out by a qualified and independent third party inspector, which in no way relieves the CONTRACTOR of any responsibility with respect to the quality of the coating work. The COMPANY’s representative assigned to the painting work shall be given at least four hours notice of any change in the schedule of the painting activities. Whenever any section is to be assembled that will prevent subsequent inspection of an area, the COMPANY’s representative shall be notified in time, so that inspection and repair activities can be carried out before proceeding with the assembly. 11.2
Final Inspection As part of the overall Quality Plan, a final inspection shall be conducted prior to the final acceptance of the paintwork. This final inspection shall include a visual check of the appearance and overblast of the coating work, and checks on DFT’s of the total applied coating system and work completed. The CONTRACTOR and the COMPANY shall both be represented and they shall sign an agreed acceptance form as part of the warranty agreement. As part of the acceptance procedure, the CONTRACTOR shall prepare a report that includes the following. General:
Names of the CONTRACTOR and the responsible personnel;
Scope of work;
Dates when work was carried out;
Good quality copies of the work and quality plan;
Deviations from this Specification and the quality plan.
Inspection equipment:
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PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
Petrofac
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D1
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Type and calibration of instruments used.
Surface preparation:
Condition of surface before preparation;
Checks on the requirements as specified for cleaned surfaces.
Coating application:
Information on coating systems being applied (i.e. product names, DFT’s);
Checks on requirements as specified for coating application;
Check on DFT’s of the total coating system applied.
Inspection reports:
11.3
A good quality copy of the inspection reports of the CONTRACTOR;
Inspection reports from an independent third party.
Rejected Work and Equipment The COMPANY shall have the right to reject any work, tools, materials, testing equipment, personnel protection, staging and scaffolding where these do not conform to the requirements of the contract or this specification. Any rejected surface preparation or coating application shall be properly marked and documented. Any rejected equipment, surface preparation and/or applied coating shall be replaced or corrected to a level in accordance with this specification.
11.4
Quality Plan Before commencing any work, a written project specific quality plan shall be submitted to COMPANY approval. This plan shall include:
A sequence for the various activities in relation to the total work to be done;
Detailed scope of the work to be done including, per item or area, the required surface preparation and coating system to be applied;
A listing of the paints and materials to be used including batch numbers;
Full details of the blast and paint equipment including, where appropriate: dehydration, temperature, any other environmental control measures, methods of access, etc;
PROJECT:
PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
11.5
CLIENT:
PEDIL REV:
Petrofac
D1
DOCUMENT NUMBER:
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Details of the personnel involved in the work together with a clear definition of their responsibilities and lines of communication;
Detailed procedures and plans for testing and inspection including the methods and equipment to be used and the frequency of their application and acceptance criteria. An example of an inspection and testing plan (ITP) is given as attached in Annex C;
Details documenting the essential steps in achieving quality;
Dew point determination table;
Calibration methods of the inspection equipment;
Qualification of personnel.
Reporting The CONTRACTOR shall submit inspection reports not less than once per week. These reports shall include details of weather conditions, air humidity, temperature, particulars of application, e.g. blast cleaning, wet and dry film thickness, and any anomalies. If required by the COMPANY, the reports shall also detail the progress of work versus the approved programme.
11.6
Inspection Personnel and Equipment Inspection personnel shall be individually certified by a recognized organisation (NACE International or equivalent) approved by the COMPANY. The CONTRACTOR shall provide and use all inspection equipment necessary to ensure that the specified conditions and quality requirements are achieved. Equipment to measure at least the following shall be used: a)
Relative humidity
minimum accuracy
b)
Air-and substrate temperature
minimum accuracy
c)
Dew point
0.2 °C.
minimum accuracy
2 %; 0.2 °C
PROJECT:
PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
12
Petrofac
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D1
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DOCUMENTATION CONTRACTOR shall maintain records of all coating and inspection work carried out in accordance with this specification (per Annex C).
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Project X – Offshore Malaysia
JU-10701A
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Painting & Coating of External Surfaces Specification
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Petrofac
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ANNEX A. EXTERNAL COATING SYSTEMS
SYSTEM NUMBER
MATERIAL
EXPOSURE
APPLICATION Piping, External Surfaces of Vessels and Process Systems
SYSTEM 1
Carbon Steel
Non Insulated, low maintenance Atmospheric Exposure, and /or high Temperature
SYSTEM 2
Carbon Steel
Insulated
All items
SYSTEM 3
Carbon Steel
Fireproofed
All items
SYSTEM 4
Stainless Steel
SYSTEM 5
Carbon Steel
Non Insulated Insulated
Structural steel including Topsides, FPSO Deck and Jacket Structure. Also includes Flare Structures, bridges and cranes
All items
Galvanized
General Atmospheric Exposure where colour requirement is specified. Includes Handrails and ladders, etc.
SYSTEM 6
Carbon Steel
Decking
Walkways Escape routes Helidecks Lay down areas
SYSTEM 7
Carbon Steel
Sea Water Exposure
Caissons, J Tubes
SYSTEM 8
Carbon Steel
Submerged Sea Water Exposure
Submerged section of Jacket including anodes
PROJECT:
PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
A.1 SYSTEM 1
Petrofac
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COATING SYSTEMS SUMMARY SHEETS NON-INSULATED ATMOSPHERIC CARBON STEEL AND/OR HIGH TEMPERATURE
PRE TREATMENT: Remove all grease and salts and other contaminants with a water miscible detergent and high pressure fresh water washing
- Piping, External Surfaces of Vessels and Process Systems - Topsides Structural Steel, FPSO Structural steel and Jacket steel above and including splash zone - Flare Support StructureSURFACE PREPARATION: BLAST CLEAN: 1A: Sa 2.5, 1B:Sa 3 SURFACE PROFILE: 1A: 30 – 85 μm, 1B: 50 – 85 μm Mechanical preparation ST 3 (local area only) subject to COMPANY approval GENERIC SYSTEM
SYSTEM 1A Topsides structural steel and Flare Support Structure operating temperature 75 %. 2. The epoxy primer in system 2A shall not contain any zinc. 3. The epoxy phenolic shall be an immersion grade with greater than 6 months test data in sea water at 160 ˚C. 4. System 2B may be applied for bulk valves in service up to 160 ˚C. 5. Zinc silicate shall have a minimum 85 % zinc dust in the dry film. Zinc dust shall conform to ISO 3549 (Ref. 41). 6. Primed surface of system 2C shall be free of zinc dust prior to top coating. 7. TSA shall be in accordance with Norsok M-501 (Ref. 44) System 2. Aluminium wire shall be grade 99.5% to DIN 8566-2.(Ref. 42). 8. The sealer in system 2D shall be suitable for temperatures up to 500 ˚C. 9. For standardization purposes, System 2A can be replaced by System 2B, where CONTRACTOR prefers.
PROJECT:
PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
SYSTEM 3
FIREPROOFED CARBON STEEL
PRE TREATMENT: Remove all grease and salts and other contaminants with a water miscible detergent and high pressure fresh water washing
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Petrofac
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STRUCTURAL STEEL AND VESSEL SUPPORTS SURFACE PREPARATION: BLAST CLEAN: Sa 2.5 SURFACE PROFILE: 30 – 85 μm Mechanical preparation ST 3 (local area only) subject to COMPANY approval GENERIC SYSTEM
SYSTEM 3A Epoxy Intumescent PFP system see note 7 1 x 50 – 70 μm Zinc rich Epoxy Primer, see notes 1 and 2 MDFT 50 μm PFP to fireproofing Specification 1 x 75 μm Polyurethane Acrylic see note 6
SYSTEM 3B Cementitious PFP 1 x 60 μm Zinc rich Epoxy Primer, see note 1 1 x 200 μm Epoxy MIO, see notes 3 and 4 MDFT 260 μm PFP to fireproofing Specification 1 x 75 μm Polyurethane Acrylic, see note 5 see note 6
NOTES: 1. Zinc rich Epoxy shall be 2 pack formulations containing minimum 80% zinc dust by mass in the dry film. Zinc dust shall conform to ISO 3549 (Ref. 41). It shall be overcoated before formation of zinc salts, otherwise these shall be removed completely prior to overcoating. 2. Under intumescent epoxy fireproofing: The primer shall be approved by fireproofing SUPPLIER based on results of shear strength. 3. Solid content of epoxy shall be > 75 %. 4. Under cementitious fireproofing: Alternative coating system may be offered, subject to fireproofing SUPPLIER’s recommendations. 5. The specific sealing/topcoat requirements for cementitious fireproofing shall be agreed with COMPANY and the fireproofing SUPPLIER. 6. Repair system shall be approved compatible systems. 7. Intumescent epoxy fireproofing SUPPLIER, grade, qualification data, application and inspection procedures shall be approved by COMPANY.
PROJECT:
PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
SYSTEM 4
STAINLESS STEEL NONINSULATED/INSULATED
Petrofac
CLIENT:
PEDIL REV:
D1
DOCUMENT NUMBER:
SFBE-0000-00-PI-SPE-0006 DATE:
PAGE NO:
08-02-2011
54 of 64
PIPING VESSELS AND PROCESS PLANT
PRE TREATMENT: Remove all grease and salts and other contaminants with a water miscible detergent and high pressure fresh water washing
SURFACE PREPARATION: SWEEP BLAST ONLY, see note 3 SURFACE PROFILE: 25 – 45 μm Mechanical preparation ST 3 (local area only) subject to COMPANY approval
GENERIC SYSTEM SYSTEM 4A Non-Insulated and Atmospheric Exposure Austenitic Steel: Operating temperature 50 – 160 ˚C Duplex Steel: Operating temperature 90 – 160 ˚C 1 x 125 μm Epoxy Phenolic 1 x 125 μm Epoxy Phenolic Topcoat TOTAL MDFT 250 μm see note 4
SYSTEM 4B Insulated and Atmospheric / Seawater Exposure All insulated Austenitic and Duplex Stainless Steel, Operating temperature below 160 ˚C 1 x 125 μm Epoxy Phenolic 1 x 125 μm Epoxy Phenolic TOTAL MDFT 250 μm see note 4
SYSTEM 4C All Insulated materials with Operating temperature 160 ˚C – 500 ˚C 1 x 200 μm Thermally Sprayed Aluminium 2 x 25 μm Silicone Aluminium Sealer TOTAL MDFT 200 μm (TSA) see notes 5 and 6 NOTES: 1. Non-insulated stainless steels, operating up to 50 ˚C do not require coating. 2. Non-insulated Duplex stainless steels operating up to 90 ˚C do not require coating. 3. Aluminium oxide or Garnet or other approved non-metallic abrasive to be used for surface preparation. 4. The epoxy phenolic shall be an immersion grade with greater than 6 months test data in sea water at 160 ˚C. 5. TSA shall be in accordance with Norsok M-501 (Ref.44) System 2. Aluminium wire shall be grade 99.5% to DIN 8566-2 (Ref. 42). 6. Sealer in system 4C shall be suitable for temperatures up to 500 ˚C. 7. SS and Cu Ni alloy piping flanges using carbon steel bolting, shall be painted on the back surface of the flange with System 4A.
PROJECT:
PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
SYSTEM 5
GALVANIZED CARBON STEEL
PRE TREATMENT: Remove all grease and salts and other contaminants with a water miscible detergent and high pressure fresh water washing. Finally, galvanizing to be scrubbed with bristle brushes and suitable detergent to remove all traces of flux
CLIENT:
PEDIL REV:
Petrofac
D1
DOCUMENT NUMBER:
SFBE-0000-00-PI-SPE-0006 DATE:
PAGE NO:
08-02-2011
55 of 64
GENERAL ATMOSPHERIC EXPOSURE WHERE COLOUR REQUIREMENT IS SPECIFIED , STAIR TREADS, GRATINGS, HANDRAILS, LADDERS, CABLE TRAYS, ETC SURFACE PREPARATION: SWEEP BLAST ONLY (see note 2 and 3) SURFACE PROFILE: 30 μm Mechanical preparation ST 3 (local area only) subject to COMPANY approval GENERIC SYSTEM
SYSTEM 5 1 x 125 μm Epoxy Mastic 1 x 75 μm Polyurethane Acrylic, see note 4 TOTAL MDFT 200 μm
NOTES: General Notes: 1. Touch-up of damaged galvanizing; 1 x 2 pack zinc rich epoxy primer, DFT 70 μm. Specific Notes: 2. CONTRACTOR shall demonstrate that sweep blasting will not cause cracking, flaking or lifting of galvanizing. 3. Etch priming may be used as an alternative to sweep blasting subject to COMPANY approval. 4. Final coat shall be light grey or white unless otherwise noted in Annex B or C.
PROJECT:
PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
SYSTEM 6
DECKING
PRE TREATMENT: Remove all grease and salts and other contaminants with a water miscible detergent and high pressure fresh water washing
Petrofac
CLIENT:
PEDIL REV:
D1
DOCUMENT NUMBER:
SFBE-0000-00-PI-SPE-0006 DATE:
PAGE NO:
08-02-2011
56 of 64
WALKWAYS, ESCAPE ROUTES, LAY DOWN AREAS, HELIDECK SURFACE PREPARATION: BLAST CLEAN: Sa 2.5 SURFACE PROFILE: 50 – 85 μm Mechanical preparation ST 3 (local area only) subject to COMPANY approval
GENERIC SYSTEM SYSTEM 6A Light Duty general Walkways and Decks 1 x 60 μm Zinc Rich Epoxy Primer, see note 3 1 x 400 μm Glass Flake Epoxy (or HB Epoxy) incorporating aggregates, see note 4 1 x 75 μm Polyurethane Acrylic, see notes 5 and 6 TOTAL MDFT 475 μm
SYSTEM 6B Escape Routes, Heavy Duty Walkways, Lay Down Areas and Helideck 1 x 60 μm Zinc Rich Epoxy Primer, see note 3 1 x 3000 μm Epoxy Compound with silica aggregate, see note 4 1 x 50 μm Polyurethane Acrylic, see notes 5 and 6 TOTAL MDFT 3 mm
NOTES: 1. Repair systems to be based on approved compatible systems. 2. Primer selection and application and overcoating to be subject to MANUFACTURER’s written recommendation. 3. The epoxy primer in System 6A and 6B is only necessary to maintain the integrity of the blasted steel surface. In situations where the primer is required the MDFT shall increase to 535 μm for System 6A. 4. Aggregates to be approved non-slip and non-sparking type. For Helideck the system shall comply with CAP 437. “Offshore Helicopter Landing Areas: A Guide to Criteria, Recommended Minimum Standards, and Best Practice” Civil Aviation Authority Standard for Helideck Design (Ref. 43). 5. Topcoat only required where safety or marking / colour requirement dictate. 6. Approved photoluminescent marking/colour requirements dictate.
PROJECT:
PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
SYSTEM 7
CARBON STEEL SEA WATER EXPOSURE
Petrofac
CLIENT:
PEDIL REV:
D1
DOCUMENT NUMBER:
SFBE-0000-00-PI-SPE-0006 DATE:
PAGE NO:
08-02-2011
57 of 64
CAISSONS AND J TUBES SUBJECT TO SEA WATER EXPOSURE Note 5
PRE TREATMENT: Remove all grease and salts and other contaminants with a water miscible detergent and high pressure fresh water washing
SURFACE PREPARATION: BLAST CLEAN: 7A, 7C: Sa 2.5 7B: Sa 3 SURFACE PROFILE: 7A: 30 – 85 μm, 7B : 50 – 85 μm Mechanical preparation ST 3 (local area only) subject to COMPANY approval
GENERIC SYSTEM SYSTEM 7A Maintainable Systems 1 x 60 μm Epoxy Primer, see note 2 and 3 1 x 400 μm Glass Flake Epoxy 1 x 75 μm Polyurethane Acrylic note 4 Ant-fouling paint note 4 TOTAL MDFT 400 μm
SYSTEM 7B Maintainable Systems 3 x 150 μm Ceramic Filled Modified Epoxy Ant-fouling paint note 4 TOTAL MDFT 450 μm
NOTES: General Notes: 1. The coating system (including any primer) for immersed services shall be certified as having high resistance to cathodic disbondment. All systems shall be tested in accordance with ASTM G8 or G42 depending on temperature. The extent of disbondment at any point from periphery of the intended holiday shall not exceed 10mm after 28 days at ambient temperature. Specific Notes: 2. Solid content of epoxy shall be > 75%. 3. The epoxy primer in System 7A is only necessary to maintain the integrity of the blasted steel surface. In situations where the primer is required the MDFT shall increase to 460 μm. 4. Anti-fouling paint shall be used for the immersed areas of the caissons and J Tubes and polyurethane acrylic shall not be used in these submerged areas. The anti-fouling paint shall be tin and copper free, shall provide antifouling properties for a minimum 2year life when exposed to seawater. 5. Jacket and appurtenances below the splash zone will not be coated and will be protected by sacrificial anode CP system.
PROJECT:
PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
SYSTEM 8
SUBMERGED SECTION OF JACKET STRUCTURE
PRE TREATMENT: Remove all grease and salts and other contaminants with a water miscible detergent and high pressure fresh water washing
CLIENT:
PEDIL REV:
Petrofac
D1
DOCUMENT NUMBER:
SFBE-0000-00-PI-SPE-0006 DATE:
PAGE NO:
08-02-2011
58 of 64
SUBMERGED SECTION OF JACKET INCLUDING CONDUCTORS
SURFACE PREPARATION: BLAST CLEAN: Sa 2.5, SURFACE PROFILE: 30 – 85 μm,
GENERIC SYSTEM SYSTEM 8 1 x 300 μm Abrasion Resistant high solids polyamide cured Epoxy TOTAL MDFT 300 μm NOTES: System 8 Continued 1. Solid content of epoxy shall be > 72%. 2. This coating system is applied in order to reduce quantity of anodes. Weld and node areas will be left uncoated as per jacket painting drawing produced by Fabrication Contractor. 3. If desired this system may be applied as two coats of 150 μm per coat. 4 System shall have proven high compatibility with cathodic protection.
PROJECT:
PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
Petrofac
CLIENT:
PEDIL REV:
D1
DOCUMENT NUMBER:
SFBE-0000-00-PI-SPE-0006 DATE:
PAGE NO:
08-02-2011
59 of 64
ANNEX B. COLOUR CODING B.1
COLOUR SCHEDULES FOR OFFSHORE EQUIPMENT Item
Colour
RAL code
Broom yellow
1032
White/red bands
9010 / 3002
Exterior of wall, cladding, bulkheads etc.
Carmine red
3002
Internal of cladding and ceilings
Grey white
9002
Black
9005
Dusty grey
7037
Top-side of helidecks
Signal green
6032
Firewater piping and equipment
Carmine red
3002
Piping, valves etc.
Grey white
9002
Structural steel Vent stacks, flare booms and crane booms etc
Wetted and intermittentlywetted Closed deck areas
Remarks Including handrails, ladders, walkway framework (bordesses) and staircases Width of the band to be agreed (approx. 4.5 m)
Broom yellow may be used if approved by the COMPANY
Helideck markings shall be agreed with the COMPANY
(See Annex C below)
NOTES: Unless otherwise specified by the COMPANY, stream identification and direction shall be applied on piping systems after the final coats have been applied and cured, The type and model shall be agreed between the COMPANY and the CONTRACTOR. The banding systems shall be durable and in the form of plastic tape or self sprung coil of the appropriate size to fit the pipe. However, identification tapes shall not contain ingredients such as free chloride that could damage either the coating, or the pipe substrate material (e.g. stainless steel or nickel-chromium alloy), and shall be applied at proper intervals to enable easy identification of the pipe, contents, and fluid direction. For insulated lines this identification shall be applied to the outer surface of the insulation. The COMPANY shall specify the colour of the topcoat and ‘banding’ to be applied.
PROJECT:
PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
B.2
CLIENT:
PEDIL REV:
Petrofac
D1
DOCUMENT NUMBER:
SFBE-0000-00-PI-SPE-0006 DATE:
PAGE NO:
08-02-2011
60 of 64
COLOUR CODING OF PIPING The commodity transported inside each pipe shall be identified by the combination of a background colour and a coding colour, by application of coloured bands (painted or adhesive tapes) compatible with the underneath coating. The colour bands shall be applied in accordance with Figure C1. The colour coding of the bands shall be in accordance with Table C1.
BACKGROUND COLOUR
120 mm
50 mm
DECORATION COLOUR
Figure C1
120 mm
CODING COLOUR
Colour Bands
The bands shall be applied where identification of the fluid is most important, i.e. on pipes around equipment, machineries and near valves. TABLE C.2 PIPING IDENTIFICATION COLOURS COMMODITY CODE
FLUID
BACKGROUND COLOUR
CODING COLOUR
AB
Breathing Air
Blue 5017
-
AG
Gas to atmosphere
Yellow 1023
Red 3020
BD
Blowdown
Yellow 1023
Blue 5017
CA
Compressed Air
Blue 5017
Red 3020
CD
Closed Drain
Orange 2004
Red 3020
CH
Chemicals
Violet 4005
Brown 8016
DP
Dry Powder Extinguisher
Red 3020
-
DW
Potable Water
Green 6024
Orange 2004
FF
Fire Foam
Red 3020
-
FG
Fuel Gas
Yellow 1023
-
FH
HP Flare
Yellow 1023
Blue 5017
PROJECT:
PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
COMMODITY CODE
CLIENT:
PEDIL REV:
Petrofac
D1
DOCUMENT NUMBER:
SFBE-0000-00-PI-SPE-0006 DATE:
PAGE NO:
08-02-2011
61 of 64
FLUID
BACKGROUND COLOUR
CODING COLOUR
FL
LP Flare
Yellow 1023
Blue 5017
FO
Fuel Oil/Diesel
Brown 8016
-
FW
Fire Fighting Water
Red 3020
Green 6024
GY
Glycol
Violet 4005
Blue 5017
HC
HP Condensate
Yellow 1023
Brown 8016
HD
Hot Oil Drain/Heating Medium Drain
Orange
Red 3020
HM
Heating Medium
Grey 7035
-
HO
Hot Oil
Orange
Red 3020
IA
Instrument Air
Blue 5017
Red 3020
LC
LP Condensate
Yellow 1023
Brown 8016
LO
Lube Oil
Yellow 1023
Blue 5017
MC
MP Condensate
Red 3020
Green 6024
ML
Methanol
Violet 4005
Black 9005
OS
Oil (Sludge)
Brown 8016
Yellow 1023
OW
Oily Water Sewer/Open Drain
Orange 2004
Black 9005
PO
Product Oil
Brown 8016
Red 3020
PW
Produced Water
Green 6024
Yellow 1023
RO
Raw Oil
Brown 8016
Yellow 1023
RS
Sewage (Raw)
Orange 2004
Black 9005
RW
Raw Water/Technical Water
Green 6024
Violet 4005
SD
Sludge (Sewage)
Orange 2004
Black 9005
SO
Slop Oil
Brown 8016
Yellow 1023
SW
Sea Water
Green 6024
Black 9005
TG
Treated Gas (Sweet)
Yellow 1023
Blue 5017
TS
Treated Sewage
Orange 2004
Black 9005
TW
De min or de ionized water
Green 6024
Brown 8016
UA
Plant/Utility Air
Blue 5017
Red 3020
UN
Nitrogen
Blue 5017
Yellow 1023
UW
Utility Water
Green 6024
Blue 5017
WF
Well Fluid
Brown 8016
Yellow 1023
WW
Waste Water
Green 6024
Brown 8016
PROJECT:
PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
CLIENT:
PEDIL REV:
Petrofac
D1
DOCUMENT NUMBER:
SFBE-0000-00-PI-SPE-0006 DATE:
PAGE NO:
08-02-2011
62 of 64
ANNEX C. INSPECTION & TESTING (FOR ITP) FOR COATING WORK Inspection and Test Plan for Coating work of Offshore Facilities CONTRACTOR:
Project: Project X
Coating system: A1
Maintenance type: Refurbishment
Date: Item
Inspection test items
1.0
Reference Documentation
2.0
Material Receipt
2.1
Coating Material Receipt
2.2
Coating Material Receipt
3.0
Frequency
Acceptance standard
Report form (1)
CONTRAC COMPANY TOR (2) (2)
COMPANY technical coating specification CONTRACTOR quality manual, Doc No……. CONTRACTOR project quality plan, Doc No…..
R
R
All
COMPANY s approved material/coating system
R
W
All
Coating material traceability Legible labels clearly identifying: -Manufacturer’s name -Product name -Approved by COMPANY -Batch number -Shelf life -Storage instructions -Date of manufacture -Product data sheet -Material safety data sheets (MSDS)
M, V, R
W
Inspection of All surfaces Surface Condition
Check on excessive salt contamination. ISO 8502-6 (Ref. 16) and ISO 8502-9 . Visible contamination etc.
R, W
W, M
3.1
Solvent or Detergent Cleaning
All surfaces
Pre-cleaning, No visible surface contamination from oil or grease etc.
R, W
W, M
3.2
High Pressure Water/Steam Cleaning
All surfaces
COMPANY’s technical specification ……
R, W
M
3.3
Climatic Conditions (air Temperature and Dew Point readings)
Every two hours The surface temperature shall be a minimum of 3 °C above the dew point, the relative humidity of the air shall be max. 85 %, the air or substrate temperature shall not be below 5 °C.
M, W, R
W
3.4
Steel Temperature
Every two hours Max. 40 ºC
R
M
3.5
Compressed Air Supply Blotter test
Twice/12 hours
R, W
W, M
No indication of oil discolouration, no indication of water contamination, ASTM D 4285)
PROJECT:
PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
CLIENT:
PEDIL REV:
Petrofac
D1
DOCUMENT NUMBER:
SFBE-0000-00-PI-SPE-0006 DATE:
PAGE NO:
08-02-2011
63 of 64
Inspection and Test Plan for Coating work of Offshore Facilities CONTRACTOR:
Project: Project X
Coating system: A1
Maintenance type: Refurbishment
Date: Item
Inspection test items
Frequency
Acceptance standard
Report form (1)
CONTRAC COMPANY TOR (2) (2)
3.6
Blast Nozzle Pressure
Every 2 hours
7 bar minimum at nozzle
R
M
3.7
Surface Profile
Once per 100 m² or three times/ per blaster per day
40 μm to 70 μm (3 mils to 5 mils). ISO 8503-1 , Testex tapes
W, R, M
W, M
3.8
Surface Dust
Once per Rating 2, ISO 8502-3, clause 6.1 100 m² or three times/ per day
W, M, R
W, M
3.9
Presence of Millscale
Once per Free of mill scale 100 m² or three times/ per day
W, M, R
W,M
3.10
Soluble Salt Contamination Test (chlorides, etc.)
Once per Residual chlorides shall be 50 mg/m² ISO 8502-6 100 m² or three and ISO 8502-9 times/ per day Pitted areas shall be checked for iron salts.
H, V, R
W, H
3.11
Visual Inspection after Abrasive Blasting
All
H, W, V, R
W, H
4.0
Calibration of Inspection Equipment
Start of Dry film thickness gauges: start of shift and production then thereafter every three hours at the mid range of every 3 hours the coating thickness. Holiday detection: start of shift and thereafter every four hours. 2500 volts ±100 volts, Adhesion tester: daily
V, W, R
W
5.0
Spray Pressure, Tip Size and Fan Angle.
At start of spraying
To match Manufacturer ’s recommendations
R
M
5.1
Primer Application
All
60 μm dry film thickness. Measure wet film thickness (see Product Data Sheet)
W, R
M
5.2
Stripe Coat Application of Primer
All
Brush applied, worked into corners, edges and crevices
V, W, R
W
5.3
Dry Film Thickness
5 per m2
Equal to or above 80 % of NDFT. Number of readings between 80 % of DFT and NDFT
SA 2½ acc. to ISO 8501-1 Minimum illuminance 500 lx
PROJECT:
PROJECT NO:
Project X – Offshore Malaysia
JU-10701A
DOCUMENT TITLE:
ORIGINATOR:
Painting & Coating of External Surfaces Specification
CLIENT:
PEDIL REV:
Petrofac
D1
DOCUMENT NUMBER:
SFBE-0000-00-PI-SPE-0006 DATE:
PAGE NO:
08-02-2011
64 of 64
Inspection and Test Plan for Coating work of Offshore Facilities CONTRACTOR:
Project: Project X
Coating system: A1
Maintenance type: Refurbishment
Date: Item
Inspection test items
Frequency
Acceptance standard
5.4
Report form (1)
CONTRAC COMPANY TOR (2) (2)
Second Stripe Coat Application
All
Brush applied, worked into corners, edges and crevices
W, R
W
5.5
Second Full Coat Application
All
120 μm dry film thickness. Measure wet film thickness (see Product Data Sheet)
W, V, R
M
5.6
Visual Inspection
All
Uniform in colour, free from irregularities such as runs, sags, fish-eyes, orange peel etc
R, W, V
W
5.7
Dry film Thickness 5 per m2
Equal to or above 80 % of NDFT. Number of readings between 80 % of DFT and NDFT
H, R, W
H, W, M
5.8
Holiday Test
100 % surface area
No holidays. 100 % of the coated surface shall be inspected in accordance with NACE RP 0188
5.9
Cure Test
2 per sprayer per day
Solvent rub test in accordance with ASTM D 4752 for inorganic zinc primers: No softening
R, W
W
5.10
Adhesion Test
1 per 5 m2
Test shall be performed using a self-aligning tester in accordance with ASTM D 4541. Minimum acceptable value shall be 5 MPa.
R, V, W
W
5.11
Coating Repair
As required
Pinholes, mechanical damage from destructive adhesion testing etc, repair as per approved procedure. Re-test for thickness and porosity as per original. Under-thicknesses, prepare surface and re-coat as per approved procedure
R, V, W
W
Legend: H
Hold
M
Monitor
R
Record
V
Visual
W
Witness
NOTES: (1) Indicate reference to CONTRACTOR’s Quality Control reporting forms or documents on which the quality data is to be recorded and/or reported. (2) These are examples of actions. Actions and action parties shall be agreed for each coating job.
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