Method Statement for APCS-113A for Alloy Steel - ---Otc - Fbe-002

Overseas Technical Coatings & Services Company (LLC)

KARAN UTI L I TI ES AND CO-G CO-GENERATI ENERATI ON PR PROJECT  OJECT 

SAUDI ARAMCO CONTRACT CONTRACT 6600021903 660 0021903 (IK)

METHOD STATEMENT FOR  SURFACE PREPARATION AND PAINTING ON ALLOY PIPING EXTERNAL SURFACES WITH APCS-113-A

MS -IC- 002

Prepared for  Approval

Rev

02

09 July, 2011

Date

Prepared By Hertel OTC

OTC/QCP.Doc, MS-IC-002 (Rev 02)

Checked By

Reviewed By

Approved By

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Overseas Technical Coatings & Services Company (LLC)

Index 1. Scope 2. Definitions 3. References 4. Procedure 4.1 Pre-Blast Checks 4.2 Surface Preparation 4.3 Cleaning 4.4 Paint, Storage & Preparation 4.5 Shop & Field Weld joints Paint Application 4.6 Repairs 4.7 Quality Control Procedure 5. Personnel Qualifications 6. Safety

OTC/QCP.Doc, MS-IC-002 (Rev 02)

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Overseas Technical Coatings & Services Company (LLC)

1.

SCOPE

This procedure covers minimum requirements of APCS 113A (liquid type epoxy coating) for  Alloy steel piping on shop application & filed weld joints external coating in buried piping spools and associated fittings in accordance with SAES-H-002. 2

3.

DEFINITIONS

2.1

COMPANY

: SAUDI ARAMCO

2.2

EPC CONTRACTOR

: PETROFAC

2.3

CLIENT

: MMG

2.4

PROJECT

: KARAN UTILITY AND CO-GENERATION

2.5

JOB NO.

: 6600021903

2.6

COATING CONTRACTOR : Overseas Technical Coatings & Services (OTC)

REFERENCES

SAEP-316

: Performance Qualification of Coating Personnel

SAES-H-002

: Internal & external coating of pipeline and piping

SAES-H-002V

: Approved Saudi Aramco Data Sheets for the pipelines Maintenance external coating

SAES-H-100

: Coating Matl’s & Application Requirements for Industrial Facilities

SAES-H-102

: Safety Requirements for Coating Application

SAES-H-200

: Storage, Handling and Installation of Externally Coated Pipe

SATIP-H-002-06

: Renovation& Repair coating for Submerged Services APCS-113A

09-SAMSS-113

: The requirements of External. Liquid Coatings for Buried P/L & Piping

SSPC-SP1

: Solvent Cleaning Specification

SSPC-SP2

: Hand Tool Cleaning Specification

SSPC-SP3

: Power Tool Cleaning Specification

SSPC-SP10

: Blast Cleaning to Near White Metal Specification OTC/QCP.Doc, MS-IC-002 (Rev 02)

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Overseas Technical Coatings & Services Company (LLC) SSPC VIS-1

: Pictorial Surface Preparation Standards for Painting Steel Structures

SSPC-PA2

: Measurement of Dry film Thickness

4 PROCEDURE

4.1

Pre-Blast Check 

4..1.1 QC Inspector shall carry out checks before blasting to determine whether cleaning is required either with the use of chemicals or solvents. Solvent clearing if required shall be carried out in accordance with SSPC - SPI. 4..1.2  No abrasive blasting shall be carried out unless the steel surface is at least minimum 3°C above the Dew Point temperature. 4..1.3 Prior to start for blasting, all sharp edges and cut-offs shall be rounded to a smooth radius and all weld spatters shall be removed. 4..1.4 The compressed air supply shall be checked free of oil, moisture and contamination. As a minimum, the inspector shall check and approve the air quality at the start & midpoint of each 8-hour period. The method of checking shall be in accordance with SAES-H-100 Para 5.4.1 4..1.5 All compressed air hoses and paint lines shall be circular in section, free of cuts, kinks and twists. Any change in direction shall be by long radius curves to maintain constant and unrestricted flow where possible. 4..1.6 All hoses and nozzle connections shall be inspected prior to commencement of work to ensure they are secure. Any defective connection will be immediately replaced. 4.2

Surface Preparation:

4.2.1

Surface preparation shall be carried out in accordance with the relevant coating system as specified in SAES H-002, APCS-113-A

4.2.2

The type of abrasive to be used shall be determined by degree of cleanliness and surface Profile requirements as specified in SAES-H-002.

4.2.3

Abrasives shall be kept dry and free of contamination. and shall comply in accordance with SAES-H-100 Para 5.2.1

4.2.4

Sufficient capacity compressors shall be used to supply free air to all elements of the abrasive and coating operation as per SAES-H-100 Para 5.4

4.2.5

The Blast profile shall be measured with “PRESS-O-FILM” (Testex tape X coarse replica tape) and Profile thickness gauge. The replica tape shall be attached with inspection report as a permanent record. OTC/QCP.Doc, MS-IC-002 (Rev 02)

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Overseas Technical Coatings & Services Company (LLC)

4.2.6

Residual chloride on the surface shall not exceed 40 mg/m².

Cleaning

4.2.1

4.3

Used abrasives shall be removed from external surfaces using a dry brush, blow down with clean dry compressed air.

Paint, Storage and Preparation

4.3.1

Paint and thinner shall be stored in well – ventilated building at storage temperature as recommended in the manufacture’s data sheet

4.3.2

The date of manufacture shall be clearly marked on each paint container and paints that have exceeded their shelf life shall be discarded

4.3.3

Paints that show signs of leakage or have gelled shall be discarded and any skins that have formed shall be cut and removed before application. Paint preparation shall be in accordance with manufacturer’s recommendation and/ or accordance with S AES-H-100- Para-7.

4.3.4

All paints shall be thoroughly mixed before application, quantities over 5 liters shall be mixed using a power mixer. If the paint cannot be mixed uniformly (thick sediment at the bottom of  the can) it shall be discarded.

4.4

Paint Application

4.4.1

The prepared surface shall be visually inspected for cleanliness and profile prior to coating.

4.4.2

Prepared surface shall be coated within a maximum of four hours and before any deterioration  begins. Surfaces that have begun to deteriorate, or have exceeded the four hours shall be re blasted.

4.4.3

Approved Paint materials for APCS 113-A as per SAES-H-002V shall be used for external application of Alloy spools including associated fittings to specify DFT. WFT will be monitored to control the required DFT.

4.4.4

Paint shall only be applied if the following conditions are met and as specified by the Manufacturer: 



o

o

Surface temperature to be above 10 C and below 60 C. Surface temperature to be also o at least minimum 3 C above dew point temperature. The surface shall be free of oil, grease, dirt, loose paint, dust, rust and other surface contaminants.

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Overseas Technical Coatings & Services Company (LLC)



There is protection from adverse weather conditions, such as winds that may blow sand, or other foreign bodies on the painted surface or it may disrupt the paint pattern or cause dry spray.

4.4.5

Recoating intervals shall be maintained as per manufacturer’s data sheet. Color contrast  between coats shall also be maintained.

4.4.6

Dry film thickness of each coat shall be measured in accordance with SSPC-PA2 using a suitable non ferrous thickness gauge.

4.4.7

All the work shall be documented for future reference.

4.6

Repairs

4.6.1 All defective areas shall be cleaned with solvents or detergents. 2

4.6.2 Areas less than 0.1M shall be hand abraded or ground back to the surface substrate using at least 80 grit disc sanders and paint touch up shall be by brush only. 4.6.3

4.7

2

Areas greater than 0.1M shall be blast cleaned to original specification and paint application shall be airless spray.

Quality Control Procedure

4.7.1

Quality control requirements are to be carried out in accordance with Inspection and test  plan of the project. All documents shall be the latest version.

4.7.2

Abrasive blasting/Painting equipment shall be checked by the crew supervisor for  suitability prior to the start of the surface preparation and coating activities (as per  approved ITP)

4.7.3

Record on a daily basis critical in process inspection activities.(As per approved ITP)

4.7.4

Paint/Coating and Equipment check list is required to be completed and signed by the Coating Crew Supervisor and verified and signed by the client Inspector  (As per approved ITP)

4.7.5

TESTEX tape for the profile reading of the blasted area. Minimum 3 tests shall be  performed during each shift.

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Overseas Technical Coatings & Services Company (LLC)

5. PERSONNEL QUALIFICATION

5.1

OTC personnel involved in preparation, application, direct supervision or inspection of  coatings shall be qualified and certified by Hertel-OTC and ARAMCO as per SAEP-316. This includes abrasive blasters, coating applicators, crew supervisors and QC inspectors.

6. SAFETY.

6.1

Safety Requirements for Painting shall be observed at all times and shall be strictly followed in accordance with SAES-H-102

6.2

The Project safety plan will be fully enforced during the duration of the work.

6.3

During application process, all lighting will be of the explosion proof type as per SAESH-102 item 4.1

6.4

A standby man will be at the work at all times during the work. His role will be observing activities in the painting work and to stop the work immediately while any safety concern arises.

6.5

All operators will wear full personal protective equipment including coveralls, safety  boots, gloves, helmets and positive air feed breathing masks in accordance with S AES-H102 item 4.3

6.6

All recommendations of the Material/Equipments manufacturers concerning the safe handling and application of their products shall be followed as per SAES-H-102 item 4.4.

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