REAL Painting Specification
Short Description
REAL Painting Specification...
Description
Reliance Engineering Associates Private Limited
SPECIFICATION G – GS – 005
Shop and Field Painting
0
24/10/02
Issued as Specification
TKH
MGC
SVKR
Rev
Date
Revision
By
Chkd
Appr
G – GS – 005 Rev 0
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Client
Reliance Engineering Associates Private Limited Contents 1. Scope ……………………………………………………………………………….. 3 2. Application Standards, Codes and Regulations ……………………………………. 3 3. General ……………………………………………………………………………… 4 4. Surface Preparation …………………………………………………………………. 4 5. Coating Preparation and Application ………………………………………………. 8 6. Inspection …………………………………………………………………………… 9 7. Work to be Performed ……………………………………………………………… 12 8. Coating System ……………………………………………………………….. 12 9. Coating Schedule …………………………………………………………………… 12 10. Colour Schedule …………………………………………………………………… 13 11. Appendices i) Appendix A : Coating System ……………………………………………… 15 ii) Appendix B : Coating Colour Schedule …………………………………… 21 iii) Appendix C : Identification of Services ………………………………….. 22 iv) Appendix D : Coating Schedule (Other than Marine environment) ………. 30 v) Appendix E : Coating Schedule (Marine environment) …………………… 41
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Reliance Engineering Associates Private Limited 1. Scope 1.1 This specification covers the surface preparation , method of application and material to be used for all coating of equipment, vessels, machinery, steel structures and piping. 1.2 Buildings shall not be painted under this specification. For building painting requirements, see building drawing and specifications. 1.3 The painting of topside facilities of marine structures are addressed under this specifications. For splash and submerged zone coating refer to marine structure specifications. 1.4 In general, shop fabricated equipment will be delivered to the job site coated with a shop applied system or manufacture’s standard finish in accordance with the requirements of this specification. 1.5 Identification of colour bands on all piping as required including insulated aluminium clad, galvanised, SS and non-ferrous piping are included.
2.
Applicable Standards, Codes and Regulations
2.1 Work shall be performed in accordance with the following Codes and Standards. Equivalent Indian Standards may be used subject to Reliance’s Approval. Works shall be in accordance with the Painting manufacture’s recommendations. 2.2 US Specifications of Steel Structures Painting Council, SSPC Volumes I and II
Swedish Standard SIS 05 59 00 British Standard 381C 1980 British Standard 729 1981 British Standard 4232 1967
Surface preparation Standards for Painting Steel Surface Colour for Identification, Coding and Special Purposes Hot dip Galvanised Coatings on Iron and Steel Articles Surface finish Blast Cleaned Steel for Painting
British Standard 1710 1975
Identification of Pipeline
British Standard 4800 1981
Paint Colours for Building Purposes
British Standard 5493 1977 NACE
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Code of Practice for Protective Coating of Iron and Steel Structures against Corrosion National Association of corrosion Engineers,USA
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Reliance Engineering Associates Private Limited 2.3 If conflicts occur between this specification, the Painting manufacturer’s recommendations and the referenced standards, Reliance’s Specialist shall be contacted for clarification.
3. General 3.1 References to SSPC shall be understood to refer to Steel Structures Painting Council Standards. 3.2 Work described shall be performed by the Painting Contractor and all tools, equipment, Paints, solvents, etc., necessary to complete the work shall be furnished by him. 3.3 The Painting Contractor shall comply with all applicable laws, regulations, ordinances, etc., of the city, country, state, province or nation pertaining to his work and painting materials. It is mandatory requirement that all operatives working to this procedure take full cognisance and implement necessary safety precautions. 3.4 Reliance’s Inspector shall have free access at all times to the work being performed by the Contractor. 3.5 Painting Manufacturer’s latest approved published instructions for application and system combinations of coatings shall be followed. Superimposed primers and coatings shall be compatible. In the event of conflicts, differences shall be brought to the Contractor’s painting specialist for resolution. 3.6 For equipment that has received shop prime coat, the Field Painting Contractor shall touch-up prime coat and apply additional coats in accordance with the Painting Schedule. It is the Contractor’s responsibility to ensure compatibility between shop and field applied paint systems. 3.7 Proper precautions shall be taken to protect other surfaces from abrasive blasting, coating over spray and spatter. Damage to other surfaces or equipment shall be repaired by the Field Painting Contractor at his expense (see paragraph 10.6). 3.8 The Field Painting contractor shall submit surface preparation and application procedures for review and acceptance by the Reliance. 3.9 Stainless steel, Aluminium and other high-alloy materials shall not be coated unless otherwise specified. Austenitic stainless steels operating between 50oC and 200oC are at risk under certain common conditions to pitting corrosion or even stress corrosion cracking. For this reason these substrates will be protected as indicated in Appendix ‘B’. 3.10 Painting Manufacturer’s instructions shall be followed as far as practicable at all times for proper storage to avoid exposure as well as extremes of temperature.
4. Surface Preparation 4.1 Metals
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Reliance Engineering Associates Private Limited 4.1.1
4.1.2
Adhesion of the paint film to surface depends largely on the degree of cleanliness of the metal surface. Proper surface preparation contributes more to the success of the paint protective system. Weld spatter shall be removed and sharp or rough welds rounded and contoured. Sharp edges shall be removed, chamfered or broken.
4.1.3
Surfaces to be painted shall be free of all grease, oil, loose rust and loose mill scale. Oil and grease shall be removed by solvent cleaning method as in SSPC-SP-1.
4.1.4
Rust, mill scale, weld spatter, flux shall be removed by methods indicated in the Painting Schedule.
4.1.5
The surface profile depth indicated under Appendix ‘A’ shall be achieved by using a medium that has good angularity of form, sharp cutting edges and is substantially free from “half rounds”.
4.1.6
If sand is used as the blasting medium it shall be delivered to site in trucks. Each truck load shall be identified with a batch number and each batch shall be tested for Chloride content (maximum allowable chloride level 0.03%) and pH value (the value should be nearly neutral i.e., pH 6 to pH 8). The tests shall be carried by owner, or by supplier with third party test certificate. The third party shall be an approved agent approved by owner.
4.1.7
Profile measurements of abrasive blast cleaned surface shall be made with a Keane Tator profile comparator, Clemtec anchor profile chips, Testex Press-O-Film or other contractor accepted method suitable for the abrasive being used.
4.1.8
Prior to any coating application the substrate shall be checked for soluble salt contamination using a suitable salt contamination meter (SCM 400). The maximum allowable level of contamination shall be 5µ gm/cm 2. Surfaces that do not meet this criteria shall be reprocessed. Should this problem occur on a frequent basis the abrasive medium shall be reexamined for quality and if necessary changed.
4.1.9
Surfaces prepared for coating shall be coated the same day and before any visible rusting occurs. (The time elapsed between blast cleaning and commencement of painting shall under no circumstances exceed 4 hours, but in any case must commence before signs of degradation occur). 4.2.0 The coating usually has a specific adhesion requirement and proper selection of abrasive is most important. Generally, an abrasive is classified according to the following characteristics: a) Size - Usually by US sieve sizes (i.e., 16x40 mesh or 1.19 mm x 0.42 mm) b)
Shape - Irregular, round. Sharp
c)
Hardness - Usually by Mohr’s Hardness scale of the present element
d)
Colour - Light or dark
e) Chemical components - Abrasives shouldn’t contain undesirable components that
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Reliance Engineering Associates Private Limited would remain on surface being cleaned. f) Specific Gravity or Weight - Heavy abrasives clean faster and impact much better while light weight abrasives are primarily used for polishing. g) pH of Abrasive - A neutral pH within the range of 7.0 ± 1 is desirable. Salt water washed abrasives are not recommended. h) Availability and Cost 4.2.1
Metal etching will remove mill scale, rust and other containment from metal to produce a white metal surface condition with an etch (anchor pattern) on the surface. Light cleaning removes only old paint and loose rust. 4.2.2 Criteria for selection of abrasives are certain key physical and chemical properties of the abrasives. Not all abrasives provide the same surface cleanliness. An abrasive effective for a commercial blast may not provide a near white or white – metal blast cleaned surface. The coating system will therefore also influence the choice of abrasive for surface preparation. 4.2.3 A consistent range of abrasive particle sizes must be maintained to produce a consistent surface and cleaning rate. 4.2.4 The cleaning rate is affected with abrasive breakdown value. The greater the particle breakdown the poorer the cleaning rate. Manufacturer’s certificate should contain the breakdown value. 4.2.5 If the abrasive source is near seawater, routine checking for soluble chlorides is a must. 4.2.6 Visual inspection shall be carried-out to detect any sharp edges, weld spatter or visible laminations. Where these are discovered they shall be ground smooth prior to coating. TABLE 2 : ABRASIVE CHART Major Component
Abrasive
Type
Steel Shot Steel Grit Iron Grit Alum.Oxide Silicon Carbide Garnet
Metallic Metallic Metallic Oxide Oxide Oxide
Slag-Coal
Conglomerate
Slag-Nickel
Conglomerate
Slag-Copper
Conglomerate
Flint Sand Limestone Zirconium Glass beads
Silica Silica Oxide Mineral Oxide
Iron Iron Iron Alumina Silicon Carbide Iron-Silica Iron-Alum Silica Iron-Alum Silica Iron-Alum Silica Silica Silica CaCO2 Silica Silica
Shape
Hardness (*)
Sp. Gravity
Round Angular Angular Angular Angular Irregular
Hard ** Hard ** Hard Hard Hard Hard
7.2 7.6 7.4 3.8 3.8 4.0
Irregular
Hard
2.8
Irregular
Hard
3.2
Irregular
Very Hard
3.3
Medium Medium Soft Hard Medium Soft/ Medium
2.7 2.7 2.4 4.5 2.7
Sharp Irregular Irregular Round Round Round / Plastic beads Organic Polymer resin Irregular * Soft materials are < 4 on Mohr’s hardness scale; Medium 4 ≤ 6; Hard ≥ 6 ** Various Hardness available
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Reliance Engineering Associates Private Limited
TABLE 3 : CLEANING RATES WITH TYPICAL ABRASIVES
Abrasive
Abrasive Consumption (lbs / Sq Ft)
Production rate (Sg Ft / Min.)
Silica Sand 16/40 Mesh
2.6
4.75
Garnet 36 Grit
3.6
3.55
Aluminium Oxide 36 Grit
3.1
4.58
Steel Grit G-40
5.5
3.06
3.6
2.69
3 Mils
3.2
3.83
2 Mil Etch
Crushed Flint 12/30 Mesh Copper Slag 16/40 Mesh
Remarks 1.5 Mil Etch Dusty 1.5 Mil Etch Very little dusty 1.5 Mil Etch Very little dusty 2.5 Mil Etch No Dust
TABLE 4 : International Standards of Blast Cleaning Cleaning Method
Swedish Std
ISO Std
SSPC Std
NACE Std
Hand tool cleaning
ST2
-
SSPC – SP2
-
Power tool cleaning
ST3
-
SSPC – SP3
-
White metal
SA3
SA3
SSPC – SP5
NACE = 1
Near white metal
SA 2 1/2
SA 2 1/2
SSPC – SP10
NACE = 2
Commercial blast
SA2
SA2
SSPC – SP6
NACE = 3
Brush-off blast
SA1
SA1
SSPC – SP7
NACE = 4
TABLE 5 : Surface profiles with various Abrasives Abrasive
Mesh Size
Max. height of Profile
Very Fine Sand
80
37 microns (1.5 Mils)
Coarse Sand
12
70 microns (2.8 Mils)
Iron Shot
14
90 microns (3.6 Mils)
Iron grit No.G16 Copper slag 1.5 – 2.0 mm grain size
12
200 microns (8.0 Mils)
-
75 – 100 microns (3 - 4 Mils)
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Reliance Engineering Associates Private Limited 5
Coating Preparation and Application 5.1
Coatings and primers shall be delivered to the job site in the original containers bearing the manufacturer’s name , product designation, batch number, shelf life and date of manufacture. Before application, they shall be stirred or agitated until the ingredients are completely mixed. Material which have exceeded the manufacturer’s recommended shelf life shall not be used. Materials shall not be used or mixed into a new batch after its recommended pot life has been exceeded. Material shall be used on a first-in, first-out basis.
5.2 To facilitate proper stirring, the paint containers shall have mouth at the top centre. 5.3 Field application shall be by brush, roller or spray gun. Local regulations regarding spray and roller coating shall be observed. A smooth uniform film shall be applied to the surfaces to be coated. 5.4 The temperature of the substrate must be a minimum of 3oC above the dew point during abrasive blast cleaning and coating. The substrate temperature shall be a minimum of 5oC and a maximum of 60oC during coating application. 5.5 Painting shall be applied in strict accordance with the painting manufacturer’s latest published instructions. In particular, the manufacturer’s recommended curing or drying time shall be allowed between coats of primer and finish. Thickness of the painting shall be in accordance with the Painting schedule or the manufacturer’s latest published instructions. In the event of conflict, differences shall be brought to the attention of the Reliance’s painting specialist for resolution. 5.6 Paints, catalysts and thinners shall be stored in well ventilated buildings free from excessive heat, sparks, flames and direct sunlight. Paints stored for short times on the job site shall be protected from direct sunlight during the summer months. 5.7 For Field joint coating where blast cleaning is not possible, minimum ST2 surface preparation to be achieved. The field paint shall be compatible to ST2 surface finish as well as to existing paint at the adjoining area. 5.8 The life time of any protective system is determined by the dry film thickness of the paint system present on weld seams and sharp edges. Special attention should be given to sharp edges to ensure that they are covered with an adequate coating thickness. 5.9 Two component (base and hardener) coatings like Air drying epoxy, Polyurethane coatings etc shall be mixed in the ratio recommended by manufacturer to ensure proper and complete curing of the coatings. Improper ratio leads to problems like soft / nondried film, poor performance, etc. The base and hardener are to be separately mixed first to obtain a homogenous mixture. The hardener is to be added to the base slowly, with continuous mixing / agitation and not the reverse. Power agitation is preferred over hand mixing. 5.10
Any addition of thinner to achieve the application viscosity should be made only after the components are thoroughly mixed. Avoid using excess thinner than the recommended volumes, since this will lead to lower DFT build up, sagging, longer curing time, etc.
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Reliance Engineering Associates Private Limited
5.11
Painting should not be undertaken during fog or mist conditions or when rain or snow is imminent, when the surface to be painted is wet with condensation or when condensation can occur during the initial drying period of the paint.
5.12
The volume solids figure given in the product data sheets of paints is the percentage of the film obtained from a given wet film thickness under specified application and conditions. The theoretical coverage can be determined from the formula below: Theoretical coverage (m2 / Litr) = Volume solids (%) x 10
5.13
Measured dft (in microns) Pump pressure and correct tip sizes will be used to produce the most desirable spray size pattern and thickness on airless spray equipment.
5.14
When using conventional spray equipment, the operator will ensure that the gun parts and outlets are maintained in a clean and working order to ensure the best of cosmetic appearance upon application.
5.15
Coating containing heavy or metallic pigments that have a tendency to settle shall be kept in suspension by continuous use of a mechanical agitator whilst being applied, to ensure uniformity over the surface area (e.g., zinc MIO’s pigmented materials).
5.16
All edges, corners, webs and inaccessible areas, shall be strip coated prior to full application. To ensure integrity of WFT/DFT over surface areas.
6 Inspection 6.1
Inspection will be performed by an inspector authorised by Reliance.
6.2
Prime coats shall be inspected and cleaned when required by Reliance’s Inspector, before applying finish coats.
6.3
Dry film thickness shall be measured after each coat by Reliance’s Inspector using a Mikrotest, Elcometer, or Reliance accepted equal.
6.4
The Painting Contarctor’s supervisor shall have in his possession at all times a wet film thickness gauge for continuous check of the wet film as applied.
6.5
Defective work shall be corrected by the Painting Contractor at his sole expense.
6.6
When more than one prime coat or finish coat is specified, use a contrasting colour in the first coat to distinguish between the first and second coats.
6.7
The average value of thickness readings taken over any square meter of a scheduled area should be equal or exceed the nominal thickness specified and in no case should any reading be less than 75% of the nominal thickness.
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Reliance Engineering Associates Private Limited 6.8
Areas where coating thickness either thin or too thick are to be marked and Paint contractor to carry-out repair at such areas. The surface areas shall be inspected to find holidays, runs, sags etc. Holidays, if detected shall be coated before full drying taking place. Runs and sags will be brushed out.
6.9
Determination of the thickness of each coat in a multi-coat system should be an inspection hold-point. When using magnetic gages to measure multi-coat systems, the average of the first coat must be determined prior to application of second coat. Readings taken after the second coat is applied will obviously be the total thickness of the two coats combined, and the specific thickness of the second coat can only be determined by subtracting the average thickness obtained from the first coat reading.
6.10 Holiday or spark testing shall be done for immersion service to find the nicks, scrapes, and pin holes in the coating film. Holiday testing shall be done after application of either the next to last, or last coat of paint. 6.11 After all the coats of paint have been applied, the inspector should verify that the appropriate clean-up is done, and that any abrasions, nicks, or scrapes are repaired as required. If the coating is within the specification the item will be offered to the client or representative inspector where required. 6.12 Occasionally, there is a need to test the adhesion of the coatings after application. “ Measuring adhesion by Tape Test” as described in ASTM D – 3359 shall be used for adhesion test. 6.13 Surface preparation and coating shall be documented using the Format No. 1 (Surface preparation and Coatings Inspection Form).
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Reliance Engineering Associates Private Limited FORMAT No. 1 :SURFACE PREPARATION AND COATING INSPECTION FORM PAGE _____ OF ______ REPORT No. : _____________________ PROJECT : _____________________ CONTRACTOR : _____________________
DATE : __________________________ DAY : __________________________ SHIFT : __________________________
COMPLEX : _____________________ UNIT No. : __________ EQUIPMENT No. : ___________________ LINE No. : ___________________________ SUBSTRATE : STEEL / CONCRETE / OTHER
INSPECTOR : ____________________ COATING SPEC No. / REV : ________ ________________________________
ENVIRONMENTAL CONDITIONS COATING WORK ACTIVITY TIME DRY BULB TEMP oC WET BULB TEMP oC RELATIVE HUMIDITY % DEW POINT oC SURFACE TEMP oC BLOTTER TEST
PRE-SURFACE PREPARATION SP – 1 : _____________________________________________
MASKING / PROTECTION : ____________________
SURFACE DEFECTS : _______________________________________________________________________________________ ___________________________________________________________________________________________________________ SURFACE PREPARATION METHOD : ________________________________________________________________________________________________ ABRASIVE TYPE / SIZE / STORAGE : _________________________________________________________________________ CLEANLINESS SPEC : ________________________________ ACTUAL : ___________________________________ PROFILE SPEC : _____________________________________ ACTUAL : ___________________________________ EQUIPMENT : ______________________________________________________________________________________________ COATING MATERIALS AND MIXING: PRODUCT (S) : _____________________________________________________________________________________________ BATCH No(s) / QUANTITIES / EXPIRATION DATE : _____________________________________________________________ THINNERS / BATCH No(s) / THINNING RATIO : --_______________________________________________________________ STORAGE : _________________________________________ MIXING : ___________________________________ INDUCTION TIME : __________________________________ POT LIFE EXPIRATION TIME : ________________ MATERIAL TEMPERATURE : _________________________ COATING / LINING APPLICATION : START TIME : _____________ FIISH TIME : ________________ COAT : PRIMER / PRIMER T.U. / SECOND / SECOND T.U. / THIRD / THIRD T.U. / OTHER___________________________ METHOD : _________________________________________ WFT : ______________________________________ RECOAT TIME / TEMP : ______________________________ CURE TIME / TEMP: _________________________ EQUIPMENT : ______________________________________________________________________________________________ APPLIED COATING VISUAL INSPECTION (FILM IMPERFECTIONS) : ______________________________________________________________ DRY FILM THICKNESS : SPEC _______________ ACTUAL ________________ METHOD ____________________ HOLIDAY TEST : ____________________________________________________ METHOD ____________________________ OTHER TESTING : ____________________________________________________ METHOD ____________________________ TOUCH UP AND REPAIR : ____________________________________________ METHOD : ___________________________ COMMENTS : (USE REVERSE SIDE) INSPECTOR’S SIGNATURE
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Reliance Engineering Associates Private Limited 7.
Work to be Performed
7.1
Work to be performed by the Field Painting Contractor includes the furnishing of materials and applying the painting in accordance with this specification.
7.2
Loading/Unloading and handling of materials, equipment and tools shall be performed by the Field Painting Contractor.
7.3
Field cleaning of pipe and equipment that is required prior to painting shall be performed by the Field Painting Contractor. This includes removal of dirt and dust which normally accumulates during storage and construction.
7.4
Work shall be protected against damage during all stages of application by the Field Painting Contractor.
7.5
The Field Painting Contractor shall be responsible for damage caused by wind blown overspray or spatter. The Field Painting Contractor shall take adequate precautions to prevent spattering and over spray of adjacent equipment, paving, structures, vessels, etc., by the use of drop cloths and shields.
7.6
The Field Painting Contractor shall protect name plates, name tags, glasses on temperature indicators, pressure gauges, level instruments, etc., by masking or applying a heavy coat of lubricant. Operating mechanisms such as valve stems and valve positioners must also be protected. Masking and lubricant applied by the Field Painting Contractor shall be removed by him after completion of all work.
7.7
The Filed Painting Contractor shall clean all spatter and over spray from equipment, vessels, tanks, piping, insulation, structures. A daily clean-up of the work area shall be made by the Field Painting Contractor to remove cartons, cans and other discarded containers or equipment.
8.
Coating System Coating systems are listed in Appendix ‘A’. Only those products listed shall be used unless alternate products are approved by Reliance.
9.
Coating Schedule
9.1 Surface preparation, priming and finish coating for all vendor supplied equipment, vessels, exchangers, pumps, instrument panels etc. shall be in accordance with the schedule shown in Appendix ‘D’. 9.2 The paint system shall be applicable to carbon steel and low alloy (9% chrome or less) 9.3 All vendor supplied items like equipments,vessels, exchangers, pumps, instrument panels etc shall conform to Appendix ‘D’. 9.4 Regardless of insulation requirements, stainless steel including “austenitic” shall not be painted. All stainless steel shall be unprotected.
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Reliance Engineering Associates Private Limited
9.5 Insulated Tanks shall not be painted. All other Tankages shall be painted in accordance with the Appendix ‘D’ (other than Marine environment) or Appendix ‘E’ (Marine environment). 9.6 All Piping will be painted in accordance with the Appendix ‘D’ or ‘E’. 9.7 Galvanising shall only be used on stair treads, open grid flooring and steel gratings. All other structural parts to be painted in accordance with Appendix ‘D’ or Appendix ‘E’.
10. Colour Schedule 10.1 In order to identify the contents of pipelines, colour code painting is required to be carried-out. The system of colour coding consists of basic identification colour together with colour bands. 10.2 The basic identification colour can be applied either on the entire length of the pipe or over a small length, minimum of 300 mm, and vary distinct from Primary and Secondary colour bands as shown in Appendix ‘C’. 10.3 The ground colour shall be as given in Appendix ‘B’. Ground colour will be applied to the entire surface of equipment except on precision machined surfaces, non-ferrous and threaded parts. On the pipes, the ground colour will be applied over the outer surface of uninsulated pipes. Valves on the pipelines shall be painted with the same ground colour. 10.4 The Service identification colour bands shall be in accordance with Appendix ‘C’. The colour band system is based on BS 1710. Colour bands as shown in ‘Figure 1’ are used over uninsulated as well as insulated piping (on cladding). 10.5 The colour bands serve the purpose of identification as well as flow direction. 10.6 Identification colour bands to be provided for Uninsulated and Insulated Process and Utility Piping. 10.7 Aluminium colour (ground colour as mentioned in Appendix B) shall be “Non Leafing” grade
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Reliance Engineering Associates Private Limited 11. Appendices Appendix A
: Coating Systems
Appendix B
: Coating Colour Schedule
Appendix C
: Identification of Services – Colour Coding of Piping
Appendix D
: Coating Schedule (Other than Marine Environment)
Appendix E
: Coating Schedule – Marine environment
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Reliance Engineering Associates Private Limited Appendix A Coating Systems TYPE
DESCRIPTION
01
Inorganic Zinc Silicate Primer
02
03
Dry film thickness
75 microns
Required surface profile:
50 microns
Maximum temperature resistance:
400oC
Minimum Volume solids
58 ASTM D2697
High Temperature Silicone Acrylic Dry film thickness :
50 microns
Required surface preparation:
Clean,dry inorganic zinc primer (type 01)
Maximum temperature resistance
200oC
Minimum Volume solids
37 ASTM D2697
High Temperature Silicone Aluminium Dry film thickness:
25 microns
Required surface preparation:
Clean,dry inorganic zinc primer (type 01)
Maximum temperature resistance
600oC
Minimum Volume solids
49 ASTM D2697
(1)
These materials must generally be exposed to 175 o C or higher to fully cure. Coating must be capable of “curing” to handle at ambient temperature.
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Reliance Engineering Associates Private Limited TYPE 04
05
DESCRIPTION Zinc Rich Epoxy Primer Dry film thickness:
50 microns
Required surface preparation:
25-35 microns
Maximum temperature resistance:
120oC
Minimum Volume Solids :
59 ASTM D2697
High Build MIO Epoxy Intermediate Dry film thickness:
125 microns
Required surface preparation : Maximum temperature resistance :
Clean, dry epoxy primer (type 04) 120oC
Minimum Volume Solids :
55 ASTM D2697
The quantity of MIO in the main pigment shall be 80% by weight 06
07
08
Aliphatic Urethane Finish Dry film thickness :
75 microns
Required surface preparation : Maximum temperature resistance :
Clean. Dry epoxy intermediate (type 05) 120oC
Minimum Volume Solids :
45 ASTM D2697
“Zinc Free” High Temperature Air Curing Finish Coat Dry film thickness :
75 microns
Required surface preparation :
Clean, dry and salt free
Maximum temperature resistance :
600oC
High Build Epoxy for Stainless Steel Dry Film thickness :
100 microns
Required surface profile :
Sweep blast with aluminium oxide
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Reliance Engineering Associates Private Limited TYPE
DESCRIPTION
09
Coal Tar Epoxy
10
11
12
13
Dry film thickness:
175 microns
Required surface profile:
75 microns
Amine Adduct Cured Epoxy Dry film thickness:
80 microns
Required surface profile:
50 microns
Inorganic sealer top coat Wet film thickness :
50 microns
Dry film thickness:
10 microns (mini.)
Maximum temperature resistance:
600 oC
Minimum volume solids:
6% ASTM D2697
Polysiloxane high heat coating Dry film thickness:
75 microns
Maximum temperature resistance:
600 oC
Minimum volume solids:
64% ASTM D2697
Inorganic Zinc Pre-construction Primer Dry film thickness:
15-20 microns
Maximum temperature resistance:
400 o C
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Reliance Engineering Associates Private Limited TYPE
DESCRIPTION
14
High Build Chlorinated Rubber Zinc Phosphate Primer Single pack chlorinated rubber medium plasticised with unsaponifiable plasticiser pigmented with zinc phosphate Dry film thickness:
75 microns
Required surface profile:
50 microns
Maximum temperature resistance:
60 o C
Minimum volume solids:
45% ASTM D2697
Main pigment content shall be 40% by weight of total pigment (min.)
15
High Build Chlorinated Rubber MIO Paint Dry film thickness:
75 microns
Maximum temperature resistance:
60 o C
Minimum volume solids:
50% ASTM D2697
The quantity of MIO in the main pigment shall be 60% by weight.
16
Chlorinated Rubber Finish Single pack plasticised chlorinated rubber medium with chemical and weather resistant pigments. Dry film thickness:
50 microns
Maximum temperature resistance:
60 o C
Minimum volume solids:
40% ASTM D2697
Main pigment content shall be 90% by weight of total pigment (Mini.).
17
Synthetic Enamel (Suitable for over-coating primer types 01 and finish coat type16) Dry film thickness:
50 microns
Volume solids:
40% ASTM D2697
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Reliance Engineering Associates Private Limited TYPE
DESCRIPTION
18
Epoxy Finish Coat
19
20
Dry film thickness:
60 microns
Minimum volume solids:
45 ASTM D2697
High Build Epoxy Intermediate Dry film thickness:
100 microns
Minimum Volume solids:
55 ASTM D2697
High Build Epoxy Intermediate Dry film thickness:
65 microns
Minimum Volume solids:
55 ASTM D2697
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Reliance Engineering Associates Private Limited The products identified in the following table match with the Coating System in Appendix ‘A’ TYPE COMPANY (Note 7) CARBOLINE
INTERNATIONAL
AMERON
01 02 03
Carbozinc 12 Carboline 1248 Carboline 4674
Interzinc 12 Intertherm 875 Intertherm 50
Dimetcote 9 FT Amercoat 891 Amercoat 878
04
Carboline 658
Interzinc 72
05 06
Carboline 190HB MIO Carboline 133HB
Interguard 400 Interthane 799 Intertherm 50 or Intern. XGP 639 Interplus 256 Á Intertuf 708
07
-
08 09
11
Carbomastic 15 Carbomastic 14 Carboline 187 Â -
12
-
Intertherm 601
13
Caroweld 11 HS
Interplate 11
10
À Interline 944 -
Dimetcote DSP
-
Apcocil-611
Linosol HB Red oxide ZP Primer
Asiochlor EHB ZP (PC 1417)
CDC Interchlor HB Primer Multibond 2000
-
15
CDC Interchlor HB MIO Multibond 2001
-
-
17
-
18 19 20
-
ASIAN
Zinc Anode 11 Apcosil-605 Epilux 4HB Asian EZRP Amercoat 68HS Zinc Rich Primer PC 1299 Epilux 155HB Ä Apcodur MIO Amercoat 383 MIO (RPL MIO) (RPL MIO) Berger Thane Apcothane HBPU Amercoat 450 SA 41 S/G (PC 1303) Apcotherm Amercoat 741 HR finish Amerlock 400 Amercoat SSPC.16 Epilux 555 Hb Apcodur CF655 Apcodur CF699 Epilux 78HBTL Amercoat 90 Ã (Note 6) Amercoat 710 Amercoat PSX 892 HS
14
16
BERGER
Interchlor Finish -
-
-
-
Asiochlor HB MIO (PC 1416) Linosol Hi Build Asiochlor HB Coating CR Paint (PC 1226) Asian Epoxy HB Coating (PC 1262) Asian Epoxy HB Coating (PC 1262) Linosol MIO
NOTE All vendor supplied items to conform to Appendix 'B'. À For potable water service Interline 925@400 microns DFT shall be used in lieu of Interline 944 Á An alternative to Intertuf 708 is Intertuf JXA 727/720 Â For potable water service, carboline 891 shall be used in lieu of carboline 187 Ã After complete cure the coating shall be thoroughly rinsed with potable water prior to being placed in service Ä Epilux 155 HB MIO shall be "RIL" grade only. Standard material shall NOT be used Å Apcodur-CF699 is approved for all services except POTABLE WATER suitable for type of application , however Data Sheet should be checked to ensure compatibility for the Æ Generally operating temperature and other special features.
G – GS - 005 Rev 0
Page 20 of 46
Reliance Engineering Associates Private Limited
Appendix B : CODE LETTER C
Coating Colour Schedule
Aluminium
BRITISH STD : 4800* -
Heated (Except Acid, Caustic, Water)
Black
00 - E - 53
Refrigerated, Tanks inside battery limits
White
-
All Tanks in Tank Farm Area
Sand
-
Light Grey
10 - A - 03
Orange
06 - E - 51
Light Grey
10 - A – 03
Light blue
20 - E - 51
Black
00 – E – 53
Fire Red
04 – E – 53
Light Grey
10 – A – 03
Yellow
08 – E – 51
Light Grey
10 - A - 03
Black
00 – E – 53
Yellow
08 – E – 51
Light Grey
10 – A – 03
Fire Red
04 – E – 53
Green
14 – C – 39
DESCRIPTION Columns , Pressure Vessels, Exchangers
COLOUR
Tankages : F
Rotating equipment : G
Pumps, Compressors, Turbines, Fans, Motors Uncovered moving parts that could cause injury
J
Instrument Equipment Piping, Valves, Fittings etc : AIR services, unless galvanised Underground (Buried)
L
Above ground – Fire Water , Foam etc All other services except the above (Service identification bands – Refer Appendix C ) Transition Flanges (between Above ground and Below ground) Structural Steel work (Unless Galvanised) and Concrete : Framework, Columns, Beams and Pipe Supports
M
Stairs, Platforms, Floor Plates, Kickplates Ladders, Ladder Cages, Hand rails
P
Electrical Equipment Fire Protection Materials and Equipment : Foamatic Hydrants, Water Hydrants, Extinguishers, Sprinkler Systems, Alarm Boxes, Fire doors, Connections and Cabinets for Fire Blankets and Hoses Safety Equipment : Safety Showers, Eyewash fountains, First Aid Equipments, etc.
Note : * Corresponding Equivalent / Nearest IS colour shade is enclosed in cl. 6.0 of Appendix – C
G – GS - 005 Rev 0
Page 21 of 46
Reliance Engineering Associates Private Limited
Table 1 : Identification of Services PIPE CONTENTS BOILER FEED WATER COOLING WATER (FRESH) COOLING WATER (SEA WATER) DESALINATED WATER EFFLUENT WATER WATER WITH OIL POTABLE WATER DEMINERALISED WATER TREATED EFFLUENT WATER
SYMBOLS
04-D-45
-
WC
WHITE
00-E-55
-
WC
WHITE
00-E-55
YELLOW
WD
SKY BLUE
18-E-49
-
WE
BROWN
06-C-39
BLACK
BROWN
06-C-39
-
BLUE
18-E-53
-
WA
RED PURPLE
02-C-33
-
WT
BROWN
06-C-39
WHITE
WO WP
GREEN (For Water)
12-D-45
20-C-37
-
WS WX
PURPLE BLUE YELLOW VIOLET
10-C-33 22-D-45
-
WK
BROWN
06-C-39
-
WR
PURPLE
24-C-33
-
SEA WATER SOUR WATER CONTAMINATED WATER PROCESS WATER FIRE WATER (FRESH) FIRE WATER (SEA WATER) DIESEL FUEL OIL
BREATHING AIR
SECONDARY IDENTIFICATION BAND
CRIMSON
WU
SEAL OR GLAND OIL FLUSHING OIL FIRE FOAM
PRIMARY IDENTIFICATION BAND
WB
UTILITY WATER
LUBE OIL
BASIC IDENTIFICATION BAND
WF
RED
04-E-53
COMPLETE PIPE
WM
RED
04-E-53
COMPLETE PIPE
DL FO LO SO
BROWN (For Oils)
06-C-39
FL FF AB
INSTRUMENT AIR
AI
PLANT AIR
AP
LIGHT GREY (For Air)
10-A-03
005 Rev 0
WHITE CRIMSON EMARALED GREEN SALMN PINK PURPLE RED PALE GREEN
00-E-55 04-D-45
-
14-E-53
-
04-C-33
-
CREAM
08-C-31
BEIGE
10-B-17
24-C-33 04-E-53 14-C-31
Page
10-C-33
00-E-53
00-E-55
LIGHT BLUE FOR COMPLETE PIPE LIGHT BLUE FOR COMPLETE PIPE LIGHT BLUE FOR COMPLETE PIPE
of 46
Reliance Engineering Associates Private Limited
PIPE CONTENTS
SYMBOLS
FUEL GAS (SWEET) FUEL GAS (SOUR) FLUE GAS OVERHEAD GAS FROM AMINE PLANT REFRIGERANT GENERAL HYDROCARBONS HYDROCARBONS WITH SULPHUR HYDROCARBONS WITH HYDROGEN HYDROCARBONS WITH HYDROGEN & H2S HYDROCARBONS WITH SOUR WATER PROCESS BLOWDOWN GENERAL HYDROCARBONS HYDROCARBONS WITH SULPHUR HYDROCARBONS WITH HYDROGEN HYDROCARBONS WITH HYDROGEN & H2S HYDROCARBONS WITH SOUR WATER HYDROGEN NITROGEN COKER MAZE DRAIN CRACKED SLOPS
BASIC IDENTIFICATION BAND
PRIMARY IDENTIFICATION BAND
SECONDARY IDENTIFICATION BAND PALE 14-C-31 GREEN VIOLET 22-C-37 -
FG
GREEN
14-C-39
FS LG
GREEN VIOLET
14-C-39 22-C-37
AG
PURPLE
24-C-39
-
RT
SEA GREEN
16-C-37
-
PA
BROWN
06-C-39
-
PB
YELLOW
10-E-49
-
PC
PURPLE
24-C-33
-
PD
PURPLE
24-C-33
YELLOW
10-E-49
VIOLET
22-D-45
GREEN
12-D-45
BROWN
06-C-39
-
YELLOW
10-E-49
-
BC
PURPLE
24-C-33
-
BD
PURPLE
24-C-33
YELLOW
10-E-49
BE
VIOLET
22-D-45
GREEN
12-D-45
HY NI
CHARCOAL WHITE
00-A-13 00-E-55
MD
BLACK
00-E-53
SC
BLACK
00-E-53
HEAVY SLOPS
SH
BLACK
00-E-53
LIGHT SLOPS
SL
BLACK
00-E-53
SKY BLUE YELLOW GREEN YELLOW GREEN YELLOW
PE
BA BB
YELLOW OCHRE (For Gases either Gaseous or Liquefied)
08-C-35
G – GS - 005 Rev 0
Page 23 of 46
18-E-49 10-E-49 12-E-53 12-C-33
Reliance Engineering Associates Private Limited
PIPE CONTENTS
SYMBOLS
CATALYST MOLTEN SULPHUR
CT
CHEMICALS
CH
AMINES
CA
HIGH STRENGTH CAUSTIC (25% OR GREATER) SULPHURIC ACID HYDROCHLORIC ACID LOW STRENGTH CAUSTIC (LESS THAN 20% CONC.) LOW LOW PRESSURE STEAM LOW PRESSURE STEAM MEDIUM PRESSURE STEAM HIGH PRESSURE STEAM HIGH HIGH PRESSURE STEAM RELIEF & BLOWDOWN STEAM LOW LOW PRESSURE CONDENSATE LOW PRESSURE CONDENSATE MEDIUM PRESSURE CONDENSATE HIGH PRESSURE CONDENSATE HIGH HIGH PRESSURE CONDENSATE
BASIC IDENTIFICATION BAND
SU
PRIMARY IDENTIFICATION BAND PINK 04-C-33 10-E-49
-
12-C-33
-
14-C-31
-
DARK GREEN
14-C-39
PALE GREEN
VA
YELLOW
10-D-45
-
HA
CREAM
10-B-15
-
CC
PALE GREEN
14-C-31
DARK GREEN
14-C-31
-
14-C-39
-
14-E-51
-
12-D-43
-
12-E-51
-
GREEN YELLOW
12-C-33
-
PALE GREEN
14-C-31
-
LC
DARK GREEN
14-C-39
-
MC
GREEN
14-E-51
-
HC
GREEN YELLOW
12-D-43
-
ZC
GREEN YELLOW
12-E-51
-
CB
YELLOW
SECONDARY IDENTIFICATION BAND -
VIOLET (For Chemical or Acid)
LIGHT GREEN PALE GREEN 22-C-37
PALE GREEN DARK GREEN
YS LS MS
GREEN GREEN YELLOW GREEN YELLOW
HS ZS BS
YC
CHARCOAL GREY (For Steam
00-A-13
& Condensate)
G – GS - 005 Rev 0
Page 24 of 46
14-C-31
14-C-39
Reliance Engineering Associates Private Limited 1.0
Flow Direction Band markings and arrows shall be made at the unit battery limits and then on convenient location at the point of use. It is recommended to adopt one method for the entire plant. 1.1
Flow direction by bands 1.1.1
The coding shall be arranged as indicated in Figure – 1.
FIGURE 1 Basic Identification Colour Band Direction of Flow B
Primary Colour Band
Dia PA C
A
D
A
Contents Code
1.1.2
For Dia > 4”, dimensions of ‘A’ and ‘D’ shall be 2 x Dia. (18” maximum) and dimensions of ‘B’ and ‘C’ shall be Dia / 2 (9” maximum).
1.1.3
For Dia < 4” , A = 100 mm, B = 50 mm, C = 25 mm and D = 100 mm.
1.1.4
Colour Band ‘C’ is located on down stream side of Basic Identification colour bands and indicates direction of flow. In case of double direction flow, the band ‘C’ will be located each side of band ‘A’.
1.2
Flow direction by Arrows
1.2.1
The arrows shall be situated in the proximity of the basic identification colour and painted White or Black in order to contrast clearly with the basic identification colour.
1.2.2
Arrow size : - For pipes diameter 2” to 6”, arrow to fit in a 25 mm x 100 mm rectangular. - For pipes diameter 8” and above, arrow to fit in a 50 mm x 150 mm rectangular.
1.2.3
Where flow of fluid is possible in either direction, the arrows will be indicated one above the other and the arrow heads in opposite directions. The colour of both the arrows will be same.
G – GS - 005 Rev 0
Page 25 of 46
Reliance Engineering Associates Private Limited 2.0
Identification with two colour bands (Primary and Secondary)
2.1. The procedure as indicated in Figure – 2 shall be used to identify services (such as for fuel gas, hydrocarbons etc) with two colour bands (Primary and Secondary) as described in Table – 1.
Figure- 2 Basic Identification Band Primary Band colour Secondary Band
D/3 D/3 D/3
Direction of Flow
C
B
A
A D
2.2 The dimensions of ‘A’, ‘B’, ‘C’ and ‘D’ are same as per para 1.1.2 and 1.1.3.
3.0
Hazardous Mediums Where the piping system carries a hazardous product, a panel of equal diagonal stripes (black and yellow colours) shall be superimposed on the pipe on both ends of the basic identification bands as detailed in Figure – 3.
Figure - 3 Direction of flow
Basic Identification Bands B
Equal Width Bands **
Primary Colour Band
PA A
B
C
A
D
Contents Code Hazard Marking
A
B
A Hazard Marking
Note : 1) ** Stripes of Black 00-E-33 & Yellow 08-E-51 2) All other dimensions are as per para 1.1.2 & 1.1.3
G – GS - 005 Rev 0
Page 26 of 46
o
45
Reliance Engineering Associates Private Limited 4.0
Details of Contents Code Indication 4.1
The contents code indications shall be painted either in White or in Black in order to contrast clearly with the colour of paint on the pipe or equipment. For insulated lines the code indications shall be painted over the cladding of the insulation.
4.2
The name of fluid flowing inside a pipeline shall be indicated. The line number shall also be painted on the pipelines. The pressure or temperature of the fluid inside the pipeline shall not be indicated.
4.3
The contents code indication as described above shall be painted at following locations or such other places where quick identification is deemed necessary. Pipe lines : At all junctions, both sides of valves, both sides of service appliances and at intervals of 30 Mtr on straight pipe lengths For long straight lengths of pipelines, e.g., transfer lines, the interval of 30Mtr for code indication may be varied at the discretion of the Reliance.
4.4
5.0
The size of lettering for code indication on the insulated as well as uninsulated pipes is as follows. These sizes are only indicative and may be varied by the Reliance Engineer. For Pipes
: Diameter 2” NB
- 25 mm letters
For Pipes
: Diameter 3” to 6” NB - 50 mm letters
For Pipes
: Diameter 8”NB and above
- 80 mm letters
Code Indication for Small Diameter Pipes Code indication marking by paint may not be done for uninsulated pipelines of nominal diameter 1 ½” and below and for insulated lines less than 1” diameter. For such pipes, the indication markings shall be punched on lead tags secured to the pipe. Such tags shall be provided at locations described in section 4.3 above. The size of the tag and the method of tying it with pipeline shall be as per advice of the Reliance Engineer.
G – GS - 005 Rev 0
Page 27 of 46
Reliance Engineering Associates Private Limited 6.0 SL No. 1
Equivalent / Nearest IS Colour Shades
CHARCOAL / CHAR. GREY
00-A-13
IS CODE / BERGER IS 671
2
BLACK
00-E-53
-
3
WHITE
00-E-55
-
4
RED PURPLE
02-C-33
BERGER-589
5
SALMON PINK / PINK
04-C-33
BERGER-435
6
CRIMSON
04-D-45
IS 540
7
FIRE RED
04-E-53
IS 536
8
BROWN
06-C-39
IS 415
9
ORANGE
06-E-51
IS 557
10
CREAM
08-C-31
IS 442
11
YELLOW
08-C-35
IS 361
12
YELLOW
08-E-51
IS 356
13
LT GREY
10-A-03
IS 631
14
CREAM
10-B-15
BERGER-095
15
BEIGE
10-B-17
IS 364
16
YELLOW
10-C-33
IS 352
17
YELLOW
10-D-45
IS 222
18
YELLOW
10-E-49
IS 365
19
GREEN YELLOW / LT GREEN
12-C-33
IS 216
20
GREEN YELLOW
12-D-43
IS 278
21
GREEN
12-D-45
IS 219
22
GREEN YELLOW
12-E-51
IS 354
23
GOLD.YELLOW
12-E-53
IS 218
24
PALE GREEN
14-C-31
IS 275
25
GREEN / DARK GREEN
14-C-39
IS 226
26
GREEN
14-E-51
IS 280
27
EMERALD GREEN
14-E-53
IS 299
28
SEA GREEN
16-C-37
IS 102
29
SKY BLUE
18-E-49
IS 177
30
BLUE
18-E-53
IS 176
31
PURPLE BLUE
20-C-37
IS 166
32
LT. BLUE
20-E-51
BERGER-134
33
VIOLET
22-C-37
BERGER-712
SHADE NAME
G – GS - 005 Rev 0
SHADE NAME
Page 28 of 46
Reliance Engineering Associates Private Limited Sl No. 34
VIOLET
22-D-45
IS CODE / BERGER IS 108
35
PURPLE
24-C-33
BERGER-728
36
PURPLE
24-C-39
IS 796
SHADE NAME
G – GS - 005 Rev 0
SHADE NAME
Page 29 of 46
Reliance Engineering Associates Private Limited
Appendix D :
Coating Schedule (Other than Marine Environment)
G – GS – 005 Rev 0
Page 30 of 46
Reliance Engineering Associates Private Limited “C’ Painting Schedule Columns/Pressure Vessels/Exchangers/Heaters
SURFACE PREP CODE
DESCRIPTION WHERE DONE
SA3 / 2 1/2
TYPE
SURFACE PREPARATION , PRIMING & COATING FIRST COAT INTERMEDIATE FINISH COAT COAT TYPE
WHERE APPLIED
Shop
01
MIN. TOTAL DFT MICRONS
TYPE
WHERE APPLIED
TYPE
WHERE APPLIED
Shop
-
-
07
Shop
150
Ca
To be insulated fireproofed upto 400o C
Cb
Uninsulated upto 120o C and nonfireproofed vessels skirts
SA2 1/2
Shop
04
Shop
05
Shop
06
Shop
245
Cc
Uninsulated 121o C to 175o C
SA3 / 2 1/2
Shop
01
Shop
-
-
02
Shop
125
Cd
Uninsulated 176o C to 400o C
SA3 / 2 1/2
Shop
01
Shop
-
-
03
Field
100
Ce
Ladders,platforms including framing and steel supports other than vessel clips, handrails, stair treads, open grid flooring, toe boards, floor plates
SA2 1/2
Cf
Austenitic stainless steel. Operating between 50oC and 120o C
“See Remark” SA 2 1/2
Cg
Austenitic stainless steel. Operating between 120oC and 200o C
“See Remark” SA 2 1/2
Ch
Stair treads, open grid flooring, steel gratings
SA 2
Hot dip galvanise to BS 729. Min. Coating WT 610 grams/m
Shop
-
-
-
Shop
-
-
02 at (30 DFT)
Shop
-
-
02 at (30 DFT)
Shop
100
Shop
60
3 Coats Bituminous paint to BS:3416 Type 1 applied by dipping, DFT 40 microns per coat
G – GS - 005 Rev 0
Primed surface to be free of zinc salts prior to finish coating As “Cc” above notes. Finish coat 03 may not fully cure until equipment is in service. Where not galvanised use systems “Cb” except as identified under code “Ch”
2
08 at (100 DFT)
REMARKS
Surface to be blast cleaned with “Vasilgrit” or other suitable Aluminium oxide abrasive. Surface to be blast cleaned with “Vasilgrit” or other suitable Aluminium oxide abrasive
120
Page 31 of 46
Reliance Engineering Associates Private Limited “C’ Painting Schedule Columns/Pressure Vessels/Exchangers/Heaters SURFACE PREPARATION , PRIMING & COATING CODE
DESCRIPTION
SURFACE PREP TYPE
Ci
Direct buried vessels upto 400o C Note 3 Note 4 Note 5
Cj
All vessels operating above 400o C
WHERE DONE
FIRST COAT TYPE
WHERE APPLIED
INTERMEDIATE COAT TYPE
WHERE APPLIED
FINISH COAT TYPE
07 11 Shop Note 3 Note 4 For this service the coating shall be Amercoat 741 applied @ 125 microns D.F.T. The coat (Amercoat 710 ) shall be applied after previous coat has fully cured only This system will only be used in tandem with cathodic protection. SA 3 / 2 1/2
SA2 1/2
Shop
Shop
01
Shop
12
Shop
-
G – GS - 005 Rev 0
-
-
WHERE APPLIED
MIN. TOTAL DFT MICRONS
Shop or Field
200
-
75
REMARKS
Page 32 of 46
Reliance Engineering Associates Private Limited “F’ Painting Schedule Tankage
CODE
DESCRIPTION
SURFACE PREP TYPE
Fa
External Insulated
WHERE DONE
-
No
Fb
External Uninsulated upto 120oC
SA2 1/2
Field
Fc
External Uninsulated 121oC to 175oC
SA2 1/2
Field
Fd
Internal Potable water
SA2 1/2
Field
Fe
Internal Industrial water, Ballast water, Slop Water, Demineralised Water
SA2 ½
Field
Ff
Internal
SURFACE PREPARATION, PRIMING & COATING INTERMEDIATE FIRST COAT FINISH COAT COAT WHERE WHERE WHERE TYPE TYPE TYPE APPLIED APPLIED APPLIED
SA2 1/2
Field
Painting
MIN. TOTAL DFT MICRONS
REMARKS
Where preparation is carried out in a shop or offsite it is mandatory that the first coat to be carried out at the same location Primed surface to be free of zinc salts prior to finish coating. Shop built tanks will be shop painted Drinking water grade, approved National Water Council Certificate required. Shop built tanks will be shop painted
Field
20
Field
18 (Note 1)
Field
200
Field
-
-
02 or 07
Field
125
10
Field
10
Field
10
Field
240
09
Field
-
-
09
Field
350
Shop built tanks will be shop painted.
240
This system for corrosive service only. Shop built tanks will be shop painted
01
01
10
Field
10
G – GS - 005 Rev 0
Field
10
Field
Page 33 of 46
Reliance Engineering Associates Private Limited “F’ Painting Schedule Tankage (Continued)
CODE
DESCRIPTION
SURFACE PREP TYPE
Fg
Fh
Fi
External Underside of all Tanks External Austenitic stainless steel operating between 50o C and 120o C External Austenitic stainless steel operating between 121o C and 200o C
SA2 ½ (Note 2)
WHERE DONE
Field
SURFACE PREPARATION, PRIMING & COATING INTERMEDIATE FIRST COAT FINISH COAT COAT WHERE WHERE WHERE TYPE TYPE TYPE APPLIED APPLIED APPLIED
09
Field
-
-
No
Painting
-
No
Painting
MIN. TOTAL DFT MICRONS
REMARKS
175
A strip 75 mm wide at plate edge shall be left bare to avoid welding contamination
Note 1: Tankage within the Tank Farms that are designated Code Fb shall be camouflaged, as such they shall be finish painted with 60 microns of paint Type 18 to ensure a dull appearance.
Note 2: Where carboline Carbomastic 14 or Apcodur CF 655 (Asian) is used as the primer for the underside of tank plate , a commercial blast to SA 2 is acceptable. ( This does not apply to any immersion services)
G – GS - 005 Rev 0
Page 34 of 46
Reliance Engineering Associates Private Limited “G’ Painting Schedule Rotating Equipment (Including Pumps, Compressors, Fans, Motors, etc.)
CODE
DESCRIPTION
SURFACE PREPARATION , PRIMING & COATING MIN. INTERMEDIATE TOTAL SURFACE PREP FIRST COAT FINISH COAT COAT DFT WHERE WHERE WHERE WHERE MICRONS TYPE TYPE TYPE TYPE DONE APPLIED APPLIED APPLIED 1. All except “Gb” as for codes Ca to Cg 2. Machinery and drivers, instruments and associated valves may be finish coated with manufacturer’s standard coating system. Note: This standard will be subject to Reliance approval Manufacturers should notify detauls of the proposed paints systems to facilitate repair and maintenance. This system must be capable of the withstanding the enviornmental conditions for a period 5 years to Re 3 on European scale of degree of rusting.
Ga
External
Gb
Moving Parts
As for the system Cb with the exception that surface preparation will be to Standard ST3
Gc
Austenitic stainless steel
Refer to Codes “Cf” and “Cg”.
G – GS - 005 Rev 0
REMARKS
Total system to be shop applied
Total system to be shop applied
Page 35 of 46
Reliance Engineering Associates Private Limited “J’ Painting Schedule Instrumentation Equipment SURFACE PREPARATION , PRIMING & COATING CODE
DESCRIPTION
SURFACE PREP TYPE
Ja
WHERE DONE
FIRST COAT TYPE
WHERE APPLIED
INTERMEDIATE COAT WHERE TYPE APPLIED
FINISH COAT TYPE
WHERE APPLIED
MIN. TOTAL DFT MICRONS
Jb
Housing and Equipment Supports Control panels
Shop or Shop or 245 06 Field Field This equipment shall have its surface prepared, primed and finished in accordance with manufacturers standards. Note: This standard will subject to Reliance approval. The system must be cable of withstanding the environmental conditions for a period of 5 years to ‘Re 3” on the European scale of degree of rusting.
Jc
Austenitic stainless steel
Refer to Codes “Cf” and “Cg”.
Shop
04
Shop
05
G – GS - 005 Rev 0
REMARKS Housing to be finished coated in seller works All panels must display a smooth finish appearance. Hammered or stippled etc. Are not acceptable.
Page 36 of 46
Reliance Engineering Associates Private Limited “L” Painting Schedule Piping, Valves and Fittings CODE
SURFACE PREPARATION, PRIMING & COATING INTERMEDIATE SURFACE PREP FIRST COAT COAT WHERE WHERE WHERE TYPE TYPE TYPE DONE APPLIED APPLIED
DESCRIPTION
FINISH COAT TYPE
WHERE APPLIED
06
Field
MIN. TOTAL DFT MICRONS
o
La1
La2
CS/AS Systems above 60 C but less than 120oC and not require steam out (Uninsulated) CS/AS Systems (i) above 120oC but less than 200oC (ii) Systems operating below 120oC but require steam out (Uninsulated)
SA2 1/2
SA2 1/2
Shop
Shop
01
01
Shop
Shop
Note 4
Note 4
-
-
02
Field
REMARKS
150
For PP insulated portion Type 01 to be applied.
125
For PP insulated portion, generally no paint is required but Type 01 may be applied.
La3
Systems above 200oC but less than 400o C (Uninsulated)
SA2 1/2
Shop
01
Shop
Note 4
-
07 (Note 7)
Field
150
For PP insulated portion, generally no paint is required but Type 01 may be applied.
Lb
Systems upto 120oC that require Colour coating
SA2 1/2
Shop
01
Shop
Note 4
-
06
Field
150
e.g. Fire water piping
SA2 1/2
Shop
14
Shop
15
Shop or Field
16
Field
200
Type 15 to be applied in shop within 28 days of Primer application.
1) Piping upto 60oC but not require steam out
Lc
2)Flare(OSBL)
120o C
Lh1
Hot insulated piping
Lh2
Hot insulated piping > 120o C
SA2 1/2
Shop
01
Shop
This is also applicable for hot insulated piping upto 120o C which require steam out.
-
Note: The coating system for “Off the Shelf” valves could be manufactures standards subject to Reliance’s approval. The system must be capable of withstanding the environmental conditions for a period of 5 years to “Re 3” on the European scale of degree of rusting. Contd. on next page
G – GS - 005 Rev 0
Page 37 of 46
Reliance Engineering Associates Private Limited “L’ Painting Schedule Piping, Valves and Fittings (Continued)
CODE
DESCRIPTION
SURFACE PREP TYPE
WHERE DONE
SURFACE PREPARATION, PRIMING & COATING INTERMEDIATE FIRST COAT FINISH COAT COAT WHERE WHERE WHERE TYPE TYPE TYPE APPLIED APPLIED APPLIED
Le
Austenitic stainless steel operating 50oC and 120oC
-
-
-
-
Lf
Austenitic stainless steel operating 121oC and 200oC
-
-
-
-
Lg1
Closed drain buried piping operating above 65oC
SA2 1/2
Shop
01
Shop
07 (Note 1)
Lg2
Operating below 65o C
SA2 1/2
Shop
09
Shop
-
Note 1:
Shop
11 (Note 2)
Shop or Field
-
MIN. TOTAL DFT MICRONS
REMARKS
200
Cathodic Protection by sacrificial anode Note 3)
75
Note 5
(
For this service , the coating shall be Amercoat 741 applied at 125 microns DFT
Note 2: This coating ( Amercoat 710) is a low solids sealer coat that shall only be applied after previous coat has fully cured Note 3:
It is mandatory that this system is protected by sacrificial anode cathodic protection
Note 4:
Intermediate coat exempted
Note 5:
External surface protection by coating and wrapping
Note 6:
Field joint Coating – Temperature from 0oC to 204oC : CDC Paint HM 21 (Primer –75 microns) and HM1248 (Intermediate-75 microns) with ST 2 surface preparation.
Note 7: Colour band as per Appendix C to be provided if Type 07 paint is not available in Light Grey colour
G – GS - 005 Rev 0
Page 38 of 46
Reliance Engineering Associates Private Limited “M” Painting Schedule
Structural Steelwork and Concrete
CODE
DESCRIPTION
SURFACE PREP TYPE
WHERE DONE
Ma
General not concrete encased
SA3 / 2 1/2
Shop
Mb
General concrete encased
SA3 / 2 1/2
Shop
Mc
Stair Treads, Open Grid Floor plates
Md Me
Mf
Stair Treads, open grid flooring, steel gratings Structural steel protection with light weight proofing Ladder, Handrails. Toe boards, Platforms including framing and steel supports
SURFACE PREPARATION, PRIMING & COATING INTERMEDIATE FIRST COAT FINISH COAT COAT WHERE WHERE WHERE TYPE TYPE TYPE APPLIED APPLIED APPLIED
14 (Note 1)
14
Shop
15
Shop
16
Field
200
Shop
-
-
16
Field or Shop (Note 2)
125
Hot dip galvanised to BS 729 Min. coating Wt. 610 grams/m
3 Coats of Bituminous paints to BS 3416 Type 1 applied by dipping. DFT 40 microns per coat
Shop
14
Shop
15
Shop
i) Primed surface to be free of zinc salts prior to finish coating ii) Intermediate coat to be applied within 28 days of primer application. Primed surface to be free of zinc salts prior to finish coating
120
As per “Mb” above
SA2 1/2
REMARKS
Where no galvanised, use system Cb except as identified under code Md (Note 3)
2
SA2 1/2
SA2 1/2
MIN. TOTAL DFT MICRONS
.
16
Field
200
Refer remarks of Code Ma (Note 1)
Note 1: Reliance Fabrication shop may apply “Pre-Construction”, based on requirement (but not mandatory) primer Type –13, DFT 15 to 20 microns. Note 2 : If fireproofing is applied away from job site, the finish paint coating over steelwork shall also be applied at the same location Note 3 : Repair to Damaged Galvanised Surfaces - Damaged areas of galvanised structures shall be feathered back to sound coating and cleaned as per SSPC-SP3. The area shall be coated with a high zinc dust content galvanising repair coating such as METAL FLUX or approved equal.
G – GS - 005 Rev 0
Page 39 of 46
Reliance Engineering Associates Private Limited “P” Painting Schedule Electrical Equipment
CODE
DESCRIPTION
SURFACE PREP TYPE
WHERE DONE
SURFACE PREPARATION, PRIMING & COATING INTERMEDIATE FIRST COAT FINISH COAT COAT WHERE WHERE WHERE TYPE TYPE TYPE APPLIED APPLIED APPLIED
MIN. TOTAL DFT MICRONS
Pa
Motors, Switchgears, Std Equipment Junction Boxes
This equipment shall be prepared, primed and finished in accordance with manufacturer’s Standards. The system must be capable of withstanding the environment conditions for period of 5 years to “Re 3” on the European scale of rusting
Pb
Equipment Supports, Motor Control Stations
SA2 1/2
Pc
Austenitic stainless steel
Pd
Cabble tray and Ladder Rack
Shop
04
Shop
05
Shop or Field
06
Shop or Field
245
REMARKS
Manufacturer’s Standard will be subject to Reliance approval .Shop fabricated supports will be painted in the shop.
Refer to Codes “Cf” and “Cg”. SA2 1/2
Hot dip galvanised to BS 729 . (Minimum coating thick, as detailed BS 729 per Steel selection)
G – GS - 005 Rev 0
Page 40 of 46
Reliance Engineering Associates Private Limited
Appendix E :
Coating Schedule (Marine Environment)
1) “C” Painting Schedule – Columns / Pressure Vessels / Exchangers / Heaters
: Same as Appendix ‘D’
2) “G” Painting Schedule – Rotating Equipment (Including Pumps, Compressors, Fans, Motor, etc)
: Same as Appendix ‘D’
3) “J” Painting Schedule – Instrumentation Equipment
: Same as Appendix ‘D’
4) “P” Painting Schedule – Electrical Equipment
: Same as Appendix ‘D’
G – GS - 005 Rev 0
Page 41 of 46
Reliance Engineering Associates Private Limited “F’ Painting Schedule Tankage
CODE
DESCRIPTION
SURFACE PREP TYPE
Fa
WHERE DONE
SURFACE PREPARATION, PRIMING & COATING INTERMEDIATE FIRST COAT FINISH COAT COAT WHERE WHERE WHERE TYPE TYPE TYPE APPLIED APPLIED APPLIED
No
External Insulated
MIN. TOTAL DFT MICRONS
REMARKS
Painting Where preparation is carried out in a shop or offsite it is mandatory that the first coat to be carried out at the same location Primed surface to be free of zinc salts prior to finish coating. Shop built tanks will be shop painted Drinking water grade, approved National Water Council Certificate required. Shop built tanks will be shop painted
Fb
External Uninsulated upto 120oC
SA2 1/2
Field
01 (60 microns)
Field
19
Field
18 (Note 1)
Field
220
Fc
External Uninsulated 121oC to 175oC
SA2 1/2
Field
01 (60 microns)
Field
-
-
02 or 07
Field
110
Fd
Internal Potable water
SA2 1/2
Field
10
Field
10
Field
10
Field
240
Fe
Internal Industrial water, Ballast water, Slop Water, Demineralised Water
SA2 1/2
Field
09
Field
-
-
09
Field
350
Shop built tanks will be shop painted.
240
This system for corrosive service only. Shop built tanks will be shop painted
Ff
Internal
SA2 1/2
Field
10
Field
10
G – GS - 005 Rev 0
Field
10
Field
Page 42 of 46
Reliance Engineering Associates Private Limited
“F’ Painting Schedule Tankage (Continued)
SURFACE PREP CODE
DESCRIPTION TYPE
Fg
Fh
Fi
External Underside of all Tanks External Austenitic stainless steel operating between 50oC and 120oC External Austenitic stainless steel operating between 121oC and 200o C
SA2 1/2 (Note 2)
WHER E DONE
Field
SURFACE PREPARATION , PRIMING & COATING INTERMEDIATE FIRST COAT FINISH COAT COAT TYPE
09
WHERE APPLIED
TYPE
Field
WHERE APPLIED
TYPE
-
-
No
Painting
-
No
Painting
WHERE APPLIED
MIN. TOTAL DFT MICRONS
REMARKS
A strip 75 mm wide at plate edge shall be left bare to avoid welding contamination
Note 1: Tankage within the Tank Farms that are designated Code Fb shall be camouflaged, as such they shall be finish painted with 60 microns of paint Type 18 to ensure a dull appearance. All other tanks shall be finish painted with 60 microns of paint Type 06 Note 2: Where carboline Carbomastic 14 or Apcodur CF 655 (Asian) is used as the primer for the underside of tank plate , a commercial blast to SA 2 is acceptable. ( This does not apply to any immersion services)
G – GS - 005 Rev 0
Page 43 of 46
Reliance Engineering Associates Private Limited “L’ Painting Schedule Piping, Valves and Fittings CODE
SURFACE PREP
DESCRIPTION
TYPE
WHERE DONE
SA2 1/2
Shop
SURFACE PREPARATION ,PRIMING & COATING INTERMEDIATE FIRST COAT FINISH COAT COAT WHERE WHERE WHERE TYPE TYPE TYPE APPLIED APPLIED APPLIED
MIN. TOTAL DFT MICRONS
REMARKS
o
Lb1
Lb2
CS/AS Systems above 60 C but less than 120oC and not require steam out (Uninsulated) CS/AS Systems (i) above 120oC but less than 200oC (ii) Systems operating below 120oC but require steam out (Uninsulated)
SA2 1/2
Shop
01
01
Shop
Shop
Note 4
Note 4
-
-
06
02
Field
Field
150
For PP insulated portion Type 01 to be applied.
125
For PP insulated portion, generally no paint is required but Type 01 may be applied.
Lb3
Systems above 200oC (Uninsulated) but less than 400o C
SA2 1/2
Shop
01
Shop
Note 4
-
07 ( Note 7)
Field
150
Lb
CS Systems upto 120oC that require Colour coating
SA2 1/2
Shop
01
Shop
Note 4
-
06
Field
150
SA2 1/2
Shop
01
Shop
15
Shop or Field
16
Field
200
For PP insulated portion, generally no paint is required but Type 01 may be applied. e.g. Fire water piping
1)CS Piping upto 60oC but not require steam out Lc
2)Flare System upto 60oC
o
Lh1
Hot insulated piping
Lh2
Hot insulated piping >120oC
120 C
SA2 1/2
-
Shop
01
Shop
-
75
-
This is also applicable for hot insulated piping upto 120o C which require steam out.
-
Note: The coating system for “Off the Shelf” valves could be manufactures standards subject to Reliance’s approval. The system must be capable of withstanding the environmental conditions for a period of 5 years to “Re 3” on the European scale of degree of rusting.
G – GS - 005 Rev 0
Page 44 of 46
Reliance Engineering Associates Private Limited “L’ Painting Schedule Piping, Valves and Fittings (Continued) SURFACE PREPARATION, PRIMING & COATING INTERMEDIATE FIRST COAT FINISH COAT COAT
SURFACE PREP CODE
DESCRIPTION TYPE
Le Lf
Austenitic stainless steel operating 50oC and 120oC Austenitic stainless steel operating 121oC and 200oC
WHER E DONE
TYPE
WHERE APPLIED
-
-
-
-
-
-
Lg1
Closed drain buried piping operating above 65oC
SA2 1/2
Shop
01
Shop
Lg2
Operating below 65oC
SA2 1/2
Shop
09
Shop
Note 1:
TYPE
07 (Note 1)
WHERE APPLIED
Shop
TYPE
11 (Note 2)
-
WHERE APPLIED
Shop or Field
-
MIN. TOTAL DFT MICRONS
REMARKS
200
Cathodic Protection by sacrificial anode ( Note 3)
75
(Note 5)
For this service , the coating shall be Amercoat 741 applied at 125 microns DFT
Note 2: This coating ( Amercoat 710) is a low solids sealer coat that shall only be applied after previous coat has fully cured Note 3:
It is mandatory that this system is protected by sacrificial anode cathodic protection
Note 4:
Intermediate coat exempted
Note 5:
External surface protection by coating and wrapping
Note 6:
Field joint Coating – Temperature from 0oC to 204oC : CDC Paint HM 21 (Primer –75 microns) and HM 1248 (Intermediate-75 microns) with ST 2 surface preparation.
Note 7:
Colour band as per Appendix C to be provided if Type 07 paint is not available in Light Grey colour
G – GS - 005 Rev 0
Page 45 of 46
Reliance Engineering Associates Private Limited “M” Painting Schedule ( MTF Area) Structural Steelwork and Concrete
CODE
DESCRIPTION
SURFACE PREP TYPE
WHERE DONE
SURFACE PREPARATION , PRIMING & COATING INTERMEDIATE FIRST COAT FINISH COAT COAT WHERE WHERE WHERE TYPE TYPE TYPE APPLIED APPLIED APPLIED
MIN. TOTAL DFT MICRONS
Ma
General not concrete encased
SA3/ SA 2 1/2
Shop
01 (60 microns)
Shop
15
Shop
16 (60 microns)
Field
185
Mb
General concrete encased
SA3/ SA2 1/2
Shop
01
Shop
-
-
16
Field or Shop (Note 2)
125
Mc
Stair treads, Open Grid Floor plates
Md Me
Mf
Stair treads, open grid flooring, steel gratings Structural steel protection with light weight proofing Ladder, Handrails. Toe boards, Platforms includiung framing and steel supports
SA2 1/2
3 Coats of Bituminous paints to BS 3416 Type 1 applied by dipping. DFT 40 microns per coat
Primed surface to be free of zinc salts prior to finish coating Intermediate coat to be applied within 28 days of primer application. Primed surface to be free of zinc salts prior to finish coating Where no galvanised, use system Cb except as identified under code Md (Note 3)
Hot dip galvanised to BS 729 Min. coating Wt.610 grams/m2
SA2 1/2
REMARKS
120 .
As per “Mb” above
SA2 1/2
Shop
01 (60 microns)
Shop
15
Shop
16
Field
200
Refer remarks of Code Ma (Note 1)
Note 1: Reliance Fabrication shop may apply “Pre-Construction”, based on requirement (but not mandatory) primer Type –13, DFT 15 to 20 microns. Note 2 : If fireproofing is applied away from job site, the finish paint coating over steelwork shall also be applied at the same location Note 3 : Repair to Damaged Galvanised Surfaces - Damaged areas of galvanised structures shall be feathered back to sound coating and cleaned as per SSPC-SP3. The area shall be coated with a high zinc dust content galvanising repair coating such as METAL FLUX or approved equal.
G – GS - 005 Rev 0
Page 46 of 46
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