QP-SPC-L- 002 Rev 2 , 16-05-2013

STANDARDS PUBLICATION

QP SPECIFICATION FOR PAINTING AND WRAPPING OF METAL SURFACES (NEW CONSTRUCTION & MAINTENANCE)

DOC NO: QP-SPC-L-002 REVISION 2

CORPORATE HSE SUPPORT

QP SPECIFICATION FOR PAINTING & WRAPPING OF METAL SURFACES (NEW CONSTRUCTION AND MAINTENANCE) Doc. No.: QP-SPC- L-002

Rev. 2

TABLE OF CONTENTS Page No. FOREWORD 1.0

OBJECTIVE …………………………… ………………………………………………………….. ……………………………................... .................

5

2.0

SCOPE………………………………………………………………..................... SCOPE……………………………………………………………….. ...................

5

3.0

APPLICATION ………………………… ………………………………………………………. ……………………………................... ..................

5

4.0 4.1 4.2

TERMINOLOGY …………………………… ……………………………………………………... ……………………….................... ................. DEFINITIONS ………………………… ……………………………………………………….. …………………………….. .................. ABBREVIATIONS ……………………………………………………. ……………………………………………………. .................

5 5 8

5.0 5.1 5.2 5.3 5.4 5.5

REFERENCE STANDARDS AND CODES ……………………….................. ……………………….................. PAINTING AND COATING – COATING – GENERAL GENERAL……………………………………….. ……………………………………….. SURFACE PREPARATION……………………………………………………… PREPARATION……………………………………………………… INSPECTION AND TESTING……………………………………………………. TESTING ……………………………………………………. COLOUR CODING………………………………………………………………... CODING ………………………………………………………………... HEALTH, SAFETY AND ENVIRONMENT……………………………………... ENVIRONMENT……………………………………...

8 8 9 9 11 11

6.0

GENERAL CONTRACTOR REQUIREMENTS……………………………….. REQUIREMENTS ………………………………..

12

7.0 7.1 7.2 7.3 7.4 7.5 7.6

HEALTH, SAFETY AND ENVIRONMENTAL REQUIREMENTS.................. GENERAL SAFETY AND HAZARD CONSIDERATIONS …………………… ACCESS ACCESS FACILITIES AND SCAFFOLDING…………………………………... SCAFFOLDING…………………………………... BLASTING AND SPRAY PAINTING EQUIPMENT…………………………… EQUIPMENT…………………………… PAINTS, SOLVENTS AND ABRASIVES……………………………………….. ABRASIVES……………………………………….. PERSONNEL PROTECTIVE EQUIPMENT…………………………………… EQUIPMENT…………………………………… PAINT, SOLVENT, CHEMICAL AND WASTE MATERIAL DISPOSAL…….. DISPOSAL……..

13 13 14 14 15 16 17

8.0 8.1 8.2 8.3

PAINTING OF NEW EQUIPMENT AND STRUCTURES…………………… STRUCTURES …………………… GENERAL REQUIREMENTS……………………………………………………. REQUIREMENTS……………………………………………………. VENDOR STANDARD COATING SYSTEMS…………………………………. SYSTEMS…………………………………. MATERIALS AND EQUIPMENT NOT TO BE PAINTED……………………... PAINTED……………………...

17 17 18 18

9.0 9.1

PAINTING OF EXISTING EQUIPMENT AND STRUCTURES……………… STRUCTURES ……………… GENERAL REQUIREMENTS……………………………………………………. REQUIREMENTS…………………………………………………….

19 19

10.0 10.1 10.2 10.3 10.4 10.5 10.6 10.7

SURFACE PREPARATION……………………………………………………… PREPARATION……………………………………………………… PREPARATORY GRINDING AND DEGREASING…………………………… DEGREASING…………………………… GENERAL BLAST CLEANING REQUIREMENTS……………………………. REQUIREMENTS……………………………. DRY BLAST CLEANING…………………………………………………………. CLEANING…………………………………………………………. WET ABRASIVE BLAST CLEANING AND WATER JETTING……………… JETTING……………… POWER TOOL SURFACE PREPARATION…………………………………… PREPARATION…………………………………… MECHANICAL HAND TOOL SURFACE PREPARATION…………………… PREPARATION …………………… CHEMICAL PICKLING……………………………………………………………. PICKLING…………………………………………………………….

20 20 21 22 23 24 25 25

11.0 11.1 11.2 11.3 11.4

PAINT APPLICATION……………………………………………………………. APPLICATION……………………………………………………………. PAINT SUITABILITY, STORAGE AND MIXING………………………………. MIXING………………………………. PAINT APPLICATION EQUIPMENT……………………………………………. EQUIPMENT……………………………………………. PAINT APPLICATION METHODOLOGY………………………………………. METHODOLOGY………………………………………. REPAIR OF DAMAGED PAINTW ORK………………………… ORK…………………………………………. ……………….

26 26 27 27 29

12.0

WRAPPING TAPE APPLICATION……………………………………………... APPLICATION……………………………………………...

30

Doc. File No.: SPC.L.002.R2

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12.1 12.2 12.3 12.4 12.5

TAPE SUITABILITY AND STORAGE…………………………………………... STORAGE…………………………………………... SURFACE PREPARATION……………………………………………… PREPARATION……………………………………………………… ……… TAPE APPLICATION METHODOLOGY……………………………………….. METHODOLOGY……………………………………….. REPAIR OF DAM AGED W RAPPING TAPE…………………………………… TAPE…………………………………… PROTECTION OF THREADED CONNECTIONS & FLANGED JOINTS …...

30 30 31 32 32

13.0 13.1 13.2 13.3 13.4 13.5

INSPECTION DURING SURFACE PREPARATION AND COATING……… COATING ……… GENERAL INSPECTION REQUIREMENTS…………………………………... REQUIREMENTS…………………………………... INSPECTION SYSTEM REQUIREMENTS…………………………………….. REQUIREMENTS…………………………………….. INSPECTION OF EQUIPMENT, MATERIALS AND ACCESS FACILITES… PREPARATORY AND COATING INSPECTION AND TEST WORK……….. INSPECTION EQUIPMENT REQUIREMENTS……………………………….. REQUIREMENTS ………………………………..

33 33 34 35 36 40

14.0

QUALITY REQUIREMENTS…………………………………………………….. REQUIREMENTS ……………………………………………………..

41

15.0

DOCUMENTATION………………………………………………………………. DOCUMENTATION……………………………………………………………….

42

16.0

PROTECTIVE SYSTEM CLASSIFICATION BY AREA, SERVICE AND MATERIAL………………………………………………………………………… MATERIAL …………………………………………………………………………

43

17.0

COATING AND WRAPPING SCHEDULES…………………………………… SCHEDULES ……………………………………

44

18.0

COLOUR CODING & IDENTIFICATION SCHEDULES ………………………

64

19.0 19.1 19.2 19.3

APPENDICES…………………………………………………………………...... APPENDICES…………………………………………………………………...... APPENDIX A: TABLES…………………………………………………………… TABLES…………………………………………………………… APPENDIX B: FIGURES…………………………………………………………. FIGURES…………………………………………………………. APPENDIX C: MINIMUM FORCED VENTILATION REQUIREMENTS FOR ENCLOSED SPACES DURING PAINT APPLICATION AND CURING…….. APPENDIX D: COLOUR CODING AND IDENTIFICATION SYSTEM FOR PIPEWORK, VALVES AND VALVE ACCESS MANHOLE COVERS………..

65 65 73

REVISION HISTORY LOG............................................................................

88

19.4


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Rev. 2

FOREWORD This document has been revised by Corporate Standards Working Group Four for Material and Corrosion Control and Mitigation - Task Force One - Painting and Wrapping (WG4-TF1), reviewed by Corporate HSE Support Department Materials and Facilities Integrity Division, Corporate Quality and Management Systems Department Standards Division and User Departments, and endorsed by QP Management for use as QP Specification for Painting & Wrapping of Metal Surfaces (New Construction and Maintenance) The document is published for QP Departments, Contractors and Consultants utilization for the painting and wrapping of metallic equipment, structures and components other than subsea pipelines, the splash zone section of riser lines and the internal surfaces of pipework and valves. It is emphasised that the requirements of the document should be adopted and utilised in their entirety for all such work undertaken for QP whenever applicable and appropriate. This document is the second revision of this QP specification, which was originally issued in January 2002. It reflects as far as possible the current QP requirements for this type of work, taking account of the present industrial practices, materials and technology and the latest applicable National and International Standards and Codes. It will be s ubject to further periodic review, to re-affirm its adequacy, conform to any changes in QP requirements and include new developments in the field. It is recognised that there will be situations where addenda, data sheets or points of clarification require to be attached to the document, in order to suit a specific application or service environment. In such situations, the contents shall not be changed or re-edited by any user but any addenda or clarifications that would entail major changes shall be brought to the attention of the Custodian Department. Any proposed exceptions or deviations from this Specification shall also be submitted, together with justification, to the Custodian Department for review and consideration. The Custodian of this document is Corporate HSE Support Department (ST). Therefore, all comments, views, recommendations, etc on this document should be forwarded to the same and copied to Manager, Corporate Quality & Management Systems Department (QA).

Whilst ST is the document Custodian, it is not mandatory that STI is involved in the selection, testing or approval of preparatory, paint and wrapping products and systems for individual applications. This responsibility lies with the Asset Owner, who should liaise with relevant project and maintenance personnel and product manufacturers in order to approve products and systems for use and carry out any required testing.

Year: 2013


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1.0

OBJECTIVE

1.1

The objective of this Specification is to define the QP requirements for the protective coating and wrapping of all new and existing metallic equipment, structures and components and the specific requirements for different types of equipment, service environment and constructional material. It provides a technical basis for developing individual painting and wrapping project specifications, coating schedules and purchase requisitions. It also enables the painting and wrapping work carried out by Contractors to be monitored for compliance with specification requirements.

1.2

2.0

SCOPE

2.1

This document specifies the minimum QP requirements for the surface preparation, painting and wrapping of metallic equipment, structures and components for both onshore and offshore facilities, including inspection, testing and reporting, for corrosion protection and aesthetic purposes during new construction and maintenance. It covers the general, safety, environmental and quality control requirements for the materials used and the surface preparation of, and application of paint and wrapping tape to, the exterior of vessels, tanks, process equipment, pipework, pipelines and structural steelwork and the interior of vessels and tanks. It identifies the specific painting and wrapping system requirements for items to be painted and wrapped for individual applications, based upon the nature of the service conditions and environment and the constructional materials involved. It details the specific surface preparation and paint system and wrapping tape requirements, including the standard of surface cleanliness and roughness, the number of coats of each type of paint and/or layers of wrapping tape and their film thickness. The following items are outside the scope of this document: a) External coating of sub-sea pipelines, which is covered by QP-SPC-L-004. b) External coating of the Splash Zone section of riser lines, which is covered by QPSPC-L-003. c) Internal cement-based lining of pipework and vessels. d) Internal coating (lining) of pipework and valves. e) Repair of rubber-lined pipework and vessels . f) External coating or reinforcement of plastic items and coating of concrete surfaces .

2.2

2.3

2.4

3.0

APPLICATION

3.1

This Specification shall be used for all painting and wrapping of newly constructed equipment, piping, structures and associated attachments, including repair during and after installation, and for the field maintenance painting and wrapping of existing facilities, from local touch up work to full refurbishment. All surface preparation, paint application and wrapping shall be carried out in accordance with this Specification and the Paint Manufacturers' recommendations. In the case of conflict between this Specification and the Paint Manufacturer's recommendations, the most stringent requirements shall apply.

3.2

4.0

TERMINOLOGY

4.1

DEFINITIONS Amplitude - The average peak to trough height of the profile of a steel surface after preparation by abrasive blast cleaning (see Profile).


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Applicator

- A party to a contract who is responsible for the application of paint coatings and wrappings, including all surface preparation. An Applicator may be a Contractor or nominated Sub-contractor. Atmospheric - The part of an onshore structure or facility that is above ground Zone level and the part of a marine structure above the Splash Zone that is subject solely to atmospheric exposure during service. Can - An acceptable non-mandatory option or options under the contract. Coating - A continuous film or layer of a suitable substance that is applied to the surfaces of an item for protective or aesthetic purposes. Consultant - A party to a contract who is responsible for providing design engineering and other consultancy services under the contract. Contractor - The party, firm or company with whom QP enters into a contract to perform the work to which this Specification applies. Degree of - The quantity and size of areas of a painted steel surface in which Paint Rusting deterioration of the paint film by rust breakthrough and under rusting is evident, expressed as a percentage of the total surface area. Dewpoint - The temperature at and below which aqueous condensation formation from the air starts to occur as a result of it becoming supersaturated with water vapour. It will be governed by the Relative Humidity of the air, higher values of which produce an increase in the dew point temperature. Dry Film - The thickness of a coat of paint, layer of tape or coating system in Thickness its fully cured condition. Dry Abrasive - A cleaning procedure in which a suitably sized and shaped dry Blast metallic or non-metallic abrasive is mixed with compressed air and Cleaning fired at metal surfaces at a pressure of around 100 psig to remove corrosion products, paint and other surface residues. Elevated - Surface of the equipment or facility that will attain a temperature in Temperature excess of 120°C during service. Fusion - An epoxy coating that is applied to preheated pipe as a powder by Bonded electrostatic spray, rapidly cured by the controlled heat from the Epoxy pipe and water quenched to give a fusion bonded coating. Fabricator - Organization responsible for the construction or fabrication of new facilities and the installation of items of equipment therein. Hold Points - Steps within the surface preparation and application procedure beyond which the applicator shall not proceed without formal authorization via an inspection report from the QP Engineer or Authorised Representative. Holidays - Discontinuities such as pinholes and small sized defects in the paint film or wrapping that significantly lower its dielectric strength.. Hot Dip - A process by which steel articles are coated with zinc by controlled Galvanising immersion in a molten zinc bath. Hot Surfaces - Metal surfaces of the equipment or facility that will normally attain a temperature in excess of 65°C and can therefore be injurious to personnel touching them. Inspector - The QP Engineer or his Appointed Representative delegated to witness QA/QC requirements and purchase order requirements and report on the compliance or non-compliance with these requirements. Doc. File No.: SPC.L.002.R2

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Lining - A protective coating on the internal surface of a vessel or pipe. Manufacturer - The party responsible for manufacture of equipment or materials to perform duties specified by QP or its Nominated Consultants. May - An acceptable non-mandatory option or options under the contract. Microns - One thousandth of a mm (expressed as “µm”) . Mouse Hole - A small hole cut in a steel plate or section to either bridge a weld or provide a drainage point. Must - A mandatory requirement to be strictly followed. Paint System - The number and type of coats of paint to be applied to a substrate to provide a required level of corrosion protection. Painting

- The application to a substrate of one or more layers of a pigmented coating material, in liquid, paste or powder form, which forms an opaque film having protective properties.

Pigment Pot Life

- Solid filler or colouring agent in a paint. - The length of time that a single pack or mixed two-pack paint will remain in a usable condition at a given temperature. - The roughness or contour of a steel surface after preparation, also known as the Anchor Pattern (see also Amplitude). - The Appointed QP Discipline Specialist Representative under the conditions of the contract. - The mass of water vapour in the air expressed as a percentage of the mass of water vapour that is required to saturate the same volume of air at the same temperature.

Profile QP Engineer Relative Humidity Shall Should Shelf Life Shop Site Splash Zone

Submerged Zone

- A mandatory requirement to be strictly followed. - A strong but non-mandatory recommendation to comply with. - The Manufacturer‟s recommended maximum storage time for a given product under recommended storage conditions. - The Vendor‟s, or Sub-contractor‟s, factory location for surface preparation and painting operations. - The field location for surface preparation and painting operations approved by QP. - The portion of a partially immersed marine structure or pipeline that is subject to both wetting by seawater or sea spray and drying by the marine atmosphere. It is to be taken as being from –3.00m (10 feet) below MSL to +4.5m (15 feet) above MSL (see Figure 1B). - The immersed portion of a marine structure from the seabed up to –3.00m (10 feet) below MSL (see Splash Zone and Figure 1B).

Substrate Thinner

- The metal surface to be prepared and coated. - An approved liquid added to a paint to reduce the viscosity and ease its application. Total Dry Film - The thickness of the complete fully cured coating or wrapping Thickness system. Vendor - The Organization responsible for manufacturing, fabricating or supplying any items for delivery to the Fabricator or QP.


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Wet Abrasive - A cleaning procedure in which a mixture of suitable abrasive in Blast fresh water is fired at metal surfaces at a pressure of up to Cleaning 2000 psig to remove corrosion products, paint and soluble salts. Water - A cleaning procedure in which fresh water is discharged onto metal Cleaning surfaces at a pressure of 2,000 - 3,000 psig, to remove surface contaminants such as dirt, residues, rust and loose coatings. Water Jetting Wet Film Thickness Wrapping

Will

4.2

ABBREVIATIONS COSHH DFT FBE LEL MIO MSDS MSL NACE PPE QA/QC SIMOPS SSPC TDFT TLV WFT

5.0

- A cleaning procedure in which fresh water is discharged onto metal surfaces at a pressure of 10,000 - 25,000 psig, to remove all scale and existing coatings. - The thickness of a paint film immediately after application when little or no solvent evaporation has occurred. - The application to a component of a continuous strip of plasticbacked self-adhesive tape that is wound on in a helical manner for protective purposes. - A mandatory requirement to be strictly followed.

-

Control of Substances Hazardous to Health Dry Film Thickness Fusion Bonded Epoxy Lower Explosive Limit (Lamellar) Micaceous Iron Oxide Material Safety Data Sheet Mean Sea Level National Association of Corrosion Engineers Personnel Protective Equipment Quality Assurance/Quality Control Simultaneous Operations Steel Structures Painting Council Total Dry Film Thickness Threshold Limit Value Wet Film Thickness

REFERENCE STANDARDS AND CODES The latest editions of the f ollowing Standards, Codes and Specifications shall apply.

5.1

PAINTING AND COATING – GENERAL ISO 1461 ISO 12944: 1-8 ISO 14713: 1-3 BS EN ISO 2063


Hot-Dip Galvanized Coatings on Fabricated Iron and Steel Articles – Specifications and Test Methods Paints and Varnishes – Corrosion Protection of Steel Structures by Protective Paint Systems Zinc Coatings – Guidelines and Recommendations for the Protection Against Corrosion of Iron and Steel in Structures Thermal Spraying - Metallic and Other Inorganic Coatings – Zinc, Aluminum and Their Alloys

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SSPC CS 23.00/ NACE 12/ AWS C23.M SSPC Manual

5.2

Rev. 2

Specification for Application of Thermal Sprayed Coatings (Metallizing) of Aluminium, Zinc or Their Alloys and Composites for the Corrosion Protection of Steel Vol. 1- Good Painting Practice Vol. 2- Systems and Specifications

SURFACE PREPARATION ASTM D6386

Standard Guide for Preparation of Zinc (Hot-Dip Galvanized) Coated Iron and Steel Product/Hardware Surfaces for Painting ISO 8501: 1-4 Preparation of Steel Substrates Before Application of Paints and Related Products - Visual Assessment of Surface Cleanliness ISO 8503: 1-5 Preparation of Steel Substrates Before Application of Paints and Related Products - Surface Roughness Characteristics of BlastCleaned Steel Substrates ISO 8504: 2 & 3 Preparation of Steel Substrates Before Application of Paints and Related Products - Surface Preparation Methods ISO 11124: 1-4 Preparation of Steel Substrates Before Application of Paints and Related Products - Specifications for Metallic Blast-Cleaning Abrasives ISO 11126: 1 & Preparation of Steel Substrates Before Application of Paints and 3-10 Related Products - Specifications for Non-Metallic BlastCleaning Abrasives SSPC Vis 1 Visual Standard for Abrasive Blast Cleaned Steel SSPC Vis 3 Visual Standard for Power- and Hand-Tool Cleaned Steel SSPC SP 1-3, 5-8 Steel Structures Painting Council and National Association of 10&11/ NACE 1-4 Corrosion Engineers Surface Preparation Standards SSPC Vis 4/ Guide and Reference Photographs for Steel Surfaces Prepared NACE Vis 7 by Water Jetting SSPC Vis 5/ Guide and Reference Photographs for Steel Surfaces Prepared NACE Vis 9 by Wet Abrasive Blast Cleaning SSPC SP12/ Surface Preparation and Cleaning of Metals by Waterjetting NACE NO. 5 Prior to Recoating NACE SP 0178 Design, Fabrication and Surface Finish Practices for Tanks and Vessels to be Lined for Immersion Service NACE SP0178 VISUAL AID

5.3

Surface Finishing of Welds Prior to Coating

INSPECTION AND TESTING ASTM D610/ SSPC Vis 2 ASTM D1212 ASTM D3276 ASTM D3359 ASTM D4228


Standard Practice for Evaluating Degree of Rusting on Painted Steel Surfaces Standard Test Methods for Measurement of Wet Film Thickness of Organic Coatings Standard Guide for Painting Inspectors (Metal Substrates) Standard Test Methods for Measuring Adhesion by Tape Test Standard Practice for Qualification of Coating Applicators for Application of Coatings to Steel Surfaces Page 9 of 88

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ASTM D4285

Standard Test Method for Indicating Oil or Water in Compressed Air ASTM D4414 Standard Practice for Measurement of Wet Film Thickness by Notch Gages ASTM D4417 Standard Test Methods for Field Measurement of Surface Profile of Blast Cleaned Steel ASTM D4541 Standard Test Method for Pull-Off Strength of Coatings Using Portable Adhesion Testers ASTM D4752 Measuring MEK Resistance of Ethyl Silicate (Inorganic) Zinc Rich Primers by Solvent Rub ASTM D4940 Standard Test Method for Conductimetric Analysis of Water Soluble Ionic Contamination on Blasting Abrasives ASTM D5064 Standard Practice for Conducting a Patch Test to Assess Coating Compatibility ASTM D7091 Standard Practice for Non-Destructive Measurement of Dry Film Thickness of Non-Magnetic Coatings Applied to Ferrous Metals and Non-Magnetic, Non-Conductive Coatings Applied to NonFerrous Metals ASTM E337 Standard Test Method for Measuring Humidity with a Psychrometer (Measurement of Wet & Dry Bulb Temperatures) ASTM F21 Standard Test Method for Hydrophobic Surface Films by Atomiser Test ISO 4628: 1-6 Paints and Varnishes - Evaluation of Degradation of Coatings Designation of Quantity and Size of Defects, and of Intensity of Uniform Changes in Appearance ISO 8502: 1-6 & 9 Preparation of Steel Substrates Before Application of Paints and Related Products - Tests for the Assessment of Surface Cleanliness ISO 11125: 1-7 Preparation of Steel Substrates Before Application of Paints and Related Products - Test Methods for Metallic Blast-Cleaning Abrasives ISO 11127: 1-7 Preparation of Steel Substrates Before Application of Paints and Related Products - Test Methods for Non-Metallic BlastCleaning Abrasives ISO 19840

SSPC PA 2 NACE SP0188 NACE SP 0274 NACE RP0287 NACE SP0490


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 Procedure for Determining Conformance to Dry Coating Thickness Requirements Discontinuity (Holiday) Testing of New Protective Coatings on Conductive Substrates High Voltage Electrical Inspection of Pipeline Coatings Field Measurement of Surface Profile of Abrasive Blast-Cleaned Steel Surfaces Using a Replica Tape Holiday Detection of Fusion-Bonded Epoxy External Pipeline Coatings of 250 to 760µm (10-30 Mils) Page 10 of 88

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5.4

COLOUR CODING ASME A13.1 BS EN 1089-3 BS 381C BS 1710 BS 4800 BS ISO 3864-1 BS ISO 7010 CAP 437 QP.ES.0.07.0020

5.5

Rev. 2

Scheme for the Identification of Piping Systems Transportable Gas Cylinders - Gas Cylinder Identification (Excluding LPG) Part 3: Colour Coding Colour for Identification, Coding and Special Purposes Identification of Pipelines and Services Schedule of Paint Colours for Building Purposes Graphical Symbols – Safety Colours and Safety Signs. Part 1: Design Principles for Safety Signs and Safety Markings Graphic Symbols – Safety Colours and Safety Signs – Registered Safety Signs Offshore Helicopter Landing Areas – Guidance on Standards Plant Equipment Tag Identifiers Corporate

HEALTH, SAFETY, ENVIRONMENT AND QUALITY ISO 9000 ISO 9001 ISO 9004

Quality Management Systems – Fundamentals and Vocabulary Quality Management Systems – Requirements Managing for the Sustained Success of an Organization. A Quality Management Approach BS EN 12811-1 Temporary Works Equipment. Part 1: Scaffolds - Performance Requirements and General Design OSHA 29 CFR Regulation Pertaining to Work in Confined Areas API STD 2217A Guidelines for Safe Work in Inert Confined Spaces in the Petroleum and Petrochemical Industries QP-PHL-S-001 QP Philosophy For Fire and Safety QP-PHL-S-038 QP Philosophy for Health and Safety Activities in Projects QP-REG-S-001 QP HSE Regulations for Contractors QP-STD-Q-004 Corporate Standard for Quality Requirements for Projects QP-STD-S-055 QP Standard for Managing Naturally Occurring Radioactive Material (NORM) HSEPR-QP-11 QP Procedure for Managing HSE in Contracts HSEGL-QP-11-01 QP Guidelines for Managing HSE in Contracts QP-GDL-V-001 QP Guideline for Waste Management QPR-DT-007 Procedure for Environmental Requirements in Projects NIOSH (USA) Occupational Safety & Health Guidelines for Chemical Hazards COSSH (UK) Control of Substances Hazardous to Health Regulations, 2004 QATAR GOVT. Bye Law No. 2, 2002. Environmental Protection Law Paint Manufacturer Product and Material Safety Data Sheets In the event of any conflict arising between this Specification and the National and International Standards and Codes referenced herein, the requirements of this Specification shall apply.


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6.0

GENERAL CONTRACTOR REQUIREMENTS

6.1

The Contractor shall, unless otherwise formally instructed by QP, supply all required approved materials for surface preparation, painting and wrapping in accordance with this Specification.

6.2

The Contractor shall, unless otherwise formally instructed by QP, provide all equipment and tools necessary to carry out the surface preparation and coating work in an effective and efficient manner. All equipment and tools shall arrive in good working order and in a sufficiently clean condition that they do not cause contamination of the coating. They shall be maintained in good working order at all times. The Contractor shall supply all materials, such as oils, greases, cleaners and spare parts, that are required for equipment maintenance purposes.

6.3

The Contractor shall provide all inspection equipment that is required to carry out the painting and wrapping fully in accordance with the Specification and shall maintain it on site in good condition throughout the duration of t he work.

6.4

The Contractor shall provide the required number of experienced and skilled personnel, together with experienced, competent and qualified supervision, to carry out the work to the required standard and efficiently within schedule, using good general painting practices as laid down in Volume 1 of the SSPC Manual. All assigned Contractor supervisory personnel shall be familiar with this Specification and the latest editions of the referenced Standards.

6.5

At QP‟s discretion, the Contractor shall be required to: (a) Submit documentation (references and records) confirming his previous experience of applying the same or similar coatings or wrappings and demonstrating Customer approval of his work quality for similar projects at similar work locations during the previous minimum period of at least five years. Before starting any coating work under the contract, prepare test panels of the (b) design specified in ASTM D4228 for the evaluation of the proposed application personnel and equipment capabilities and paint them with the specified coating system in the proposed manner . (c) Have the test panels evaluated in accordance with ASTM D4228 to qualify such personnel that are considered to have applied the specified coating to an acceptable standard. (d) Ensure that all required testing and qualification work is witnessed and evaluated by the QP Engineer and, if appropriate, the Paint Manufacturer‟s Representative.

6.6

Prior to commencement of the work, the Contractor shall submit for the QP Engineer‟s approval a detailed procedure showing how he intends to carry out the work in accordance with this Specification. He shall provide full details of any Sub-contractor that he intends to use, the location of each part of the work, the preparatory and coating materials that he intends to use, the proposed work sequence, with specific attention to the HSE requirements and the precautions required to meet them, and any other information that QP may require to clarify his work intentions. The Contractor shall ensure that this Specification, Product Data Sheets for all products used and Operating Instructions for all equipment are available at each work site location.

6.7

The required standard of workmanship shall be achieved strictly in accordance with this Specification and other relevant documents, such as site and safety regulations and applicable Standards and Codes. Deviations from the Specification and documents are


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not allowed, unless formally authorised by QP. However, compliance with the requirements of this Specification shall not relieve the Contractor of his responsibility to carry out all preparatory, coating and wrapping and associated inspection and test work in accordance with good working practices, principles and work standards.

6.8

The Contractor shall ensure that all SIMOPS requirements are complied with and be responsible for protecting all adjacent equipment, structures and surrounding facilities that are not to be coated from mechanical damage, blasting abrasive, paint splashes and overspray during the surface preparation and coating work both at workshop locations and at site. Wherever possible, blast cleaning shall be carried out in a separate enclosure or sheeted area to paint application but as a minimum these areas shall be isolated from each other by secure barriers. Instruments, equipment identification plates, electrical and isolating flange components and machined surfaces are especially important in this respect. The Contractor shall take particular care to mask these components against such damage and contamination.

6.9

The Contractor shall maintain at each job site a log which shall consist of Daily Progress Forms. These forms could be a management summary or the Daily Inspection Report Forms for the contract, the required contents of which are detailed in Su b-clause 13.2.5 and a typical format of which is shown as Table 4A. They shall be signed on a daily basis by the Site Supervisor or Engineer-in-Charge and submitted to the QP Engineer. In the event that the work is carried out at an approved offsite location or outside of Qatar, the Daily Progress Report Forms shall form part of the required project documentation.

6.10

No surface preparation and/or coating application work shall be carried out in the absence of the QP Engineer or without his knowledge or consent. Any such work shall be considered not to meet the Specification.

6.11

The Contractor shall be directly responsible to QP for completion of all work. No distinction is made between the responsibilities and liabilities of the Fabricator, Vendor or Contractor. This Specification shall be equally binding on all parties. The Contractor is liable for his actions and those of his Sub-contractors.

6.12 Any prepared, coated or wrapped areas that are considered to be defective or in any way not to conform with this Specification shall be rectified by the Contractor. Any instruments, components or adjacent equipment that are damaged or contaminated with paint shall be cleaned or replaced at the discretion of the QP Engineer.

7.0

HEALTH, SAFETY AND ENVIRONMENTAL REQUIREMENTS

7.1

GENERAL SAFETY AND HAZARD CONSIDERATIONS

7.1.1 The Contractor shall be responsible for carrying out all surface preparation, painting and wrapping work in a completely safe and professional manner, in addition to meeting all QP technical and quality control standards. He will be required to provide good and safe access facilities and working conditions, appropriate preparatory, coating and inspection equipment in good working order and suitable personnel protective equipment and safety devices. 7.1.2 The Contractor shall fully comply with QP health, safety and environmental requirements specified in QP Safety Regulations for Contractors, QP Philosophy for Health and Safety Activities in Projects, QP Corporate Fire and Safety Philosophy, QP Waste Management Specification and associated Procedures and Guidelines. These


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cover the working conditions, scaffolding and access, PPE, safety equipment, fire and explosion hazards, solvents, lighting, ventilation and earthing of equipment. 7.1.3 The Contractor shall prepare a detailed Job Hazard Analysis Report for the job at the worksite at the outset. This shall identify all potential safety, health and environmental hazards that could arise and ensure that all necessary preventive measures and equipment to avoid each potential hazard are adopted and made available. The Job Hazard Analysis Report shall be approved by the QP Safety Officer before starting work 7.1.4 The Contractor shall ensure that all required fire fighting equipment is in position at all times in all identified hazardous areas, such as paint mixing locations, at vessel entries and close to approved diesel-driven equipment. 7.1.5 The Contractor shall carry out documented Safety Audits of the access facilities, preparatory and painting equipment and materials, personnel protective equipment and surface preparation, painting and wrapping practices used at an agreed frequency, which should be at least monthly. He shall maintain a Log in which he records the findings and actions taken, for review by the QP Safety Officer.

7.2

ACCESS FACILITIES AND SCAFFOLDING

7.2.1 The Contractor shall provide safe and easy access to all areas of surfaces of components and equipment that are to be prepared and coated. This shall enable the specified method and standard of surface preparation, painting and wrapping to be achieved and confirmed by inspection. The access arrangement shall be such that operators are able to stand up with body and arms free of scaffolding or staging. Rope access can be considered for tall steel structures. None of the scaffolding or staging members shall be in direct contact with the component that is being worked on and masking of any area of the component shall be m inimised. 7.2.2 The access facility, whether permanent or temporary, shall in all cases be subject to approval by the QP Safety Officer. Scaffolding shall comply with the QP Safety Regulations. The Contractor shall supply and maintain rigging and scaffolding equipment capable of enabling completion of the work in accordance with the requirements of BS EN 12811 Part 1. Its safety and security shall be regularly checked and recorded in accordance with a recognised scaffolding safety inspection and auditing system, such as the “Scafftag” System.

7.3

BLASTING AND SPRAY PAINTING EQUIPMENT

7.3.1 Air hoses, blasting hoses, spray lines and any other hoses that are subjected to any internal pressure shall be marked with identification numbers showing the dates when they were manufactured and first used. All such hoses, blasting pots any other pressurized equipment shall be provided with valid dated pressure test certificates stating the test pressures used and the safe working pressures that must not be exceeded. The Contractor shall ensure that all hoses and pressurised components are carefully inspected for signs of wear and the presence of defects prior to each use and that no hoses are used for more than six months after their last test date. They shall then be fully inspected and retested at their design pressure before being remarked and certified for a further period of use. All compressor air and blasting hose couplings shall be secured using approved stainless steel snatch wires. 7.3.2 Blast cleaning and spray painting equipment shall be used fully in accordance with Manufacturer‟s recommendations. The air feed, blasting and spray painting hoses sha ll incorporate a suitable anti-static material in their construction. The guns shall be fully earthed and spark proofed on each occasion when they are used. All other precautions Doc. File No.: SPC.L.002.R2

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shall be taken to prevent any build up of electrostatic charge, particularly when they are to be used in confined spaces. The Contractor shall check all such items for electrical conductivity and replace any items showing signs of breakdown that could give rise to static electrical discharges during service. 7.3.3 Blasting nozzles shall be fitted with a Deadman‟s Handle located as close to the blast nozzle as practical. Its design must ensure that the Handle cannot, in any circumstances, be held in the “ON” position by any means other than hand pressure. Paint spray guns shall be fitted with effective Manufacturer‟s trigger lock and tip guards. 7.3.4 Areas in which blast cleaning is carried out shall be sheeted in and cordoned off as necessary for safety purposes, to minimise contamination of adjacent areas and to enable spent abrasive to be collected for controlled disposal. Warning signs shall be erected as requested by the QP Engineer. This shall exclude all unauthorised personnel that could be injured by stray spent abrasive or harmful dust from old paintwork. Where power tools are being used to remove old paint or rust, precautions shall also be taken to exclude unauthorised personnel from the work area and minimise contamination.

7.4

PAINTS, SOLVENTS AND ABRASIVES

7.4.1 The Contractor shall ensure that the Manufacturer‟s Material Safety Data Sheet s and NIOSH(USA) / COSHH(UK) Statements are available for all paints, solvents, chemicals and abrasives used throughout the work period. Compliance with Manufacturer‟s safety precautions for products shall be an essential element in meeting the job specification. In cases of conflict, the most stringent safety requirements and precautions shall apply. 7.4.2 All paints, solvents, equipment cleaners and other chemicals used shall be stored in closed, clearly labelled original containers. The containers shall be stored in secure enclosed, sheltered and well-ventilated storage areas or structures, where they are protected from direct sunlight, open flames and electrical discharges. They must be verified as being maintained at temperatures well below the Manufacturer‟s maximum recommended storage temperature for the products. The use of air-conditioned and temperature controlled storage areas shall be considered for situations where excessive ambient temperatures are expected. The storage conditions shall meet all Manufacturer requirements and QP Fire and Safety Regulations for the types of chemical involved. 7.4.3 Abrasives used shall be free from radioactivity and toxic or harmful substances such as arsenic, lead, cyanide and free silica and shall not produce excessive quantities of fine dust that could cause environmental damage. Upon arrival in Qatar, it is mandatory for the Supplier to arrange for batches of mineral abrasives such as garnet to be sampled and tested for radioactivity, in line with MOE requirements. MOE shall provide batches of abrasive which prove acceptable with a Radioactivity Clearance Certificate (RCC). Upon receipt of each batch at QP sites, the Contractor shall submit the RCC to the QP Engineer for review and approval. Batches without an RCC shall be quarantined and each batch shall be sampled for further MOE testing prior to being accepted for use. All abrasives shall be sealed in watertight packages, which shall be stored under dry sheltered conditions, wherever the work location will permit. Abrasive delivered in defective packaging shall be rejected. 7.4.4 Handling and mixing of all paints, solvents and chemicals shall be carried out strictly in accordance with the Manufacturer‟s recommended procedures and safety and health precautions, to ensure personnel safety. Safety precautions shall be clearly detailed on the relevant Product Technical Data Sheets and Material Safety Data Sheets, as well as on the product containers. The Contractor procedure shall indicate how these safety Doc. File No.: SPC.L.002.R2

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7.4.5

7.4.6

7.4.7

7.4.8

7.5

Rev. 2

and health requirements will be met. Where a specification indicates restrictions on the use of certain chemicals, adherence to these restrictions is considered mandatory. The Contractor shall apply the products strictly in accordance with the Manufacturer‟s safety recommendations, which shall also be clearly detailed on the relevant Product Technical Data Sheets. Contractor painting procedure shall address the occupational health and safety requirements for and during paint application and identify any specific hazards associated with particularly toxic paints or solvents which are to be used. Where paints containing over 1% lead in the dry paint film are proposed, the Contractor shall make this fact known to the QP Engineer and be able to demonstrate that he is able to apply the paint within the requirements of the QP Health and Safety Regulations. Application of solvent-borne paints in restricted areas or inside vessels or tanks requires particularly careful planning and attention. Good ventilation through such vessels is essential, to ensure that the threshold limit value (TLV) and lower explosive limit (LEL) of the vapour are not exceeded at any time. The Contractor shall ascertain the TLV and LEL of the solvents contained in all paint products used, to establish the level of ventilation that he is required to provide. Where this cannot be achieved by natural ventilation, a forced ventilation system using a suitable air eductor and incorporating equipment for measuring the air flow shall be installed. A method for calculating the minimum forced air ventilation requirement for an enclosed space is given in Appendix C. Good ventilation is required in paint mixing and thinning areas, if these are enclosed. The Contractor shall take care when spray applying a paint that contains a highly volatile solvent or a thinner in close proximity (within one metre) of a gas, smoke or fire detector on QP facilities. Such detectors are extremely sensitive to vapours fr om certain types of solvents and alarms can be activated by their presence.

PERSONNEL PROTECTIVE EQUIPMENT

7.5.1 All personnel involved in site work, from materials handling to access construction, preparatory cleaning, paint mixing and application and waste material handling and disposal, shall wear appropriate personnel protective equipment (PPE) for their work. The minimum level of PPE required for lung, eye, face, hand, foot and body protection for each type of work is indicated in Tables 10A-12A but this should not be taken as a comprehensive guide. The PPE requirements for each activity shall be specified on the QP Work Permit. The Contractor shall be responsible for providing the PPE that is required for all activities under a contract. The requirements shall be established from his Job Hazard Analysis Report on each type of work (see Sub-clause 7.1.3), which should identify all possible safety and health hazards to be addressed. 7.5.2 All personnel employed in blast cleaning and the spray application of paints and solvents shall wear air-fed masks. They shall be coupled to a clean air supply fed by an independent filtered source. The masks shall be ventilated by clean, cool air served through a regulator filter to prevent abrasive dust and paint solvents from being inhaled by the operators. If the breathing air supply is obtained from a compressor driven by a diesel fuel engine, a carbon monoxide detector shall be installed in the air supply line. The masks shall be cleaned and disinfected daily and a record of their usage maintained and verified by the QP Safety Officer or his Appointed Representative. 7.5.3 The Contractor shall be responsible for ensuring that suitable types of protective footwear, handwear, headwear and overalls are used for the appropriate hazards identified for each activity.


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7.6

Rev. 2

PAINT, SOLVENT, CHEMICAL AND WASTE MATERIAL DISPOSAL

7.6.1 During and upon completion of preparatory and painting work, facilities shall be arranged by the Contractor to effectively and safely collect and manage all waste materials. These shall include spent abrasive, old paintwork and unwanted or spoilt paints, solvents and chemicals, plus used equipment such as brushes, rags, hoses, scaffold components and other waste materials. The Waste Management System used shall fully comply with QP Environmental Regulations and all necessary precautions shall be taken to safeguard the surrounding environment. 7.6.2 The Contractor shall arrange to dispose of all waste materials and unwanted consumables in an acceptable manner at Government-approved disposal sites. He shall maintain a formal record of the materials disposed of, the disposal dates and the disposal sites used, in accordance with QP Regulations and Qatari Environmental Protection Law.

8.0

PAINTING OF NEW EQUIPMENT AND STRUCTURES

8.1

GENERAL REQUIREMENTS

8.1.1 All surface preparation and painting or wrapping of newly constructed equipment and structures shall be completed in the Contractor‟s, or his Sub -Contractor‟s, workshop or fabrication yard, unless otherwise specified within the relevant contract drawings or tender documents or approved in writing by the QP Engineer. Individual items of equipment may be delivered to site in only the primed or partly painted condition, with the written agreement of the QP Engineer. In such situations, the application of the remaining coats of paint shall be carried out on site after installation of the equipment. 8.1.2 The partly or fully fabricated items of equipment and structures that have been completely prepared and painted prior to transportation to site shall be carefully packed, secured and handled to provide maximum protection against mechanical damage of the paint coating during transportation and installation on site. The Contractor shall subsequently make good any damage to the paintwork on the equipment incurred up to the point of commissioning. 8.1.3 Partially fabricated and non-fabricated items, including steel plate and structural members, may with the QP Engineer‟s approval, be prepared, primed and, where necessary, partially painted prior to transportation to site. In such cases, the Contractor shall ensure that the paint coating applied in the workshop has sufficient durability to prevent the onset of corrosion during transportation and throughout the storage and construction period on site. The Contractor shall repair any damage to the paintwork incurred up to the point of delivery and ensure that all masking tape used to protect surface areas that subsequently require to be welded from being blast cleaned and painted are removed prior to the items being delivered to site. 8.1.4 All surfaces of components that will be inaccessible after site assembly shall be fully prepared and painted prior to assembly, irrespective of the painting arrangement agreed for the remainder of the equipment. Pipework shall be fully coated in the area of pipe supports, together with the supports themselves, before being installed. A thin layer of Teflon shall then be fitted between the pipe and the supports, to minimize subsequent damage to the paint coating at these contact points. 8.1.5 Equipment and components, including individual pipe sections and valves, which require to be painted shall be accompanied by a Coating Release Note. In addition to confirming their readiness to be painted, this Note shall identify the coating system or Doc. File No.: SPC.L.002.R2

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8.1.6

8.1.7

8.1.8

8.1.9

8.2

Rev. 2

partial coating system that requires to be applied and the required topcoat paint colour. Equipment and components that require to be stress relieved after manufacture shall not be painted until all heat treatment has been satisfactorily completed. Whilst equipment and pipework may be fully painted prior to being hydrotested, except where a sensitive leak test (per ASME B31.3) is required, it is preferred that such items are not painted until this activity has been completed wherever possible. Where site welds require to be coated after hydrotesting, the welded areas shall be prepared and the full paint coating shall be applied to them as per the original project specification. All local welding of equipment and drilling of holes for attachments shall be completed before cleaning and coating begins. This includes the fitting of wear pads or doubler plates to pipework at support and anchor points and the welded closure of mouseholes required for equipment fabrication. Weep holes in reinforcing pads, doubler plates and supports shall not be filled with grease, as required, until the components have been blast cleaned and painted, to avoid contamination of the surface or paint film. Contractors may require painted items to be transported before the Paint Manufacturer‟s specified minimum coating cure time has been reached. In su ch cases, the Contractor shall verify the request to QP in writing and the liability for the repair of any damaged areas of paintwork shall be agreed. All preparatory and coating work carried out at the Contractor‟s or Sub-Contractor‟s premises shall be subject to planned inspection, as detailed in Clause 13.0. The Contractor shall carry out documented inspection at every stage of the activity. Prearranged inspections shall be carried out with the QP Engineer at specified hold points. Final acceptance of the preparatory and coating work carried out on each component, in line with the specified requirements, shall be confirmed by the issuance of a Delivery Release Note signed by the Contractor Representative and approved and dated by the QP Representative. No painted components shall be released from Contractor or SubContractor premises without approved Delivery Release Notes.

VENDOR STANDARD COATING SYSTEMS

8.2.1 The coating systems and finishes applied by Vendors of specially designed items of equipment, such as pumps and compressors, are expected to be in accordance with the relevant Schedule of this Specification. Standard coating systems offered may be acceptable to QP but full details of the proposed system, together with evidence of its previous satisfactory use in similar environmental conditions, shall be provided at the outset for evaluation and approval by the QP Engineer. 8.2.2 Vendors supplying packaged or skid-mounted units shall ensure the compatibility and compliance with the Specification of their overall coating system with that applied to the individual items of equipment by Sub-vendors. The Vendor shall be responsible for coordinating the inspection of all the Sub- vendor‟s surface preparation and painting work.

8.3

MATERIALS AND EQUIPMENT NOT TO BE PAINTED Unless otherwise specified by the QP Engineer or in contract documentation such as material or equipment data sheets or project specifications, for equipment or service colour coding purposes or for other reasons specified by the end user, the following materials and equipment components shall not be prepared or painted, a) Aluminum, unweathered zinc and copper alloy surfaces. b) Non-pressurised stainless steel or nickel alloy component surfaces. NOTE – Pressure-containing or hot insulated stainless steel and nickel alloy components, including pipework and instrument tubing, shall be externally painted


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c) d) e) f) g) h) i) j) k) l) m) n)

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Greased nipples and fittings and lubricated surfaces. Machined and close working tolerance surfaces. Gasket contact surfaces and exposed seals, bearings and glands. Threaded connections and components requiring to be dismantled (see Clause 12.5) Friction grip surfaces. Equipment identification plates and information and warning signs. Valve stems, movable linkages, compressor or pump shafts. Heat tracing equipment and electrical cables. Instruments and gauges, especially glass components . Essential equipment openings, such as vents, drains and air intakes. Areas of components to be site welded or welds that are to be sensitive leak tested. Exposed parts of electrically insulating flange kit components.

9.0

PAINTING OF EXISTING EQUIPMENT AND STRUCTURES

9.1

GENERAL REQUIREMENTS

9.1.1 All surface preparation and maintenance painting of existing equipment and structures shall be completed at the relevant QP site, unless otherwise specified in the relevant contract drawings or tender documents or approved in writing by the QP Engineer. Individual items of equipment may be removed from site for preparation and painting at the QP workshop or fabrication yard, with the written agreement of the QP Engineer. 9.1.2 A detailed survey shall be carried out by or on behalf of the QP Engineer at the outset, to establish the condition of the existing paintwork on the equipment and structures to be painted. The findings of this survey shall be used to determine the nature and scope of the maintenance preparation and painting work required, in accordance with the guidelines given in the individual Painting Schedules. 9.1.3 The degree of rusting and extent of coating breakdown on each area and component shall be established in accordance with the standards specified in ISO 4628 Part 3 or ASTM D610/SSPC Vis 2 and these standards shall be used to determine the type of surface preparation and extent of painting required. The equivalent ISO and ASTM degrees of paint rusting are given in Table 1A. I t may be necessary to dislodge areas of loose and under-rusted paint, to establish the full extent of the coating breakdown. If the boundaries of such areas of paint breakdown cannot be reliably determined, the whole surface shall be fully prepared. 9.1.4 Heavily corroded areas of equipment and structures shall be reported to the QP Engineer for review, to avoid possible perforation of thin walled areas occurring during preparatory cleaning prior to repainting. Drainage holes should, where possible, be drilled at traps and water accumulation points prior to painting. 9.1.5 At the outset, attention shall be paid to the provision of suitable access to all areas of existing equipment or structure for painting. The underside of pipework at and around support points and the areas between closely-spaced structural members may present particular problems. Access difficulties shall not be considered acceptable as a basis for poor workmanship. Any specific concerns in this regard shall be raised in writing with the QP Engineer prior to or at the start of the contract, to reach mutual agreement. 9.1.6 Areas of sound existing paintwork may require to be repainted for aesthetic or other reasons. All such areas shall be cleaned as required for the paint system that is


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subsequently to be applied. Particular attention shall be paid to cleaning out and preparing crevices, traps and other details at which dirt and wash water can accumulate 9.1.7 The preparation of existing painted surfaces shall ensure that all loosened and underrusted paintwork is removed back to a firm edge with suitable feathering of sound paint to give a smooth chamfered profile and that all other surface irregularities such as sags and runs are removed prior to over-coating. 9.1.8 Sweep blast cleaning shall only be carried out for the preparation of existing paintwork with the QP Engineer‟s agreement after an assurance has been provided that the use of this technique will not be detrimental to the sound coating. This cleaning technique requires a high level of operator skill, the use of a low nozzle pressure and fine abrasive and a low angle of abrasive impingement (typically 30 ) on the surface from an increased nozzle to surface distance of around one metre. A sample area of the coated surface should be test prepared by this technique and the required quality agreed before any sweep blast cleaning is permitted. 

10.0 SURFACE PREPARATION 10.1

PREPARATORY GRINDING AND DEGREASING

10.1.1 Unless otherwise specified, steelwork to be painted and/or wrapped shall be mechanically pre-treated and degreased as follows prior to any preparatory cleaning being carried out. 10.1.2 All metal surfaces to be painted and/or wrapped, and particularly welded joints and seams, shall initially be carefully visually inspected for the presence of surface-breaking defects, such as laminations, surface porosity and cold lap. All such defects shall be reported for evaluation. Shallow defects in non-critical components shall be fully ground out to give a smooth rounded surface profile, in accordance with the preparatory requirements for grade P3 of ISO 8501 Part 3 . Defects which extend more deeply into the metal and all defects in pressure-containing components shall be referred back to the QP Engineer for possible rejection. 10.1.3 All sharp and rough edges, mechanical indentations and other surface irregularities shall be ground off to give gently rounded contours, with a minimum radius of 2mm. All burrs and metal protrusions, such as weld spatter and slag, shall be ground off t o give a smooth profile, in accordance with the preparatory requirements for grade P3 of ISO 8501 Part 3. For the treatment of similar surface details inside vessels to be lined, the preparatory requirements of NACE SP 0178 shall apply. Any defects or irregularities which become apparent after blast cleaning shall be similarly dressed before the affected areas are re-blast cleaned. 10.1.4 All metal surfaces shall be examined and tested as necessary for the presence of oil, grease and drawing and cutting fluids. Thick grease and heavy oil deposits shall be removed from the metal surfaces by light scraping and any loose surface residues by scraping or brushing, preferably followed by wiping with solvent or detergentimpregnated rags. Particular attention shall be paid to bolt holes and drainage holes. 10.1.5 Those surfaces that are, or are likely to be, contaminated with oil or grease shall be solvent cleaned with a suitable water-soluble biodegradable degreasing agent using rags (for small areas), an immersion tank (for small items) or a spray gun (for large areas), in accordance with SSPC-SP1 requirements. Solvent-cleaned, dirty and otherwise contaminated unpainted and previously-painted surfaces shall then be thoroughly washed down with fresh water (containing less than 25ppm chlorides), Doc. File No.: SPC.L.002.R2

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ensuring that the oil-water emulsion formed is completely removed from the metal, before the surfaces are allowed to fully dry. Fresh water washing shall generally be carried out at a nominal pressure of 3,000 psig, although a lower nominal pressure of 2,000 psig is acceptable for water washing internal surfaces of small vessels and tanks. 10.1.6 In situations where fresh water washing is not possible, subject to approval by the QP Engineer, solvent cleaning may be carried out with an appropriate non-filming solvent. 10.1.7 Metal surfaces to be painted and/or wrapped that do not require to be blast cleaned shall be thoroughly washed with fresh water containing a suitable water-soluble biodegradable degreasing agent, at a nominal pressure of 3,000 psig (or 2,000 psig for internal vessel and tank surfaces), to remove all oil, grease and other contamination. Galvanised steel surfaces that are not sweep blast cleaned shall be similarly water washed, using a stiff bristle brush to remove all water-soluble zinc salts. 10.1.8 Similar washing with fresh water containing a suitable degreasing agent and even solvent washing of partially painted components shall take place between coats of paint or layers of tape at the discretion of the QP Engineer. This is particularly important in offshore situations and in onshore situations where either over-coating has been delayed for more than 72 hours or where the partially painted or wrapped surfaces are seen to be contaminated with oil, grease or parti culate matter. 10.1.9 Degreased and water washed surfaces shall be checked for residual oil and grease using the atomized water spray test as per ASTM F21 (Sub-clause 13.4.1.(d)) and further degreasing carried out if residual oil or grease is found to be present.

10.2

GENERAL BLAST CLEANING REQUIREMENTS

10.2.1 The preferred method of surface preparation for all metal surfaces is dry blast cleaning. This preparatory technique shall be used wherever possible for the painting and/or wrapping of all newly constructed equipment and the maintenance repainting of existing equipment, except when limited breakdown of the existing coating dictates the use of other methods of surface preparation. In situations where it is considered impractical or unsafe to carry out blast cleaning, the matter shall be referred to the QP Engineer for his approval to use an alternative cleaning method. 10.2.2 For high fire risk situations, where spark production during blast cleaning is considered unacceptable, the use of approved fully shielded vacuum dry blast cleaning equipment with standard abrasives, conventional blast cleaning with non-sparking expendable abrasives such as chalk, water abrasive blasting or water blasting shall be required. 10.2.3 Prior to the commencement of blast cleaning, the Contractor shall ensure that all adjacent surfaces and equipment that could be damaged by stray abrasive, including flanges, valves, exposed parts of electrically insulating flange kits and instruments, are adequately protected against such mechanical damage. 10.2.4 At the outset, the surfaces of each component shall be examined and their original condition categorized. For unpainted steelwork, it will be a rust grade from A to D, as specified in ISO 8501 Part 1. For painted steelwork, it will be a degree of rusting, as specified in ISO 4628 Part 3 or ASTM D610/SSPC Vis 2. 10.2.5 Each component shall then be fully blast cleaned to produce a surface appearance that conforms to the requirements designated and illustrated in ISO 8501 Part 1 for the relevant standard of surface cleanliness, original rust grade and type of abrasive used. This shall generally be to Sa 3 standard (visually clean/white metal finish) for newly constructed equipment and at least Sa 2.5 standard (very thorough/near white metal finish) for maintained equipment. Equivalent SSPC and NACE standards to the ISO Doc. File No.: SPC.L.002.R2

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standards are given in Table 2A. If the specified standard of surface preparation cannot be achieved after repeated blast cleaning, because of the original steel condition, the matter shall be referred to the QP Engineer for arbitration. 10.2.6 The selection and particle size and shape of the abrasive used for blast cleaning shall be such as to give the metal surfaces a uniform profile or anchor pattern that is suitable for the coating to be applied with minimum abrasive usage. The required profile height of the surfaces will be related to the total dry film thickness of the specified paint coating Coating Total Dry Film Thickness Up to and incl. 225 microns 250 up to and incl. 300microns 350 microns and above

Average Peak to Trough Profile Height 35-50 microns 50-75 microns 75-100 microns

10.2.7 At the discretion of the QP Engineer, tests may require to be carried out on selected areas of the blast cleaned surfaces, to ensure that they are free from excessive dust and particulate matter, residual millscale and chlorides, oil and grease and, for nonferrous substrates, iron salts prior to paint application, as detailed in Clauses 13.4.3.(f) – 13.4.3.(j). If excessive surface contamination is identified by these tests, the surfaces shall be re-prepared as necessary and re-tested until they do meet the specified cleanliness requirements. 10.2.8 Once metal surfaces have been blast cleaned to the required standard, no solvents, cleaning solutions or inhibitive or acid washes shall be used on them. 10.2.9 At the start of the contract, two small sections of plate shall be blast cleaned using the specified abrasive under the agreed blast cleaning conditions and with the appropriate air blowdown. The blast cleaned plates shall be checked by the Contractor and the QP Engineer for surface cleanliness, profile height and residual particulate matter, in accordance with the relevant standards. Once it has been agreed that these plate sections meet the specified blast cleaning requirements of the contract, the Contractor shall put them into transparent, hermetically sealed plastic wallets. One plate shall be retained by each party. In the event of subsequent disputes arising regarding the standard of blast cleaning achieved, they shall be used for arbitration purposes.

10.3

DRY BLAST CLEANING

10.3.1 Dry blast cleaning shall be carried out with an approved type, brand, grade and batch of abrasive, which shall comply with the appropriate ISO 11124 Standard for metallic abrasives or ISO 11126 Standard for non-metallic abrasives. For environmental and health reasons, garnet abrasive is generally preferred and shall be used for all offshore blast cleaning. Expendable abrasives, such as platinum slag, copper slag and coal slag, and recyclable abrasives, such as garnet and steel grit, may be considered for onshore site work. Recyclable abrasives are best suited for workshop rather than site conditions but if a recyclable abrasive is proposed, the recycling equipment, procedure and quality control testing measures to be employed shall be reviewed and approval by the QP Engineer before its use can be sanctioned. Neither sand nor contaminated recycled abrasive will under any circumstances be allowed for blast cleaning. 10.3.2 The selection of abrasives for the dry blast cleaning of corrosion resistant ferrous alloys and non-ferrous metals and alloys shall be subject to t he approval of the QP Engineer. 10.3.3 The air compressor used for dry blast cleaning shall be fitted with adequately sized after-coolers, to ensure that the compressed air supplied is completely dry. It shall also be fitted with suitable traps, separators and filters, which shall be regularly emptied of Doc. File No.: SPC.L.002.R2

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water and oil. Any accumulated moisture and oil in the air receiver vessel shall be removed by regular air purging. The air compressor shall under no circumstances be allowed to operate at temperatures in excess of 110 C. The air supply shall be checked for water and oil contamination as per the procedure specified in ASTM D4285 prior to blast cleaning and regularly throughout blast cleaning operations. The compressed air supply used for dry blast cleaning shall be of sufficient pressure and volume to enable rapid and efficient cleaning rates to be achieved. Blast cleaning shall always be carried out at a minimum nozzle air pressure of 100 psig (7 barg), as measured with a hypodermic needle gauge. Blast cleaning shall not be carried out in the vicinity of recent surface preparation and painting locations, where dust or spent abrasive from this operation could contaminate either freshly cleaned metal surfaces or a wet or tacky paint film. The weather conditions shall be monitored prior to and constantly throughout the work period. No dry blast cleaning shall be carried out when the relative humidity of the air exceeds 85% or the metal temperature is within 3 C of the dew point temperature. A much lower relative humidity of around 60% is required for blast cleaning inside tanks and vessels and suitably sized dehumidifier equipment is generally required to achieve these low internal humidity levels. No dry blast cleaning other than preliminary scale removal shall be carried out outside daylight hours at external locations. Surface preparation may also be suspended at the QP Engineer‟s discretion when he considers that adverse weather conditions are likely to develop before priming of the blast cleaned surfaces can be satisfactorily completed. Upon achieving the required level of surface cleanliness by dry blast cleaning, the abrasive supply shall be shut off and as much spent abrasive and dust as possible shall be removed from the cleaned metal surfaces by either thoroughly blowing them down with compressed air at the full blasting air pressure or vacuum cleaning them. Brushing the surfaces is also beneficial in removing embedded particulate matter. Vacuum cleaning shall be used for the removal of abrasive and dust from the internal surfaces of vessels and tanks prior to lining them. The surfaces shall be tested for the presence of residual particulate matter as per the procedure specified in ISO 8502 Part 3. The maximum acceptable size and quantity of retained matter shall be Class 2 Rating 2. Surfaces on which locally corroded areas display evidence of staining after blast cleaning, indicative of salt contamination, shall be thoroughly washed down with fresh water and allowed to dry before being re-blast cleaned to the specified standard. All dry blast cleaned surfaces shall be primed or painted before any visible rust blooming is evident and certainly within at most four hours of cessation of blast cleaning. The work must be planned to ensure that this requirement is always met. 

10.3.4

10.3.5

10.3.6



10.3.7

10.3.8

10.3.9

10.4

WET ABRASIVE BLAST CLEANING AND WATER JETTING

10.4.1 Wet abrasive blast cleaning and water jetting are more specialized cleaning techniques that shall only be considered for use on wet, damp or salt-contaminated salt -contaminated surfaces, under under wet and high humidity ambient conditions, at high fire risk locations where spark formation is considered unacceptable, and when water-dispersing, moisture-tolerant and moisture-curing primers are to be applied to t he cleaned surfaces. 10.4.2 Free water shall be removed from f rom the metal surfaces using compressed air, squeegees or mops immediately upon completion of cleaning until no visual signs of water remain. 10.4.3 The metal surfaces shall be cleaned by wet abrasive blasting or water jetting to produce a finish complying with the appropriate visual and non-visual surface preparation Doc. File No.: SPC.L.002.R2

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standards for the primer that is to be applied, as specified in SSPC-SP 12 / NACE 5 and illustrated in SSPC Vis 5/NACE Vis 9 (for water abrasive blast cleaning) and SSPC Vis 4/NACE Vis 7 (for water jetting). Evaluation of the visual surface condition may be complicated if significant rust blooming occurs during the drying c ycle. To minimize mi nimize rust formation during drying, a corrosion inhibitor that is compatible with the primer may by agreement be added to the final wash water. 10.4.4 The acceptance criteria for the cleanliness of wet abrasive blasted and water jetted metal surfaces shall be based upon their t heir visual appearance, an absence of soluble ir on salts and an acceptably low chloride contamination level, when tested as detailed in Clauses 13.4.3.(h) and 13.4.3.(i). 10.4.5 The cleaned metal surfaces shall be coated with the appropriate water-dispersing, moisture-tolerant and moisture-curing primer as soon as all free water has been removed from them. No Schedule for the use of this type of primer is given in this document. Paint Manufacturers‟ recommendations must be sought regarding the selection and use of such primers for any application. 10.4.6 Wet W et blast cleaning and water jetting techniques and the application of water-dispersing, moisture-tolerant and moisture-curing primers may be carried out under wet and high humidity conditions. Subsequent paint application shall, however, be carried out under the ambient conditions required for conventional painting, i.e. maximum relative humidity 85% and metal surface temperature at least 3°C above dew point temperature. 10.4.7 Contractors proposing to use water abrasive blast cleaning c leaning shall provide the QP Engineer with a plan for the safe disposal of the expendable wet abrasive, stating the measures that are to be taken to ensure that it does not cause blockage of site drains. 10.4.8 Contractors shall also provide the QP Engineer with detailed method statements for the use of these wet cleaning techniques, stating the safety precautions that they intend to take in handling these dangerous high pressure water streams. These shall comply, as a minimum, with the operating and safety requirements requirements of SSPC SP -12 / NACE 5.

10.5

POWER TOOL SURFACE PREPARATION

10.5.1 It is stated above that metal surfaces shall be prepared by blast cleaning wherever possible. There are, however, situations where components or areas of components cannot realistically be blast cleaned, because of their shape, complexity or remote location. In such situations, these components or areas may with the prior approval of the QP Engineer be cleaned as thoroughly as possible using power-driven tools, fitted with approved discs and wire brushes. 10.5.2 Details of the proposed power tool cleaning method to be adopted and the tools to be used for power tool preparation shall be submitted to the QP Engineer for approval. These may include rotary wire brushes, abrasive discs, orbital sanders, vibratory and rotary hammers and needle guns. The method statement shall identify all necessary precautions that require to be taken for the t he safe use of the proposed tools. 10.5.3 The minimum preparatory standard required for power tool cleaned surfaces shall be S t 3 standard in accordance with ISO 8501 Part 1 or SP3/SP11 standard in accordance with SSPC-Vis3. Care shall be taken to ensure that the metal does not become polished during cleaning. 10.5.4 Power tool cleaning shall continue for a minimum distance of 25mm into the adjoining blast cleaned surfaces or, when the prepared areas continue up to existing painted areas, the interface area shall be feathered back for a minimum distance of 25mm into Doc. File No.: SPC.L.002.R2

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the sound coating, to prevent lifting of the old coating and provide a smooth sound base for the new paint. 10.5.5 With recessed welds that are located in areas which cannot be blast cleaned and are also inaccessible for power disc and power wire brush cleaning, the use of powerdriven impact tools, such as vibratory and rotary hammers and needle guns, may with the agreement of the QP Engineer be considered for primary surface preparation, followed by manual wire brush cleaning. 10.5.6 All power-driven preparatory equipment shall be of a type and quality and be used in a manner that avoids creating indentations, grooves, burrs or sharp edges in existing coatings and metal substrates. The use of orbital sanders fitted with suitably graded abrasive discs or sheets is preferred for existing sound coatings. Smudges and surface contamination left by wire brushes or discs shall be removed with a water-soluble solvent. The areas shall then be rinsed with fresh water and dried. In areas where fresh water washing is not possible, with the t he approval of the QP Engineer, solvent cleaning in accordance with SSPC-SP1 requirements shall be performed. 10.5.7 In high fire risk locations where power or even hand tool cleaning is required, the items of equipment used shall be of a non-sparking type that is approved by the QP E ngineer.

10.6

MECHANICAL HAND TOOL SURFACE PREPARATION

10.6.1 Mechanical hand tool surface preparation shall only be permitted in areas that cannot be blast or power tool cleaned, because of their t heir inaccessibility or isolation. 10.6.2 Details of the proposed cleaning method to be adopted and the tools to be used for hand tool preparation shall be submitted to the QP Engineer for approval. These may include hand wire brushes, scrapers, pneumatic needle guns and chipping hammers. The method statement shall identify all necessary precautions that require to be taken for the safe use of the proposed tools. 10.6.3 All loose rust, mill scale, paint, welding flux and weld spatter shall be removed from the surfaces by hand brushing, scraping, chipping, hammering or a combination of these methods and stratified rust and scale shall be removed by chipping or hammering. The surfaces shall then be thoroughly cleaned to St 3 standard in accordance with ISO 8501 Part 1 or SP2 standard as per SSPC-Vis 3. 10.6.4 In areas where the coating has been locally damaged or the prepared surfaces are taken back to an existing painted surface, the substrate may be prepared by mechanical hand tool cleaning but the edges of the prepared area must be carefully feathered back a minimum distance of 25mm into the adjacent sound coating, to prevent it lifting and provide a smooth sound base for the new paint.

10.7

CHEMICAL PICKLING

10.7.1 Chemical pickling to white metal in accordance with the requirements of SSPC-SP8 may, with the agreement of the QP Engineer, be considered as an alternative to blast cleaning in situations and for components where it is a more practically and economically viable preparatory technique. 10.7.2 The pickling solution used shall be approved by the QP Engineer as being suitable for treating the constructional material used for the component or equipment involved and shall contain a suitable inhibitor to prevent localised or excessive general corrosion of the treated component surfaces. 10.7.3 The pickling procedure shall identify all necessary requirements for the safe handling, storage, use and subsequent subsequent disposal of the pickling solution and any added chemicals. Doc. File No.: SPC.L.002.R2

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11.0 PAINT APPLICATION 11.1

PAINT SUITABILITY, STORAGE AND MIXING

11.1.1 Unless otherwise specified, all the paint products comprising a coating system for a component shall be technically acceptable and approved products that are purchased from the same Paint Manufacturer with his assurances that:a) All products products are fully compatible with each other. b) The primer is suitable for the standard of surface preparation specified. c) The complete coating coating system is suitable suitable for the intended service environment, temperature and conditions to which it will be subjected. The suitability of all paint products for an application shall be based upon satisfactory experience of their previous use for similar applications and conditions, appropriate laboratory testing or both. Wherever possible, all vendors and sub-contractors for a particular project shall be requested to use the same paint manufacturer and products for the for the protection of equipment of equipment and components they have been contracted to supply. 11.1.2 Particular care is required in the selection of primers and paints for maintenance painting. Specific assurance shall be sought from the Paint Manufacturer regarding the compatibility of maintenance primers and paints with existing paint and coating systems. Where doubts exist regarding paint compatibility, field trials shall be carried out on selected areas of the paintwork to be over-coated, as specified in ASTM D5064. 11.1.3 Batches of paint received shall be checked for f or correct labelling and stored under secure, sheltered and temperature-controlled conditions. The temperature within the paint storage area shall be monitored daily with a calibrated digital thermometer and formally recorded for review. Batches shall be used in the order in which they are received. The paint identification and storage system must ensure that this is the case. Prior to use, each batch shall be checked to ensure that it is still in the original, sealed and properly labelled Manufacturer‟s M anufacturer‟s containers and is marked with its shelf lif e date. 11.1.4 Paints which are not contained in original, fully sealed manufacturer‟s containers and batches that have exceeded their shelf life date shall be discarded. Paints which are found to have gelled or thickened to such an extent that they cannot be easily mixed, irrespective of their shelf life date, shall also be discarded. 11.1.5 Paints shall be thoroughly mixed in accordance with Manufacturer‟s data sheets, using suitable rotary stirrers wherever possible, immediately prior to and regularly during use. Care shall be taken to ensure that all settled material at the bottom of containers has been fully dispersed and solvated to produce a liquid of uniform consistency. Five litre and larger sized containers of paint shall always be m ixed using rotary stirrers. 11.1.6 When multi-pack paints are used, the separately packaged curing agent or hardener shall only be added to the base paint after the latter has been thoroughly mixed. Good working practice would dictate that only a sufficient quantity of paint that can be used within its pot life under the prevailing climatic conditions and within the current working period should be mixed. Whenever possible, small units of paint materials shall be used for performing minor repairs, so as to avoid incorrect part mixing and paint wastage. This is especially applicable to coating repairs inside tanks and vessels, for which only 5 litre or smaller sized containers shall be used. 11.1.7 Standard units of multi-pack paints shall not be broken down to provide smaller quantities without the prior agreement of the QP Engineer. Such agreement shall only


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be given if it can be procedurally shown and practically demonstrated that accurate measurements of the quantities of the components to be mixed can be m ade.

11.2

PAINT APPLICATION EQUIPMENT

11.2.1 Airless spray and conventional air spray equipment used for paint application shall be of suitable design for the specific paint to be applied. Plural spray pumps shall be used for paints with a short pot life at high temperatures. Equipment shall be used in accordance with the Manufacturer‟s operating instructions and recommendations for the application of that paint. It shall be fitted with suitable pressure regulators and gauges, to enable the operating conditions to be controlled and monitored. 11.2.2 The air pressure to the paint pump for airless spray paint application shall be adjusted to be sufficiently high to properly atomise the paint for optimum spraying effectiveness but should not be significantly higher than this value. 11.2.3 The pressure and volume of air used for conventional air spray paint application shall be sufficiently high at the spray gun to atomise the applied paint to the degree and at the rate required. It shall not, however, be so high that it will cause excessive solvent evaporation or paint loss by overspray. The air supply shall be maintained dry and uncontaminated by fitting the compressor with suitable water traps, separators and filters. The requirements for their maintenance and testing shall be as specified in Subclause 10.3.3. 11.2.4 The fluid tips of airless spraying guns shall be of the orifice size and fan angle and the fluid control gun shall be of the construction recommended by the Paint and Equipment Manufacturers. Fluid tips shall be of the shielded type, to prevent skin penetration by the high pressure paint. The air caps, nozzles and needles of air spraying guns shall be those recommended by the relevant Paint and Spray Equipment Manufacturers. 11.2.5 The spraying equipment shall be fitted with suitable filters, and a moisture trap and additional filter as necessary if a conventional spray pot is used. It shall be maintained clean throughout the working period, to ensure that no dirt, dry paint or other foreign material is deposited in the paint film. The equipment shall be thoroughly washed out with solvent to remove all residual paint at the end of each working period. Any solvent left in the equipment shall be completely removed before applying any further paint. 11.2.6 Brushes used for paint application shall be of good quality and of a style that is suitable for the paint to be applied and the components to be painted. Round or oval brushes are most suitable for rivets, bolts and irregular or heavily roughened surfaces, whilst wide flat brushes are most suitable for large flat areas. 11.2.7 Neither brushes over five inches wide nor rollers shall be used for paint application, other than for the final smoothing of high volume solids paints.

11.3

PAINT APPLICATION METHODOLOGY

11.3.1 No paint application shall be carried out until all required surface preparation carried out has been accepted by the QP Engineer. All metal surfaces shall be primed as soon as possible after surface preparation has been completed and approved. For dry blast cleaned surfaces, this shall be before any visible re-rusting of the metal occurs and certainly within four hours of blast cleaning cessation. For power tool and hand tool cleaned surfaces, it shall be the same working day as they are prepared. 11.3.2 Prior to the commencement of paint application, particularly by spraying, the Contractor shall ensure that all adjacent surfaces and equipment that could be adversely affected by paint, including flanges, valves and instruments, are protected against paint Doc. File No.: SPC.L.002.R2

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overspray and contamination. At site, the floor shall be covered with a tarpaulin or sheet during paint application, to prevent dust, sand or abrasive contamination of the blast cleaned surfaces or applied paint film. 11.3.3 The preferred methods for the application of paints to prepared metal surfaces are airless spray or conventional air spray, due to the superior paint thickness control and coating appearance that can be achieved. Brush and other application methods shall only be used, with QP Engineer approval, for small and isolated areas, such as during stripe or patch repair painting, or where the Paint Manufacturer‟s recomm endations dictate their use. The number of coats and types of paint and the surfaces to be painted shall be as specified in the contract documents. The applicators shall be familiar with the Paint Manufacturer‟s data and instruction sheets for each paint a nd shall ensure that they are applied in accordance with these recommendations. Each product and the individual coats of multi-layer products shall be tinted a sufficiently different colour to aid identification during paint application and coating inspection. The colour of the final coat shall meet the requirements of Tables 6A-9A and Appendix D for the component and service involved. 11.3.4 The weather conditions and the metal temperature shall be monitored at the start of, and regularly throughout, the working day. No paint application shall be carried out when the relative humidity is greater than 85%, or 60% inside tanks and vessels, or the metal surface temperature is less than 3°C above the ambient dew point temperature, except with the prior written approval of the QP Engineer. The maximum and minimum surface temperatures at which a paint can be applied will depend upon its nature and curing temperature. The Manufacturer‟s recommendations shall be used as the definitive guide but no paint shall be applied at surface or ambient temperatures below 5°C or above 50°C without Manufacturer‟s approval. No external spray paint application shall be carried out when the wind speed exceeds 15 knots (7.5 metres/second) other than with the QP Engineer‟s agreement. No painting shall be carried out outside daylight hours at external locations, unless specifically approved in writing by the QP Engineer. 11.3.5 Prior to the application of the full coat of primer and each succeeding coat of paint by whatever method, all edges, corners, crevices and poorly accessible features, continuous and stitch welds, holes, bolts, rivets and pitted areas shall be stripe painted with the appropriate paint material by brush, ensuring that the material is worked firmly into the metal surfaces. These stripe coated areas shall extend a minimum of 25mm from the relevant feature. 11.3.6 The full coat of primer or paint shall be applied to the component as soon as possible after stripe painting. Stripe painting after application of the full coat may only be carried out by exception with the formal agreement of the QP Engineer. In this eventuality, the stripe paint shall be tinted a slightly different colour to the full coat material to aid identification. In either situation, care shall be taken to avoid solvent entrapment. 11.3.7 Where paint application is carried out by brush, the brushing shall be done in such a way that a smooth coat of as uniform a thickness as possible is obtained. All runs and sags shall be brushed out and the paint shall be as free as possible from pores, discontinuities and brush marks. Paint shall be worked into all crevices and corners. 11.3.8 Where paint is applied by spray, the spraying technique used shall ensure that a uniform layer of wet paint of the required thickness is deposited on all surface areas. All runs, sags and overspray shall be brushed out and inclusions, pinholes and other blemishes rectified immediately. If there are an excessive number of runs, the paint shall be removed and the surfaces repainted using either a more suitable paint mix for Doc. File No.: SPC.L.002.R2

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the climatic conditions or a modified spraying technique or equipment. When applying high build coatings, a cross hatch spraying technique is considered beneficial in producing uniform paint films. Areas that are inaccessible or unsuitable for effective spray painting, such as crevices, poorly accessible features, continuous and stitch welds, cracks and blind areas of bolts and rivets, shall be locally painted by brush. 11.3.9 Each coat of paint shall be allowed to cure for at least the minimum period of time at the prevailing temperature recommended by the Manufacturer before being over-coated. However, its recommended maximum over-coating period at this temperature shall not be exceeded. The work must be planned to ensure that this requirement is met. Where over-coating of a partly painted component is delayed for more than 72 hours, after a dust storm or strong wind (typically exceeding 12 knots or 6 metres per second) or at the discretion of the QP Engineer, such as when oil or other surface contamination is evident, the painted surfaces shall be solvent cleaned and/or fresh water washed as necessary to remove surface contamination without damaging the coating before being over-coated. They shall also be lightly abraded when the over-coating period has been exceeded or if there is any concern about contamination or overspray on the previous coat. After application of the complete paint system, it shall be allowed to fully cure as per the Manufacturer‟s recommendations before the component is handled o r moved. If the paint does not cure within the recommended period, at the discretion of the QP Engineer, a sample shall be removed to ascertain the cause of the problem.

11.4

REPAIR OF DAMAGED PAINTWORK

11.4.1 All areas of paintwork that are locally damaged during transportation, handling, erection, surface preparation or paint application shall be repaired as required to fully rectify the coating damage to the QP Engineer‟s satisfaction. 11.4.2 When the coating is damaged but the metal substrate is not exposed, the damaged areas of paintwork shall be gently abraded back to the sound coating using emery paper or a fine grinder. These areas shall then be wiped with suitable solvent and fresh water washed, to remove all debris. This technique is especially preferred for the preparation of damaged vessel and tank linings. The periphery of the repair areas shall be feathered back for a minimum distance of 25mm into the adjacent undamaged coating by light abrasion or grinding, to produce a smooth chamfered surface profile for the repair coating. Sweep blast cleaning shall only be used for the preparation of damaged coatings with the QP Engineer„s agreement, subject to the conditions stated in Sub-clause 9.1.8. 11.4.3 When the coating is damaged back to the base metal such that areas of the metal substrate are exposed, the exposed metal shall be cleaned to the original specified standard prior to repainting it. For larger areas of exposed metal, local dry blast cleaning, using a small vacuum blast cleaning unit, shall be used wherever possible. For small and isolated areas or where the use of blast cleaning is not practical, power tools may have to be used, with the approval of the QP Engineer, to obtain the required preparatory standard. As with partially damaged coatings, the periphery of the repair areas shall be feathered back for at least 25mm into the adjacent undamaged coating, to produce a smooth chamfered surface profile for the repair coating. 11.4.4 The prepared partially or completely damaged areas of the coating shall then be repaired by the local application of the requisite number of coats of paint to obtain the original coating system and thickness. If the repaired areas are scattered and exceed nominally 5% of the total surface area, at the QP Engineer‟s instruction, a cosmetic topcoat shall be applied to the full affected surface area to avoid an unsightly patchy Doc. File No.: SPC.L.002.R2

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appearance. This cosmetic topcoat paint requirement is equally applicable to the maintenance repair of existing paintwork, although its applicability to large items such as tanks shall be assessed by the QP Engineer.

12.0 WRAPPING TAPE APPLICATION 12.1

TAPE SUITABILITY AND STORAGE

12.1.1 Prior to the commencement of any wrapping work, the Contractor shall submit details of the type and brand of cold-applied wrapping tape and the primer or adhesive that it is proposed to apply plus a detailed application method statement, for approval by the QP Engineer. The document shall be accompanied by the Tape Manufacturer‟s data sheets for the products involved, confirming their suitability for the expected service conditions and environment. The wrapping tape shall be a heavy-duty tropical grade material. 12.1.2 The product data sheets shall include as a minimum the following details:(a) Service temperature limits and chemical resistance of the wrapping tape and its adhesive or primer. (b) Type and recommended minimum wet film thickness of the primer or adhesive. (c) Minimum and maximum recoating interval of the primer or adhesive prior to tape application. (d) Whether the tape requires a special application machine or is suitable for hand application. (e) Manufacturer‟s recommended voltage to use for holiday detection testing. 12.1.3 Unless otherwise specified, the f iller, primer, adhesive and wrapping tape used shall be purchased from the same manufacturer with his assurances that:(a) All products are all fully compatible with each other. (b) The tape primer and adhesive, when required, are compatible with the paint coating over which they will be applied. (c) The complete wrapping system is suitable for the intended service environment, temperature and conditions to which it will be subjected. 12.1.4 As with paints, the containers of primer, adhesive and putty filler and the rolls of wrapping tape shall be individually identified and stored under secure, sheltered and temperature-controlled conditions. Each roll of tape should ideally have the product name, batch number and production date stamped on or embossed in the back of the tape for easy field identification. The containers and rolls shall be used in the order received. Those which have been opened or damaged or have exceeded their shelf life date shall be discarded. The handling, mixing and application of primers and adhesives shall be as detailed in Clause 11.0.

12.2

SURFACE PREPARATION

12.2.1 Component surfaces that are to be wrapped shall have been coated with part of the paint system that has been specified for the appropriate service environment prior to being primed and wrapped. The paint coating is required to guard against the occurrence of general and localized corrosion of the metal beneath the layer of tape by water that gains access though local points of tape damage and poorly adherent overlaps and joints. 12.2.2 The surfaces to be wrapped shall have been degreased, prepared and partially coated with the paint system specified for the relevant service environment and conditions by the methods and to the standards specified in Clauses 10.0 and 11.0. Doc. File No.: SPC.L.002.R2

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12.2.3 Subsequent surface preparation for tape primer or adhesive application shall be in accordance with the Wrapping Tape Manufacturer‟s reco mmendations. It may simply require the paint coating to be water washed or degreased and lightly abraded to obtain a suitably roughened surface profile for good primer adhesion. If the recommended over-coating period of the previously-applied paint has been exceeded, it may even be necessary to apply an additional tie-coat of a suitable paint. 12.3

TAPE APPLICATION METHODOLOGY

12.3.1 As with the application of paints, the weather conditions and the metal temperature shall be monitored at the start of and regularly throughout the working day. No prim er or wrapping tape shall be applied when the relative humidity is greater than 85% or the metal surface temperature is less than 3°C above the ambient dew point temperature. The maximum and minimum surface temperatures at which a tape can be applied will depend upon the nature of the adhesive and carrier materials. The Manufacturer‟s recommendations shall be used as the definitive guide. No wrapping shall be carried out outside daylight hours at external locations unless approved in writing by the QP Engineer. 12.3.2 Pipe flanges and fittings shall be protectively wrapped in the same manner as the adjacent pipework, unless otherwise specified. 12.3.3 Pitted or uneven surface areas and components with irregular shaped surfaces that are difficult to wrap, such as areas of flanges, tees and valves, shall be filled with the Manufacturer-approved putty filler, to produce a suitably smooth profile for wrapping 12.3.4 The primer or adhesive shall be applied to the painted component surfaces by brush or spray, as recommended by the Manufacturer, to give the required wet film thickness. When the Manufacturer recommends that no primer or adhesive is required for the application of its tapes to painted surfaces, no primer or adhesive shall be applied. 12.3.5 When the required primer or adhesive is at the appropriate stage of drying, the protective “waxed paper” shall be pulled back from the adhesive side of the wrapping tape and it shall be slowly wound onto the component surface in a spiral arrangement with moderate tension using either the approved tape applicator tool or by hand. Gentle uniform pressure shall be applied to avoid any creases or wrinkles and ensure that it is in firm contact with the primer or adhesive. 12.3.6 The tape shall be wound in such an arrangement and manner that there is 55% minimum overlap of one layer of tape onto the previous layer, ensuring double layer coverage on all areas, and that all overlapping joints have a smooth profile and are fully and continuously bonded to the previous layer. 12.3.7 When a new roll of tape is started, the new tape shall be overlapped a minimum circumferential length of 150 mm onto the end of the old tape. When a surface adjacent to a previously wrapped surface is wrapped, the new tape should overlap a minimum distance of 150mm back onto the existing tape. 12.3.8 Wrapping tape that is permanently exposed to sunlight shall be overwrapped with a light-reflecting tape to prevent degradation of the original wrapping by ultraviolet radiation. A suitably mechanically tough grade of tape shall be used for applications where it is considered to be at risk from stone or mechanical handling damage and it shall be overwrapped as necessary with a physically protective overwrap. 12.3.9 Wherever possible, the authorised QP Painting Inspector shall witness the backfilling of buried wrapped pipework and vessels, to ensure that there is no m echanical damage to the wrapping after it has been fully inspected and holiday detection tested. Welded and Doc. File No.: SPC.L.002.R2

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flanged pipe joints shall be left unwrapped until all pressure testing has been completed, unless otherwise specified in writing by the QP Engineer.

12.4

REPAIR OF DAMAGED WRAPPING TAPE

12.4.1 All areas of wrapping tape that are found to have physical defects, such as creases, wrinkles, poor adhesion or mechanical damage, or to be below the required thickness or to contain pinholes shall be rejected. 12.4.2 Locally damaged areas of tape and holidays shall be repaired to the satisfaction of the QP Engineer by peeling back the tape, cleaning all tape adhesive from the affected painted surfaces, lightly abrading the paint, re-priming the painted surfaces with tape adhesive as required and rewrapping the affected areas as previously, ensuring a 150mm minimum overlap onto intact wrapping tape on either side of damaged areas. 12.4.3 If the tape is extensively damaged or contains widespread pinholes, it shall be completely removed together with the tape primer/adhesive back to the painted metal surfaces and the whole painted component surfaces shall be lightly abraded with emery paper, re-primed with the tape adhesive and rewrapped to the required standard.

12.5

PROTECTION OF THREADED CONNECTIONS & FLANGED JOINTS

12.5.1 It is stated in Sub-clause 8.3.(f) that threaded connections and components which require to be dismantled shall not be painted unless otherwise specified. This is due to the difficulty of periodically dismantling painted fastener components at such connections. Threaded components are also difficult to prepare, paint or wrap by conventional means. There is nevertheless a requirement that all threaded components, such as bolts and nuts, shall be given some f orm of protective coating and this shall be specified in the contract and approved in practice by the QP Engineer. Particular requirements may be necessary for electrically insulated, dissimilar metal flanged joints. For threaded connections and components which do not require to be periodically dismantled, it will be possible to prepare and paint the externally exposed surfaces of the assembled fastener components with the specified coating system. 12.5.2 The alternative use of ultra violet (UV)-resistant plastic caps filled with suitable corrosion inhibited grease, such as Ilex OT grease or equivalent, may be considered for the in-situ protection of assembled nuts, washers and the end sections of bolts. The cap design shall be such that, once fitted, they are firmly locked in place and cannot be inadvertently removed. The Contractor shall submit details of the design and material of the caps and the grease that are proposed for use, for approval by the QP Engineer. 12.5.3 The sections of bolts and other fastener components inside the flange faces of flanged joints may be protected by fitting a proprietary clamped stainless steel band having an internal rubber sealing membrane, with a drain nipple at its low point for joint leakage detection, or by sealing the periphery of the flanged joints with a suitable mastic sealant after fitting a drain nipple. 12.5.4 The use of proprietary site-applied thermoplastic encapsulation products may, subject to QP approval by satisfactory field testing, also be considered for the in-situ protection of assembled threaded components, flanged joints, machined surfaces and other similar features. Such encapsulation products shall be considered as strippable temporary protective systems, because of the ease with which the material can be removed from the surfaces, rather than longevity of t he protection provided. 12.5.5 As with other protective systems, the Contractor shall submit details of all encapsulation materials and any primer or adhesive that it is proposed to apply, plus a detailed Doc. File No.: SPC.L.002.R2

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application method statement, for approval by the QP Engineer. The document shall be accompanied by the Encapsulation Manufacturer‟s Data Sheet for the product s to be applied, confirming their suitability for the service conditions and environment. 12.5.6 Encapsulation materials are generally applied by specialist Contractors or using specialised proprietary equipment. Full details of the application system and required equipment shall be made available to the QP Engineer for approval before any encapsulation work is allowed to take place.

13.0 INSPECTION DURING SURFACE PREPARATION AND COATING 13.1

GENERAL INSPECTION REQUIREMENTS

13.1.1 All surface preparation, painting and wrapping work carried out under or to the intent of this Specification shall be subject to systematic inspection at each stage of prepreparation, surface preparation, painting/wrapping and repair by the QP Engineer. In addition, the work shall be subject to random inspection as and when the QP Engineer deems it necessary. 13.1.2 The basic inspection requirements and system shall be detailed in a formal Quality Inspection and Test Plan and presented by the Contractor as part of the contract documentation for approval by the QP Engineer. A typical Inspection & Test Plan Checklist is shown as Table 3A. Such a Plan shall not relieve the Contractor from his responsibility to carry out all work in a safe and timely manner using skilled personnel and good practices to achieve a high quality product meeting all other specification requirements. 13.1.3 All defective or non-conforming work identified at each stage shall be rectified to the required standard by the Contractor. Any preparatory, painting or wrapping work carried out to this Specification that is not systematically inspected and approved by the QP Engineer at each stage shall be deemed not to meet the Specification. The coating or wrapping shall be removed from all affected areas and they shall be re-prepared and recoated or rewrapped to the approval of the QP Engineer by the Contractor. 13.1.4 The Contractor shall provide an authorised person who is a qualified Painting Inspector to the minimum standard specified below to coordinate the inspection work carried out and report the results obtained. The proposed Contractor employee, who may be a Supervisor or Manager, shall also be individually acceptable to the QP Engineer. Additionally, either an appointed QP Painting Inspector or a QP approved qualified Third Party Painting Inspector shall act on behalf of the QP Engineer under the contract, to ensure that the required inspection work is being carried out in a satisfactory and effective manner to consistently give a good quality product. 13.1.5 All proposed Painting Inspectors shall be qualified to at least NACE Level 2, I Corr Level 2 or CSWIP (ex BGas) Level 2 and shall have at least five years approved postqualification work experience of industrial painting of oil and gas f acilities at inspector or supervisor level. The certification and resume of each Inspector shall be submitted to the QP Engineer for approval and they shall be interviewed at the start of each contract, as necessary, to confirm their technical capability. The Inspectors shall consult the Paint Manufacturer to obtain the necessary technical support to ensure compliance with product recommendations. 13.1.6 The Contractor shall provide a comprehensive range of approved inspection equipment at each site of any work that is in progress to enable all inspection work that is required under the approved Inspection and Test Plan and Work Specification to be carried out. Doc. File No.: SPC.L.002.R2

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This shall as a minimum include the items of equipment detailed in Clauses 13.5.1 and 13.5.2. He shall provide sufficient “sets” of commonly used inspection equipment to avoid any delays in carrying out the required inspection at all work sites.

13.2

INSPECTION SYSTEM REQUIREMENTS

13.2.1 The proposed inspection system for all preparatory, painting and wrapping work shall operate via a series of Hold Points in the work schedule, from which the Contractor shall not proceed until he is given formal clearance by the QP Engineer. This does not mean that these are the only points at which inspection shall be carried out. It is intended that the Inspection and Test Plan will ensure that relevant inspection is carried out prior to, during and after each activity in the work schedule. 13.2.2 The relevant Hold Points, which shall be considered as mandatory under all contracts, are as follows. These items are also identified as Hold Points in Table 3A. a) Approval of working procedures, safety precautions and QA/QC system. b) Authorisation of Permit to Work. c) Acceptance of preparatory, painting, wrapping and inspection tools and equipment type and condition. d) Acceptance of surface preparation standards. e) Acceptance of primer coat. f) Acceptance of complete paint coating. g) Acceptance of complete wrapping system. h) Acceptance of remedial coating and wrapping repairs. 13.2.3 All Hold Points shall be strictly observed and recorded. Any surface preparation or painting or wrapping work undertaken without Hold Point clearance shall be re-worked by the Contractor. 13.2.4 The QP Engineer shall be given at least 48 hours notice of any Hold Point inspections that require to be carried out. Whilst work is in progress the QP Engineer shall be given at least 24 hours notice of any change in the inspection schedule. All parts of the work shall be made accessible for the inspection in good lighting, with all areas evenly illuminated to a level of not less than 500 lux daylight or artificial light. In the event of the Contractor wishing to cancel a pre-arranged inspection, he is required to give the QP Engineer at least one hour‟s notice, unless otherwise f ormally agreed. 13.2.5 Full details of the inspection work carried out and the results obtained shall be reported by the authorised Contractor Painting Inspection on a daily basis in a standard Daily Inspection Report Form, the format of which shall be approved at the outset by the QP Engineer. This Form may also be used as a Daily Progress Report. A typical Daily Inspection Report format is given in Table 4A, although other formats may be equally acceptable, but it shall as a m inimum contain the following information. a) Contractor and client name, project title, reference and revision number and work location. b) Date. c) Project specification and revision and applicable coating schedule(s). d) Inspection and test plan number and revision. e) Technical queries or technical deviation requests related to coating or wrapping. f) Nature and sizes of items undergoing preparation and painting or wrapping, areas worked on and constructional materials involved. g) Components and parts requiring different coating schedules, such as skirts and saddles of high temperature vessels and supports of high temperature pipework. h) Areas not painted or wrapped and protective measures taken. Doc. File No.: SPC.L.002.R2

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i) j)

Original condition of metal substrate or coated surface. Weather conditions, relative humidity, dew point and air and metal temperatures at start of each shift and every two hours throughout the working day. k) Preliminary cleaning and degreasing carried out, including solvents used. l) Method of surface preparation and equipment used, including abrasive type, product brand name, particle size range and batch number. m) Standard of surface preparation and cleanliness and surface profile height obtained n) Manufacturer, product name and number and batch number of all paints and wrapping tapes applied. o) Number of coats of each product applied to each area of each item and application method used. p) Specified dry film thickness (D.F.T.) of each coat of paint and complete paint coating system (T.D.F.T.) and measured wet film thickness (W.F.T.) of each coat and D.F.T. of each coat and complete paint coating system. q) Areas wrapped by each tape and measured tape thickness. r) Locations and sizes of areas of paintwork and wrapping repaired. s) Any comments relating to the work that the Contractor feels are relevant. 13.2.6 These Daily Inspection Report Forms shall be completed, signed and dated by the authorised Contractor (or Sub-Contractor, if the work is sub-contracted out) Painting Supervisor/Inspector on a daily basis. For sub-contracted work, they shall be reviewed and approved by the Contractor Painting Supervisor/Inspector. They shall subsequently be reviewed and approved by the QP or authorized TP Painting Inspector. One copy shall be submitted to the Contractor‟s Engineer for review, one copy sent to the Contractor management and the third copy retained in the site working file. At the end of the Contract, a summary Close Out Inspection Report, a typical format for which is shown as Table 5A, shall be completed, signed and dated, reviewed and approved as above and sent for the QP Engineer‟s approval.

13.3 INSPECTION OF EQUIPMENT, MATERIALS AND ACCESS FACILITIES 13.3.1 The QP Engineer shall have the right to inspect all tools, equipment, plant, instruments, materials, and access scaffolding and facilities that are used or to be used in the performance of the preparatory, coating application, wrapping and inspection work at the start of and at all times during the contract. The Contractor shall make all parts of the worksites accessible for these inspections. 13.3.2 QP reserves the right to reject any tools, equipment, plant, instruments, materials or access facilities which are considered unsuitable, unserviceable, inadequate or unsafe for the proposed work or not to fully meet the contract requirements. All rejected items and materials shall be reported as such and replaced or rectified as instructed by the QP Engineer. 13.3.3 The Contractor shall provide recent calibration certificates from QP approved Third Party Laboratories for all equipment and instrumentation used for the contract, where appropriate and as requested by the QP Engineer. Equipment and instrumentation which cannot be calibrated shall be replaced by the Contractor, if considered to be unserviceable or unsuitable by the QP Engineer. 13.3.4 Upon request, the Contactor shall permit the QP Engineer or his authorized Painting Inspector to use any item of inspection equipment, to assess its reliability, accuracy and suitability for the proposed inspection activity. If any item is deemed to be inadequate to carry out an inspection activity, an alternative item that is acceptable to the QP Engineer shall be provided by the Contractor. Doc. File No.: SPC.L.002.R2

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13.4

Rev. 2

PREPARATORY AND COATING INSPECTION AND TEST WORK

13.4.1 Prior to Surface Preparation a) Presence of surface-breaking laminations, surface roughness and sharp edges. All surfaces shall be visually inspected. There shall be no surface-breaking laminations or undue surface roughness and all edges shall have a rounded profile. b) Presence of gross oil, grease and particulate matter contamination. Surfaces shall be visually inspected. There shall be no visible oil or grease contamination and the surfaces shall be free from particulate matter contamination. c) Basic rust grade of uncoated metal surfaces or degree of coating breakdown of coated metal surfaces. Shall be assessed by visual inspection in conjunction with Standard ISO 8501 Part 1 or SSPC-Vis 1 for uncoated metal surfaces and ISO 4628 Part 3 or ASTM D610/SSPC-Vis 2 for coated metal surfaces. Rust grade A - C metal surfaces are acceptable but rust grade D surfaces shall be referred to the QP Engineer for acceptance for blast cleaning. The degree of coating breakdown shall determine the maintenance preparatory and repainting requirements. d) Presence of residual oil or grease contamination on solvent washed and fresh water rinsed surfaces. Shall be tested with atomised water spray from a spray gun containing fresh water in accordance with ASTM F21. There shall be no evidence of oil or grease contamination. A clean dry rag shall be used for subsequently drying the metal. e) Presence of residual chloride on surfaces, especially stainless steel . (Subsidiary test that shall be carried out at the discretion of the QP Engineer). Shall be tested in accordance with either ISO 8502 Part 6 (for contaminant extraction) and ISO 8502 Part 9 (for conductometric measurement) or using a proprietary Salt Contamination Meter for conductometric measurement. If the conductivity exceeds 2 150 µS/cm , the matter shall be referred back to the QP Engineer for assessment. Note - Conductometric measurements on a surface determine the total soluble salt concentration, including sulphates, nitrates and bicarbonates as well as chlorides. However, in the Qatari environment, it is considered that chloride will be the major component of soluble salt contamination. The contaminant levels established from conductivity measurements will therefore be taken as the chloride contamination level. Surfaces may, if required, be analysed for discrete chloride contamination either by titrimetric analysis in accordance with ISO 8502 Part 2 of a sample washing obtained as per ISO 8502 Part 6 or by the use of a proprietary chloride surface contamination test kit. 13.4.2 Throughout the Working Day a) Relative humidity and dew point of the atmosphere. Shall be measured in accordance with Method B of ASTM E337 using a whirling psychrometer (wet and dry bulb thermometers) in conjunction with Hydrometric Tables. Alternatively, a digital relative humidity and dewpoint meter may be used, subject to it being calibrated daily against a whirling psychrometer. The relative humidity shall be below 85% during external surface preparation, painting and wrapping but shall be below 60% during internal surface preparation and painting of vessels and tanks. b) Metal surface temperature. Shall be measured using a suitable contact thermometer. It shall be at least 3°C above the dew point temperature for surface preparation, painting and wrapping and below the recommended upper temperature limit for application of the paint and wrapping tape product. Doc. File No.: SPC.L.002.R2

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13.4.3 Before and During Surface Preparation a) Type, grade and cleanliness of abrasive used for blast cleaning. The information marked on the labels of the bags of abrasive shall be recorded. The abrasive shall be of the specified type and grade and be within its expiry date. All batches of expendable abrasive and especially recycled abrasive shall be tested for oil, grease and salt contamination. For oil and grease contamination, the abrasive shall be agitated in a 1:1 ratio with fresh water for two minutes in a vial, left to stand for 10 minutes and then agitated for a further two minutes. The surface of the water shall then be checked for floating oil. There shall be no evidence of oil or grease contamination. For salt contamination, a set weight or volume of the abrasive shall be immersed in and agitated with a set volume of deionised water in a container for a specified minimum period of time in accordance with ISO 11127 Part 6 or ASTM D4940, respectively. The electrical conductivity of the solution obtained shall then be measured. It shall be less than 250 µS/cm (to ISO 11127 Part 6) or nominally 250 µmho/cm (to ASTM D4940), although these two specifications are not entirely equivalent. The chloride contamination level of the abrasive shall be measured in accordance with ISO 11127 Part 7 or a proprietary chloride test kit for abrasives and shall not exceed 25 ppm. b) Presence of oil or water in compressed air used for blast cleaning . A piece of clean white absorbent paper or cloth shall be held at the air outlet at a suitably low operating pressure in accordance with ASTM D4285. There shall be no evidence of oil or water residues on the paper or cloth. c) Air pressure used for blast cleaning. Shall be measured at the blasting nozzle by inserting a hypodermic needle pressure gauge in the air line adjacent to the nozzle. The blast cleaning air pressure shall be100 psig m inimum at the nozzle. d) Standard of surface cleanliness produced. Shall be assessed on blast cleaned, power tool and mechanically cleaned surfaces by visual inspection using ISO Standard 8501 Part 1 or SSPC-Vis 1 or Vis 3. Blast cleaned surfaces shall be cleaned to ISO 8501-1 Sa 3/ SSPC SP5 standard except for atmospherically exposed surfaces for maintenance repainting, for which ISO 8501-1 Sa 2.5/SSPC SP10 standard cleanliness shall be accepted. Power tool and hand tool cleaned surfaces shall be cleaned to ISO 8501-1 St 3/ SSPC SP3/11 standard. e) Profile height of blast cleaned surfaces. Shall be measured using a suitable grade of Testex replica tape plus a portable m icrometer gauge or a suitable surface profile comparator gauge in accordance with NACE RP 0287 or ASTM D4417 Method C. The maximum peak to valley heights on the tested areas of the blast cleaned surfaces shall be within the range specified for t he Coating Schedule. f) Quantity and quality of residual dust and particulate matter on blast cleaned surfaces. Shall be assessed using transparent self-adhesive tape, a small pocket microscope and Standard ISO 8502 Part 3. The maximum acceptable size and quantity of retained particulate matter shall be Class 2 Rating 2. g) Presence of residual millscale on blast cleaned steel surfaces. (Subsidiary test which shall be carried out at the discretion of the QP Engineer). Shall be detected using a dropper bottle containing acidified copper sulphate solution. Discontinuities in the deposited copper layer indicate the presence of residual millscale. There shall be no evidence of residual millscale on the surfaces. The tested areas shall be dried and locally re-blast cleaned to remove the copper layer and any residual test solution. Doc. File No.: SPC.L.002.R2

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h)

i)

j)

Rev. 2

Presence of iron salts on stainless steel and non-ferrous metal, water abrasive blast cleaned and water jetted surfaces. (Subsidiary test which shall be carried out at the discretion of the QP Engineer). Shall be detected by applying test paper impregnated with potassium hexacyanoferrate (III) solution to the lightly wetted surfaces, as per Annex A of DD ENV ISO 8502 Part 1. The presence of iron salts is indicated by the test paper turning a bright blue colour. There shall be no discernible iron salt contamination of the surfaces. The tested areas shall be dried and locally re-blast cleaned to remove any residual surface chemical contamination. Presence of residual chlorides on blast cleaned surfaces. (Subsidiary test that shall be carried out at the discretion of the QP Engineer). Selected surface areas shall be conductometrically tested for soluble salts as detailed in Sub-clause 2 13.4.1.(e). The surface conductivity shall not exceed 40 µS/cm , which equates to a 2 2 chloride surface concentration of approximately 5 µg/cm (50 mg/m ), if chlorides are accepted as being the primary constituent of the soluble salts. Quantitative assessment of the surface chloride concentration, when required to confirm that the above level of chloride contamination has not been exceeded, shall be made either by titrimetric analysis in accordance with ISO 8502 Part 2 of a sample washing obtained as per ISO 8502 Part 6 or by the use of a proprietary chloride surface contamination test kit. The tested areas shall be locally rewashed, dried and reblast cleaned to remove any residual surface chemical contamination. Presence of residual oil or grease contamination on blast cleaned surfaces (Subsidiary test that shall be carried out at the discretion of the QP Engineer). Shall be tested with atomised water spray from a spray gun containing fresh water in accordance with ASTM F21. There shall be no evidence of oil or grease contamination. A clean dry rag shall subsequently be used to dry the m etal.

13.4.4 Prior to and During Paint & Wrapping Application a) Type, brand and condition of primer, adhesive, paint and wrapping tape used. The information marked on the labels of the primer, paint and tape containers, including batch numbers and expiry dates, shall be recorded and the product condition ascertained. The products shall be as per the relevant specification and colour and be within their expiry dates and the containers shall be in good condition. Samples may be taken at the discretion of the QP Engineer. b) Presence of rust on blast cleaned surfaces at time of primer application. Surfaces shall be carefully visually examined in good light, with all areas evenly illuminated to a level of not less than 500 lux daylight or artificial light. There shall be no evidence of visible rust blooming in any area. c) Time between blast cleaning and priming. Shall be established by recording and reviewing the time at which blast cleaning was started immediately before priming. All areas shall be primed within four hours of being blast cleaned but see also Clause 13.4.4.(b). d) Primer, undercoat and topcoat paint thickness and uniformity. Shall be measured by taking random wet film thickness measurements on each coat of paint immediately after application using a stainless steel comb or wheel gauge. Systematic dry film thickness measurements shall subsequently be taken on the paint film after each coat has dried using a QP approved model magnetic or eddy current dry film thickness gauge as a minimum in accordance with the measurement frequency requirements of SSPC-PA 2. For coatings containing MIO Doc. File No.: SPC.L.002.R2

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e)

Rev. 2

pigment, which can produce a magnetic response, confirmation of the dry film thickness measurements may be obtained by carrying out destructive testing of the same coating on a test panel. All coats shall also be visually inspected for defects and non-uniformities. The wet film thickness of each coat during paint application shall be sufficient to ensure that the specified dry film thickness will be applied to all surfaces. The average dry film thickness of each coat of paint shall meet or exceed the specified thickness in all areas, with only isolated local readings marginally below, but not less than 90% of, the specified thickness or exceeding 120% of that thickness. There shall be no visible defects or non-uniformities in any area. Over-coating periods for and condition of paints. Shall be established by recording the time at which each coat of paint was applied and relating this to the Paint Manufacturer‟s recommended over -coating period for the product at the prevailing metal temperature. Each coat of paint shall be over-coated within the recommended minimum to maximum over-coating period at the prevailing metal temperature. The surface of each coat of paint shall be smooth and free from visible overspray, non-uniformities and particulate matter or other contamination. The requirement for intermediate degreasing, washing or abrasion shall be recorded. Inorganic zinc silicate primer shall also be solvent rub tested with MEK in accordance with ASTM D4752, to ensure that it has fully cured prior to being overcoated. A solvent resistance rating of 4 to 5 shall be acceptable.

13.4.5 After Paint and Wrapping Application a) Thickness and uniformity of complete paint coating or wrapping. Shall be measured by carrying out a detailed systematic dry film thickness measurement survey on all areas using a QP approved model magnetic or eddy current dry film thickness gauge as a minimum in accordance with the measurement frequency requirements of SSPC-PA 2. For coatings containing MIO pigment, which can produce a magnetic response, confirmation of the dry film thickness measurements may be obtained by carrying out destructive testing of the same coating on a test panel. The average dry film thickness of the full paint system shall meet or exceed the specified coating thickness in all areas, with only isolated local readings marginally below, but not less than 90% of, the specified thickness or exceeding 120% of that thickness. There shall be no significant variations in coating thickness. Wrappings shall have a smooth, integrally jointed and uniform appearance, with a generous overlap of layers. b) Final appearance of paint film or wrapping. Shall be approved by careful visual inspection of the fully coated or wrapped surfaces, to ensure that they are free from runs, sags, orange peeling, fish eyes, overspray, dirt and grit entrapment, wrinkles, open joints and mechanical damage. There shall be no visible defects or nonuniformities in any area of the coating or wrapping, particularly at and around edges and corners, and the joints and edges in the wrapping shall be smoothly and fully bonded, with no evidence of local distress. c) Curing time for complete paint coating Shall be established by recording the time at which the topcoat paint was applied and relating this to the Paint Manufacturer‟s recommended full coating cure period at the prevailing metal temperature. Supplementary double rub or modified thumb cure tests using a suitable solvent and/or abrasion with emery paper may be carried out to confirm the degree of cure. The complete paint coating shall have been allowed to cure for at least the recommended period of time at the prevailing metal temperature before Doc. File No.: SPC.L.002.R2

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d)

e)

f)

13.5

Rev. 2

being handled. It shall show good resistance to mechanical and abrasion testing, with no evidence of softening during solvent rub testing. Presence of holidays in complete paint film or wrapping tape. Shall be carried out to ensure the continuity and integrity of a paint coating (lining) and/or wrapping. The requirement for this test shall depend upon the project specification and the nature of the component being coated or wrapped but comprehensive holiday detection testing shall be required for tank and vessel linings and buried or immersed coatings and wrappings. At the discretion of the QP Engineer, it may be carried out on any coated or wrapped component at random in a workshop or at site, if there is a concern about the coating continuity or integrity. Holidays shall be detected by carrying out testing in accordance with the methodology specified in NACE SP 0274 for pipeline coatings and wrappings, NACE SP 0490 for FBE coatings at field joints and NACE SP 0188 for other coatings and wrappings, using appropriate QP approved low or high voltage DC holiday detection equipment at a test voltage relative to the measured coating and/or wrapping thickness specified by the applicable NACE Standard, unless otherwise advised by the Paint or Wrapping Manufacturer, whose test requirements shall prevail. There shall be no evidence of holidays or areas of excessively low coating or wrapping thickness which cause the holiday detector to activate at the specified test voltage, after limited local repair of the coating and/or wrapping if necessary. Adhesion of coating. (Subsidiary test that shall be carried out at the discretion of the QP Engineer). Shall be measured on the dry paint film using a cemented dolly and a pull-off measurement device in accordance with ASTM D4541. The measured coating adhesion strengths shall be referred to the Paint Manufacturer 2 for approval against the product specification but shall not be less than 5N/mm (5MPa). Adhesion testing is not appropriate for coatings which require to be thermally cured during service in order to develop their full adhesive strength or for wrappings. Identification of areas for repair. Areas of the paint coating or wrapping that require repair shall be carefully identified on the components themselves and recorded in the reports so that these can readily be re-inspected during and upon completion of the repair work. The reasons why repairs are required shall also be recorded in the reports, together with full details of the repair work carried out.

INSPECTION EQUIPMENT REQUIREMENTS

13.5.1 The following inspection equipment shall, as a minimum, be supplied in good working order at each work site by the Contractor. a) A whirling or sling psychrometer and hydrometric tables. b) A contact thermometer with a suitable temperature range. c) A small spray gun containing potable or distilled water. d) White absorbent paper or cloth. e) A hypodermic needle pressure gauge of a suitable pressure range. f) Either a suitable grade of Testex tape plus a portable micrometer gauge or an approved surface profile comparator gauge. g) A roll of transparent self-adhesive tape and a pocket microscope. h) Sufficient stainless steel combs or wheel type wet film thickness gauges for all painters and inspectors. i) Several approved model magnetic or eddy current dry film thickness gauges with suitable shims. Doc. File No.: SPC.L.002.R2

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j)

ISO Standard 8501 Part 1 and/or SSPC Vis 1, ISO 8501 Part 3 and/or SSPC Vis 3, ISO 8502 Part 3, and ISO 4628 Part 3 and/or ASTM D610/SSPC Vis 2. 13.5.2 The following inspection equipment shall, as a minimum, be supplied by the Contractor if the contract or the QP Engineer requires them. a) Chloride titration chemicals or proprietary test kits for surfaces and abrasives. b) A small dropper bottle containing acidified copper sulphate solution. c) Test paper impregnated with potassium hexacyanoferrate(III) solution. d) Standard self-adhesive (e.g. Bresle) sample extraction patches. e) Electrical conductivity meter or proprietary salt contamination meter. f) An approved model high or low voltage D.C. holiday detector. g) A set of dollies, a tube of epoxy cement and a pull-off measuring device. Alternative specialised inspection equipment and materials may be provided for specific types of inspection and testing, subject to approval by the QP Engineer. 13.5.3 The dry film thickness gauges shall be calibrated using an insulating shim of similar thickness to that of the partial or complete paint film to be inspected held over a sample of the same material as that to be painted with a similar blast cleaned surface profile, in accordance with SSPC-PA 2. The calibration sample could be a plate of the substrate material blasted to a standard agreed with the QP Engineer. The gauges shall be calibrated at the start of the working day, at least twice during each shift when in use and when a change in the coating thickness range occurs.

13.5.4 Holiday Detection, when required by the project specification or at the direction of the QP Engineer to ensure the integrity of a paint coating or wrapping, shall be carried out using calibrated QP approved high and/or low voltage equipment that meets the requirements of the applicable NACE Standard. All appropriate safety guidelines and rules shall be followed when using this equipment.

14.0 QUALITY REQUIREMENTS 14.1

The Contractor shall be fully responsible for ensuring that all surface preparation, painting and wrapping work meets the relevant QP quality control (QC) standards, in addition to being carried out in a timely and professional manner and being fully and clearly reported. This will require him to use well trained and suitably skilled operators and supervisory staff and good quality, well maintained preparatory and application equipment and inspection tools.

14.2

The Contractor and his Sub-Contractors shall operate a Quality Management System meeting the requirements of the relevant parts of ISO 9001. Guidance on Contractor conformance with the requirements of ISO 9001 is given in QP Quality Requirements for Projects Standard QP-STD-Q-004.

14.3

Prior to placement of the contract, the Contractor and his Sub-Contractors shall demonstrate the compliance of their Quality Management System with QP requirements by submitting their Quality Assurance (QA) Manual for review and approval. As a minimum, the QA Manual shall contain:(a) A company profile and Quality Policy Statement. (b) A management structure organigram and details of individual managerial responsibilities. (c) A detailed list of all the activities carried out by the company with their interactions, preferably accompanied by a Flowchart.


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14.4 14.5

Rev. 2

(d) The Quality Control Plans for each activity from material purchasing and handling through to final inspection, testing and document control, including the treatment of non-conformances and corrective actions. (e) A Document Control System for the review and update of procedures and the retention of quality control records related to each contract. (f) Employee training and education system and records. (g) Auditing methods procedures, including incident/accident investigation. (h) Safety and environmental policy and assessment of each activity. The Contractor and his Sub-Contractors shall be subject to Audit by QP prior to placement of the contract and during the term of the contract, as deemed necessary. Prior to commencement of the work, the Contractor shall submit his Quality Inspection and Test Plan to the QP Engineer for review. This shall detail the individual preparation, painting and wrapping activities involved and the inspection and test methods that will be used to ensure that they are carried out to an acceptable standard. The Plan will generally be in tabular form and will indicate the type and level of inspection and testing that is required at each stage of the work. It should also contain references to verifying documents, acceptance criteria and personnel responsible for each activity. A typical Quality Inspection and Test Plan Checklist is shown as Table 3A.

14.6 All personnel involved in the preparation, painting and wrapping work and any SubContractor proposed for this work shall be formally approved by the QP Engineer, possibly as indicated in Sub-clause 6.5, before the work begins. 14.7 Prior to commencement of the work, a formal minuted Pre-start Meeting shall be held between the QP Engineer, Contract Administrator, relevant Contractor management and supervisory staff and the Contractor and QP Painting Inspectors. The full scope of the work required under the contract shall be discussed. All issues relating to the clarity or consistency of the surface preparation and/or painting and wrapping requirements detailed within the Tender documents and on relevant drawings shall be formally raised and clarified at this Meeting. This will enable the quality requirements for the work to be mutually agreed.

15.0 DOCUMENTATION 15.1 All correspondence, drawings, instructions, data sheets, design calculations and all other written information shall be in English language. In the case of dual languages, one language shall be English and the other Arabic. 15.2 All dimensions and measurements shall be in SI units, unless otherwise specified. 15.3 The Contractor shall provide QP with his fully detailed written work proposals, procedures, material data sheets, material test results and test certific ates. 15.4 The Contractor shall maintain a comprehensive recording and reporting system on all aspects of surface preparation, paint and wrapping application and Quality Control inspection and testing. This shall as a minimum meet all the requirements of this Specification and QP-STD-Q-004. A final report shall be submitted to QP, summarising all the work performed and the inspection and test results for approval. 15.5 All documents, from texts and specifications to data sheets and drawings, shall be provided with electronic files in the approved software of MS Word, Excel and Auto Cad. Design calculations shall also be submitted in the approved software system agreed with QP.


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Rev. 2

16.0 PROTECTIVE SYSTEM CLASSIFICATION BY AREA, SERVICE AND MATERIAL SCHEDULE NO. 1Un 1In 1F 2Un 2In 2F 3

DESCRIPTION OF AREA, SERVICE AND MATERIAL General Exposure to Atmosphere* – New Construction of Uninsulated Items General Exposure to Atmosphere* – New Construction of Insulated Items General Exposure to Atmosphere* – New Construction of Fireproofed Items General Exposure to Atmosphere* – Maintenance of Uninsulated Items General Exposure to Atmosphere* – Maintenance of Insulated Items General Exposure to Atmosphere* – Maintenance of Fireproofed Items Uninsulated Steel With a Design Temperature of 120-400 C 

3HT

Uninsulated Steel Items With a Design Temperature Above 400 C

4

Insulated Ferrous Items With a Design Temperature of 120-250 C

5

Items Exposure to Seawater and Seaspray in Splash Zone

6

Internal Surfaces of Steel Hydrocarbon and Water Storage Tanks

7

Underside of Steel Storage Tank Floor Plates





8A

Internal Vessel Surfaces in Lower Pressure and Temperature Corrosive Service

8B

Internal Vessel Surfaces in Higher Pressure and/or Temperature Corrosive Service

9

Zinc Coated Steel Surfaces

10

Helideck and Walkway Non-Skid Surfaces

11

Buried and Fully Immersed Pipelines (Field Joint Coating and Maintenance Painting)

12

Stainless Steel and Non-Ferrous Metal Surfaces

13

Self-Adhesive Tape Wrapping for Buried and Immersed Pipelines and Steelwork

* “Exposure to Atmosphere” means either fully exposed to the weather or only sheltered from direct sunlight and rain. Items located in fully enclosed conditions or inside air conditioned buildings are subject to less corrosive conditions and other coating systems may be considered. Doc. File No.: SPC.L.002.R2

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17.0 COATING AND WRAPPING SCHEDULES 17.1

The following 19 Coating and Wrapping Schedules are designed to cover all the types of equipment, exposure locations and conditions and constructional metals that are likely to be encountered in QP facilities.

17.2

The preparatory and painting or wrapping requirements are shown in sequential order and require to be fully followed. The only basis for a deviation from a Schedule requirement is by prior formal written agreement from the QP Engineer.

17.3 Attention is drawn to the Notes at the bottom of each Schedule, which should be consulted carefully before any paint is purchased or any work is planned or carried out.


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Rev. 2

COATING SCHEDULE 1Un (Revision 1) GENERAL EXPOSURE TO ATMOSPHERE – UNINSULATED NEWLY CONSTRUCTED ITEMS Uninsulated and non-fireproofed new structural steelwork and uninsulated external surfaces of new carbon steel tanks, vessels, towers, exchangers, heaters, pipework and pipelines located above ground (onshore) and above Splash Zone (offshore) with a design temperature of between 0 C and 120 C. 



SURFACE PRETREATMENT Remove all oil, grease and other contamination using a water-soluble degreasing agent, followed by thorough fresh water washing. SURFACE PREPARATION Blast clean to Sa 3 standard as per ISO 8501-1 plus Supplement using a suitably sized abrasive to give a surface profile amplitude of 50-75 microns. (See Clause 11.4) REPAIR OF DAMAG ED COATING Vacuum or spot blast clean to Sa 3 standard per ISO 8501-1 plus Supplement. Power tool cleaning to St 3 standard is only acceptable for small areas that are inaccessible or impractical for blast cleaning by agreement. Abrade with emery paper or lightly grind areas of partial coating damage. GENERIC CLASSIFICATION OF COATING PRIMER COAT

Two-component zinc-rich epoxy primer* MID COAT

1

High-build two-component polyamide-cured micaceous iron oxide (MIO)-pigmented epoxy** MID COA T

2***

High-build two-component polyamide-cured micaceous iron oxide (MIO)-pigmented epoxy** FINAL COAT

Two-component aliphatic polyurethane high gloss enamel APPLICATION OF COATING

MICRONS

PRIMER COAT

Apply zinc-rich epoxy primer by airless spray or brush MID COAT

50

@

100

@

100

@

50

=

300

1

Apply MIO-pigmented epoxy by airless spray or brush MID COA T

@

2***

Apply MIO-pigmented epoxy by airless spray or brush FINAL COAT

Apply aliphatic polyurethane enamel by airless spray or brush TOTAL DRY FILM THICKNESS***

NOTES : 1. * Zinc-rich epoxy primer shall contain a minimum of 90% metallic zinc by weight in the dry film. 2. ** The epoxy midcoat paint pigment shall contain a minimum of 80% lamellar MIO by weight. 3. *** Topside surface of tank floating roofs shall be painted with a third mid coat of epoxy paint (to give a total dry film thickness of 400 microns). 4. The coats of epoxy mid coat paint shall be tinted different colours to aid visual identification. 5. Unless otherwise authorized by the QP Engineer , the Paint Manufacturer‟s recommendations for paint application shall apply. Doc. File No.: SPC.L.002.R2

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COATING SCHEDULE 1In (Revision 1) GENERAL EXPOSURE TO ATMOSPHERE – INSULATED NEWLY CONSTRUCTED ITEMS Insulated newly constructed structural steelwork and insulated external surfaces of new carbon steel tanks, vessels, towers, exchangers, heaters, pipework and pipelines located above ground (onshore) and above the Splash Zone (offshore) with design temperature of between -46 C and 120 C. 



SURFACE PRETREATMENT Remove all oil, grease and other contamination using a water-soluble degreasing agent, followed by thorough fresh water washing. SURFACE PREPARATION Blast clean to Sa 3 standard as per ISO 8501-1 plus Supplement using a suitably sized abrasive to give a surface profile amplitude of 50-75 microns. (See Clause 11.4) REPAIR OF DAMAGED COA TING Vacuum or spot blast clean to Sa 3 standard per ISO 8501-1 plus Supplement. Power tool cleaning to St 3 standard is only acceptable for small areas that are inaccessible or impractical for blast cleaning by agreement. Abrade with emery paper or lightly grind areas of partial coating damage. GENERIC CLASSIFICATION OF COATING PRIMER COAT

Two-component zinc-rich epoxy primer* MID COAT

1

High-build two-component polyamide-cured micaceous iron oxide (MIO)-pigmented epoxy** MID COAT

2

High-build two-component polyamide-cured micaceous iron oxide (MIO)-pigmented epoxy** APPLICATION OF COATING

MICRONS

PRIMER COAT

Apply zinc-rich epoxy primer by airless spray or brush MID COAT

50

@

100

@

100

=

250

1

Apply MIO-pigmented epoxy by airless spray or brush MID COAT

@

2

Apply MIO-pigmented epoxy by airless spray or brush SS*** TOTAL DRY FILM THICKNE

NOTES : 1. * Zinc-rich epoxy primer shall contain a minimum of 90% metallic zinc by weight in the dry film. 2. ** The epoxy midcoat paint pigment shall contain a minimum of 80% lamellar MIO by weight. 3. *** Areas that protrude through the insulation also require a 50 micron thick coat of aliphatic polyurethane high gloss topcoat paint. 4. The coats of epoxy mid coat paint shall be tinted different colours to aid visual identification. 5. Unless otherwise authorized by the QP Engineer , the Paint Manufacturer‟s recommendations for paint application shall apply.


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Custodian Dept.: ST


Rev. 2

COATING SCHEDULE 1F (Revision 1) GENERAL EXPOSURE TO ATMOSPHERE – FIREPROOFED NEWLY CONSTRUCTED ITEMS Newly constructed structural steelwork and external surfaces of new carbon steel vessels, towers, exchangers, heaters, pipework and pipelines located above ground (onshore) and above the Splash Zone (offshore) with a design temperature of between -46 C and 120 C that are subsequently to be covered with a proprietary fire resistant coating material. 



SURFACE PRETREATMENT Remove all oil, grease and other contamination using a water-soluble degreasing agent, followed by thorough fresh water washing. SURFACE PREPARATION Blast clean to Sa 3 standard as per ISO 8501-1 plus Supplement using a suitably sized abrasive to give a surface profile amplitude of 35-50 microns. REPAIR OF DAMAGED COA TING (See Clause 11.4) Vacuum or spot blast clean to Sa 3 standard per ISO 8501-1 plus Supplement. Power tool cleaning to St 3 standard is only acceptable for small areas that are inaccessible or impractical for blast cleaning by agreement. Abrade with emery paper or lightly grind areas of partial coating damage. GENERIC CLASSIFICATION OF COATING BENEATH FIRE RESISTANCE COATING (Note 1*) PRIMER COAT

Two-component zinc phosphate-pigmented epoxy primer MID COAT

High-build two-component polyamide-cured micaceous iron oxide (MIO)-pigmented epoxy** APPLICATION OF COATING

MICRONS

PRIMER COAT

Apply zinc phosphate-pigmented epoxy primer by airless spray or brush

@

50

Apply MIO-pigmented epoxy by airless spray or brush

@

100

S TOTAL DRY FILM THICKNES

=

150

MID COAT

NOTES : 1. * An alternative proprietary protective system will require to be used where the coating manufacturer advises that the application of his specified fire resistant coating system will prejudice the fireproofing guarantee. In such situations, the manufacturer’s requirement shall be mandatory. 2. ** The epoxy midcoat paint pigment shall contain a minimum of 80% lamellar MIO by weight. 3. Areas that protrude through the fireproofing also require to be coated with a second 100 micron thick, differently tinted coat of the specified midcoat paint and 50 micron thick coat of aliphatic polyurethane high gloss topcoat paint. 4. Unless otherwise authorized by the QP Engineer , the Paint Manufacturer‟s recommendations for paint application shall apply.


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Custodian Dept.: ST


Rev. 2

COATING SCHEDULE 2Un (Revision 1) GENERAL EXPOSURE TO ATMOSPHERE - UNINSULATED EXISTING ITEMS MAINTENANCE Uninsulated and non-fireproofed existing structural steelwork and uninsulated external surfaces of existing carbon steel tanks, vessels, towers, exchangers, heaters and pipework located above the ground (onshore) and splash zone (offshore) with a design temperature of between 0 C and 120 C 



SURFACE PRETREATMENT Remove all oil, grease and other contamination using a water-soluble degreasing agent, followed by thorough fresh water washing. SURFACE PREPARATION Dependent upon condition of existing paintwork. 1. No visible coating breakdown Ri 0 (ASTM No 10) level (where overcoating for aesthetic or other reasons). Abrade pretreated surfaces with emery paper for good topcoat adhesion. 2. Partial or variable coating breakdown with primer intact or localised underrusting to no more than Ri 3 (ASTM No. 6) level. Locally blast clean degraded areas to Sa 2.5 standard as per ISO 8501-1 plus Supplement or, where blast cleaning is impractical, power tool clean to St 3 standard. At the QP Engineer’s discretion, fully blast clean the surfaces to Sa 2.5 standard. 3. More extensive coating breakdown to Ri 4 (ASTM No. 4) level or worse. Fully blast clean surfaces to Sa 2.5 standard per ISO 8501-1 plus Supplement. Power tool cleaning to St 3 standard is only acceptable for small areas and areas that are impractical for blast cleaning by agreement. Use a suitable blast cleaning abrasive to give a surface profile of 50-75 microns. GENERIC CLASSIFICATION OF COATING PRIMER COAT*

High-solids two-component polyamide-cured surface-tolerant epoxy primer MID COAT**

High- build two-component polyamide-cured micaceous iron oxide (MIO)-pigmented epoxy*** FINAL COAT

Two-component aliphatic polyurethane high gloss enamel APPLICATION OF COATING

MICRONS

PRIMER COAT

Apply surface-tolerant epoxy primer by brush (preferably) or airless spray*

@

125

@

125

@

50

=

300

MID COAT****

Apply MIO-pigmented epoxy by airless spray or brush ** FINAL COAT

Apply aliphatic polyurethane enamel by airless spray or brush TOTAL DRY FILM THICKNESS NOTES :

1..* Patch prime locally blast cleaned areas and fully prime fully blast cleaned surfaces. No priming is required for abraded surfaces. 2. ** Apply a full midcoat to surfaces after patch or full priming. 3. *** The epoxy midcoat paint pigment shall contain a minimum of 80% lamellar MIO by weight. 4. **** Topside surface of tank floating roofs shall be painted with second coat of mid coat paint (to give a total minimum dry film thickness of 400 microns). 5. Unless otherwise authorized by the QP Engineer, the Paint M anufacturer‟s recommendations for paint application shall apply.


Page 48 of 88

Custodian Dept.: ST


Rev. 2

COATING SCHEDULE 2In (Revision 1) GENERAL EXPOSURE TO ATMOSPHERE – INSULATED EXISTING ITEMS MAINTENANCE Insulated existing structural steelwork and insulated external surfaces of existing carbon steel tanks, vessels, towers, exchangers, heaters, pipework and pipelines located above ground (onshore) and above the Splash Zone (offshore) with a design temperature of between -46 C and 120 C. 



SURFACE PRETREATMENT Remove all oil, grease and other contamination using a water-soluble degreasing agent, followed by thorough fresh water washing. SURFACE PREPARATION Dependent upon condition of existing paintwork. 1. No visible coating breakdown Ri 0 (ASTM No. 10) level. No overcoating required. 2. Partial or variable coating breakdown with primer intact or localised underrusting to no more than Ri 3 (ASTM No. 6) level. Locally blast clean degraded areas to Sa 2.5 standard as per ISO 8501-1 plus Supplement or, where blast cleaning is impractical, power tool clean to St 3 standard. At the QP Engineer‟s discretion, fully blast clean the surfaces to Sa 2.5 standard. 3. More extensive coating breakdown to Ri 4 (ASTM No. 4) level or worse. Fully blast clean surfaces to Sa 2.5 standard per ISO 8501-1 plus Supplement. Power tool cleaning to St 3 standard is only acceptable for small areas and areas that are impractical for blast cleaning by agreement. Use a suitable blast cleaning abrasive to give a surface profile of 50-75 microns. GENERIC CLASSIFICATION OF COATING PRIMER COAT*

High-solids two-component polyamide-cured surface-tolerant epoxy primer MID COAT**

High-build two-component polyamide-cured micaceous iron oxide (MIO)-pigmented epoxy*** APPLICATION OF COATING

MICRONS

PRIMER COAT

Apply surface-tolerant epoxy primer by brush (preferably) or airless spray* MID COAT

@

125

@

125

=

250

1

Apply MIO-pigmented epoxy by airless spray or brush** TOTA L DRY FILM THICKNESS****

NOTES : 1. *.Patch prime locally blast cleaned areas and fully prime fully blast cleaned surfaces. No priming is required for abraded surfaces. 2. ** Apply a full midcoat to surfaces after patch or full priming. 3. *** The epoxy midcoat paint pigment shall contain a minimum of 80% lamellar MIO by weight 4. **** Areas that protrude through the insulation also require a 50 micron thick coat of aliphatic polyurethane high gloss topcoat paint. 5. Unless otherwise authorized by the QP Engineer , the Paint Manufacturer‟s recommendations for paint application shall apply.


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Custodian Dept.: ST


Rev. 2

COATING SCHEDULE 2F (Revision 1) GENERAL EXPOSURE TO ATMOSPHERE –FIREPROOFED EXISTING ITEMS MAINTENANCE Existing structural steelwork and external surfaces of existing carbon steel vessels, towers, exchangers, heaters, pipework and pipelines located above ground (onshore) and above the Splash Zone (offshore) with a design temperature of between 0 C and 120 C that are covered with a proprietary fire resistant coating material. 



SURFACE PRETREATMENT Remove all oil, grease and other contamination using a water-soluble degreasing agent, followed by thorough fresh water washing. SURFACE PREPARATION (AFTER REMOVALOF FIRE RESISTANT COATING) Dependent upon condition of existing paintwork. 1. No visible coating breakdown Ri 0 (ASTM No. 10) level. No overcoating required. 2. Partial or variable coating breakdown with primer intact or localised underrusting to no more than Ri 3 (ASTM No. 6) level. Locally blast clean degraded areas to Sa 2.5 standard as per ISO 8501-1 plus Supplement or, where blast cleaning is impractical, power tool clean to St 3 standard. At the QP Engineer‟s discretion, fully blast clean the surfaces to Sa 2.5 standard. 3. More extensive coating breakdown to Ri 4 (ASTM No. 4) level or worse. Fully blast clean surfaces to Sa 2.5 standard per ISO 8501-1 plus Supplement. Power tool cleaning to St 3 standard is only acceptable for small areas and areas that are impractical for blast cleaning by agreement. Use a suitable blast cleaning abrasive to give a surface profile of 35-50 microns. GENERIC CLASSIFICATION OF COATING BENEATH FIRE RESISTANT COATING (Note 1*) PRIMER COAT

High-solids two-component polyamide-cured surface-tolerant epoxy primer** APPLICATION OF COATING

MICRONS

PRIMER COAT

Apply surface-tolerant epoxy primer by brush (preferably) or airless spray TOTAL DRY FILM THICKNESS***

@

125

=

125

NOTES : 1. * An alternative proprietary protective maintenance coating will require to be used where the coating manufacturer considers that the application of his specified fire resistant coating system will prejudice the fireproofing guarantee. In such situations, the manufacturer’s requirement shall be mandatory. 2. ** Patch prime locally blast cleaned areas and fully prime fully blast cleaned surfaces. No priming is required for abraded surfaces. 3. *** Areas that protrude through the fireproofing also require to be coated with an additional 125 micron thick coat of MIO-pigmented epoxy midcoat paint plus a 50 micron thick coat of aliphatic polyurethane high gloss topcoat paint. 4. Unless otherwise authorized by the QP Engineer , the Paint Manufacturer‟s recommendations for paint application shall apply.


Page 50 of 88

Custodian Dept.: ST


Rev. 2

COATING SCHEDULE 3 (Revision 1) UNINSULATED STEEL ITEMS WITH A DESIGN TEMPERATURE OF 120 C TO 400 C External surfaces of uninsulated carbon steel tanks, vessels, towers, exchangers, heaters, pipework and associated structural steelwork operating at elevated design temperatures. SURFACE PRETREATMENT Remove all oil, grease and other contamination using a water-soluble degreasing agent, followed by thorough fresh water washing. SURFACE PREPARATION NEW CONSTRUCTION

Blast clean to Sa 3 standard as per ISO 8501-1 plus Supplement using a suitable abrasive to give a surface profile amplitude of 35-50 microns. Power tool cleaning is not acceptable for this system. (See Clause 11.4) REPAIR OF DAMAG ED COATING Vacuum or spot blast clean to Sa 3 standard as per ISO 8501-1 plus Supplement. MAINTENANCE

1. If the primer is intact, lightly blast clean or mechanically abrade to remove damaged topcoat paint and thoroughly fresh water wash using a stiff bristle brush to remove soluble zinc salts. 2. If the primer has suffered breakdown or a marked reduction in film thickness, blast clean affected areas to Sa 3 standard as per ISO 8501-1 plus Supplement using a suitable abrasive to give a surface profile of 35-50 microns. GENERIC CLASSIFICATION OF COATING * PRIMER COAT Ethyl-based two-component inorganic zinc silicate primer MID COAT

Acrylic modified silicone FINAL COAT

Acrylic modified silicone APPLICATION OF COATING

MICRONS

PRIMER COAT***

Apply zinc silicate primer by air or airless spray

@

50**

@

25

@

25

=

100

MID COAT

Apply silicone acrylic by air or airless spray FINAL COAT

Apply silicone acrylic by air or airless spray TOTAL DRY FILM THICKNESS

NOTES : 1. * Locally damaged areas of primer shall be repaired with a 50 micron thick brush-applied coat of a suitable high temperature resistant zinc-containing primer. 2. ** Zinc silicate coating thickness shall not exceed 75 microns at any point. 3. *** No primer is required if the intact coating requires to be overcoated for aesthetic reasons. 4. Unless otherwise authorized by the QP Engineer , the Paint Manufacturer‟s recommendations for paint application shall apply.


Page 51 of 88

Custodian Dept.: ST


Rev. 2

COATING SCHEDULE 3HT (Addition) UNINSULATED STEEL ITEMS OPERATING AT TEMPERATURES ABOVE 400 C External surfaces of uninsulated carbon steel equipment, pipework and structural steelwork, such as the upper sections of flare stacks, operating at or subject to high design temperatures. SURFACE PRETREATMENT Remove all oil, grease and other contamination using a water-soluble degreasing agent, followed by thorough fresh water washing. SURFACE PREPARATION NEW CONSTRUCTION

Blast clean to Sa 3 standard to ISO 8501-1 plus Supplement using a suitably sized abrasive to give surface profile amplitude of 75 - 100 microns. Power tool cleaning is not acceptable for this system. (See Clause 11.4) REPAIR OF DAMAGED COA TING Vacuum or spot blast clean to Sa 3 standard as per ISO 8501-1 plus Supplement. MAINTENANCE

1. If metal coating is intact, sweep blast clean and fresh water wash to remove aluminium salts. 2. If metal coating has suffered breakdown, blast clean affected areas to Sa 3 standard to ISO 8501-1 plus Supplement using a suitable abrasive to give a surface profile of 50-75 microns. GENERIC CLASSIFICATION OF COATING FIRST COA T

Sprayed aluminium metal SEALER COAT

Modified silicone FINAL COAT

Modified silicone SMALL COMPONENTS & MAINTENANCE COATING FOR DAMAGED METAL COATING***/**** High temperature silicone-based inert multi-polymeric matrix APPLICATION OF COATING

MICRONS

PRIMER COAT

Apply aluminium metal by thermal spray

@

200*

MID COAT

Apply modified silicone by air or airless spray

@

25**

@

25

FINAL COAT

Apply modified silicone by air or airless spray

250 SMALL COMPONENTS & MAINTENANCE COATING FOR DAMAGED METAL COATING***/**** Apply two coats of silicone-based inert multi-polymeric matrix by air or airless spray 2 @ 100 = 200 TOTAL DRY FILM THICKNESS

=

NOTES : 1. * Specified aluminium metal coating thickness shall be the minimum local coating thickness. 2. ** Sealer coat thickness will be difficult to measure on highly porous sprayed metal coating. 3. ***Small components impractical to aluminium coat shall be painted with inert multi-polymeric matrix paint. 4. *** If metal coating is intact, spray apply one thin coat of modified silicone paint @ 25 microns. 5. Unless otherwise authorized, Coating Manufacturer‟s application recommendations shall apply . Doc. File No.: SPC.L.002.R2

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Custodian Dept.: ST


Rev. 2

COATING SCHEDULE 4 (Revision 1) INSULATED FERROUS ITEMS WITH A DESIGN TEMPERATURE OF 120 C TO 250 C External surfaces of insulated carbon and stainless steel tanks, vessels, towers, exchangers, heaters, pipework and structural steelwork operating continuously at elevated design temperatures SURFACE PRETREATMENT Remove all oil, grease and other contamination using a water-soluble degreasing agent, followed by thorough fresh water washing.

SURFACE PREPARATION NEW CONSTRUCTION

Blast clean to Sa 3 standard as per ISO 8501-1 and Supplement using a suitably sized abrasive to produce a surface profile amplitude of 35-50 microns. REPAIR OF DAMAGED COA TING (See Clause 11.4)

Vacuum or spot blast clean to Sa 3 standard as per ISO 8501-1 and Supplement. Power tool cleaning to St 3 standard is only acceptable by agreement for areas that are impractical for blast cleaning. Abrade with emery paper or lightly grind areas of partial coating damage. MAINTENANCE

1. No visible coating breakdown Ri 0 (ASTM No. 10) level. No overcoating required. 2. Partial or variable coating breakdown with localised underrusting to no more than Ri 3 (ASTM No.6) level. Locally blast clean degraded areas to Sa 2.5 standard*** or, the QP Engineer‟s discretion, fully blast clean the surfaces to Sa 2.5 standard***. 3. More extensive coating breakdown to Ri 4 (ASTM No. 4) level or worse. Fully blast clean surfaces to Sa 2.5 standard per ISO 8501-1 plus Supplement using a suitable blast cleaning abrasive to give a surface profile of 35-50 microns. Power tool cleaning to St 3 standard is only acceptable for small areas and areas that are impractical for blast cleaning by agreement. GENERIC CLASSIFICATION OF COATING*/** PRIMER COAT High-temperature resistant aluminium-pigmented oleo-resinous**** FINAL COAT

High-temperature resistant aluminium-pigmented oleo-resinous**** APPLICATION OF COATING

MICRONS

PRIMER COAT

Apply aluminium-pigmented oleo-resinous by air or airless spray

@

50*****

@

50*****

FINAL COAT

Apply aluminium-pigmented oleo-resinous by air or airless spray

=

TOTAL DRY FILM THICKNESS

100

NOTES : 1. * Insulated carbon and stainless steel surfaces that will be operating continuously at temperatures over 250 C do not require to be painted, unless specified in the Contract or requested by the QP Engineer. 2. ** Insulated surfaces of equipment that is only designed to operate infrequently at temperatures over 250 C shall be prepared and painted as per t his Schedule. 3. *** A suitable non-metallic and low chloride abrasive shall be used for blast cleaning stainless steel items. 4. **** Written assurance shall be obtained from the Paint Manufacturer that the paint product offered will fully and rapidly cure at ambient temperatures and that it has acceptable high temperature resistance for the design operating temperatures. 5. ***** Two thinly spray applied coats are generally required to obtain the required DFT and promote rapid paint film curing. 6. Unless otherwise authorized, Paint Manufacturer‟s application recommendations shall apply.


Page 53 of 88

Custodian Dept.: ST


Rev. 2

COATING SCHEDULE 5 (Revision 1) ITEMS EXPOSED TO SEAWATER & SEASPRAY IN THE SPLASH ZONE Areas of steel structures and pipework subject to partial immersion in seawater and seaspray in the Splash Zone, such as offshore platforms, boat landings and jetties and pump house structures and cranes in seawater intake and discharge areas ( but excluding riser lines). SURFACE PRETREATMENT Remove all oil, grease and other contamination using a water-soluble degreasing agent, followed by thorough fresh water washing. SURFACE PREPARATION NEW CONSTRUCTION

Blast clean to Sa 3 standard as per ISO 8501-1 plus Supplement using a suitably sized abrasive to give a surface profile amplitude of 75-100 microns. (See Clause 11.4) REPAIR OF DAMAGED COA TING Vacuum or spot blast clean to ISO 8501-1 plus Supplement using a suitably sized abrasive to give a surface profile amplitude of 75-100 microns. Power tool cleaning is not acceptable for even local repair of this coating system when fully cured. Sweep blast cleaning may be used by agreement. MAINTENANCE

Unless no visible coating breakdown is evident, blast clean the surfaces to Sa 2.5 standard as per ISO 8501-1 plus Supplement using a suitably sized abrasive to give a surface profile amplitude of 75-100 microns. Power tool cleaning is not acceptable for this Schedule. GENERIC CLASSIFICATION OF COATING PRIMER COAT Two-component high solids glassflake-reinforced polyamine-cured epoxy FINAL COA T***/****

Two-component high-solids glassflake-reinforced polyamine-cured epoxy APPLICATION OF COATING

MICRONS

PRIMER COAT

Apply glassflake-reinforced epoxy by airless spray* ** FINAL COAT Apply glassflake-reinforced epoxy by airless spray* TOTAL DRY FILM THICKNESS

@

500

@

500

=

1000

NOTES : 1. * Brush application shall be used for stripe painting and touch-up areas. 2. ** More than two coats may be required to achieve the required total dry film thickness. 3. *** Splash zone handrails and intake/discharge structures and cranes shall also be painted with at least one topcoat of suitably colour coded compatible polyurethane topcoat paint. 4. Full coating shall be confirmed as free of pinholes by holiday detection testing when practicable 5. Unless otherwise authorized by the QP Engineer , the Paint Manufacturer‟s recommendations for paint application shall apply.


Page 54 of 88

Custodian Dept.: ST


Rev. 2

COATING SCHEDULE 6 (Revision 1) INTERNAL SURFACES OF STEEL HYDROCARBON & WATER STORAGE TANKS Topside floor surface of hydrocarbon and water tanks, bottom and top 1.8m of internal shell surface of hydrocarbon tanks, including curb angle and peripheral metre wide band of underside roof surface of cone roof tanks, and full internal shell and underside roof surface of water tanks . SURFACE PRETREATMENT Remove all oil, grease and other contamination using a water-soluble degreasing agent, followed by low pressure fresh water washing. SURFACE PREPARATION NEW CONSTRUCTION

Blast clean to Sa 3 standard as per ISO 8501-1 plus Supplement using a suitably sized abrasive to give a surface profile of 75-100 microns. REPAIR OF DAMAGED COA TING (See Clause 11.4) Vacuum or spot blast clean to ISO 8501-1 plus Supplement using a suitably sized abrasive to give a surface profile amplitude of 75-100 microns. Power tool cleaning to St 3 standard is only acceptable by agreement for areas that are inaccessible or impractical for blast cleaning. MAINTENANCE

Unless no visible coating breakdown is evident, blast clean the surfaces to Sa 2.5 standard as per ISO 8501-1 plus Supplement using a suitably sized abrasive to give a surface profile amplitude of 75-100 microns. Power tool cleaning to St 3 is only acceptable for small and inaccessible areas. GENERIC CLASSIFICATION OF COATING * PRIMER COAT Two-component high-build solvent-free polyamide-cured epoxy**/*** FINAL COAT

Two-component high-build solvent-free polyamide-cured epoxy**/*** APPLICATION OF COATING

MICRONS

PRIMER COAT

Apply solvent-free epoxy by airless spray

@

300

@

300

=

600

FINAL COAT

Apply solvent-free epoxy by airless spray TOTAL DRY FILM THICKNESS

NOTES: 1. Relative humidity inside tanks shall not exceed 60% during blast cleaning and painting (Appendix C). 2. Final removal of abrasive and dust from inside tanks shall be carried out using a vacuum cleaner. 3. * Epoxy primer shall be used on power tool cleaned areas and may by agreement be used as a holding primer on blast cleaned surfaces, subject to provision of data confirming compatibility with the epoxy paint 4. ** Non-tainting “food grade” epoxy paint with Health Certification is required inside potable water tanks 5. *** Alternative pigmented epoxy coatings may be used for all services and epoxy phenolic coatings may be considered for non-potable water and certain n on-crude hydrocarbon services subject to satisfactory QP approval. 6. Full coating shall be subject to high voltage holiday detection to ensure there are no pinholes. 7. Cathodic protection system may be installed in water tanks, and in crude tanks when specified contractually, but the applied coating system shall be resistant to cathodic disbondment. 8. Unless otherwise authorized by the QP Engineer , the Paint Manufacturer‟s recommendations for paint application and curing, including the provision of adequate ventilation, shall apply.


Page 55 of 88

Custodian Dept.: ST


Rev. 2

COATING SCHEDULE 7 (Revision 1) UNDERSIDE SURFACE OF STEEL STORAGE TANK FLOOR PLATES Underside surface of steel storage tank floor plates prior to laying and welded fabrication. SURFACE PRETREATMENT Remove all oil, grease and other contamination using a water-soluble degreasing agent, followed by thorough fresh water washing. SURFACE PREPARATION NEW CONSTRUCTION

Blast clean to Sa 3 standard as per ISO 8501-1 plus Supplement using a suitably sized abrasive to give a surface profile amplitude of 75-100 microns. REPAIR OF DAMAGED COA TING (See Clause 11.4) Vacuum or spot blast clean to ISO 8501-1 plus Supplement using a suitably sized abrasive to give a surface profile amplitude of 75-100 microns. GENERIC CLASSIFICATION OF COATING PRIMER COAT *

Two-component polyamide-cured surface-tolerant epoxy primer FINAL COAT

Two-component polyamide-cured surface-tolerant epoxy primer APPLICATION OF COATING

MICRONS

PRIMER COAT

Apply surface-tolerant epoxy primer by airless spray**

@

200

@

200

=

400

FINAL COAT

Apply surface-tolerant epoxy primer by airless spray** TOTAL DRY FILM THICKNESS

NOTES : 1. * Epoxy holding primer may by agreement be used for the short term protection of blast cleaned surfaces, subject to provision of data confirming compatibility with the subsequent epoxy paint.

2. ** Brush application for patch repair of damaged areas of coating only. 3. A cathodic protection system shall be installed beneath the tank floor to protect the underside surface against soilside corrosion in areas of coating damage due to welding / paint breakdown. 4. Specified coating system shall be confirmed as being resistant to cathodic disbondment. 5. Unless otherwise authorized by the QP Engineer , the Paint Manufacturer‟s recommendations for paint application shall apply.


Page 56 of 88

Custodian Dept.: ST


Rev. 2

COATING SCHEDULE 8A (Addition) INTERNAL SURFACES OF VESSELS IN CORROSIVE SERVICE AT LOW PRESSURE/TEMP. Internal lining of vessels and exchangers for service at design pressures up to 15 barg and temperatures up to 70 C that are subject to corrosive process chemicals. 

SURFACE PRETREATMENT Remove all oil, grease and other contamination using a water-soluble degreasing agent, followed by low pressure fresh water washing. SURFACE PREPARATION NEW CONSTRUCTION

Blast clean to Sa 3 standard as per ISO 8501-1 plus Supplement using a suitably sized abrasive to give a surface profile of 75-100 microns and remove all abrasive and dust by vacuum cleaner. REPAIR OF DAMAGED COA TING (See Clause 11.4) Vacuum or spot blast clean to ISO 8501-1 plus Supplement using a suitably sized abrasive to give a surface profile amplitude of 75-100 microns. Power tool cleaning is not acceptable for even local repair of this coating. Abrade partially damaged coatings with emery paper and solvent wipe them. MAINTENANCE

Unless no visible coating breakdown is evident, blast clean the surfaces to Sa 3 standard as per ISO 8501-1 plus Supplement using a suitably sized abrasive to give a surface profile amplitude of 75-100 microns. Power tool cleaning is not acceptable for this Schedule. GENERIC CLASSIFICATION OF COATING PRIMER COAT

Two component high-build solvent-free modified epoxy or vinyl ester*/** FINAL COAT

Two component high-build solvent-free modified epoxy or vinyl ester*/** APPLICATION OF COATING *** PRIMER COAT Apply solvent-free modified epoxy or vinyl ester by airless spray**** *** FINAL COAT Apply solvent-free modified epoxy or vinyl ester by airless spray**** ***** TOTAL DRY FILM THICKNESS

MICRONS @

300-500

@

300-500

=

600-1,000

NOTES :

1. * Assurance shall be obtained from Paint Manufacturer that the specified coating has proven resistance to all process chemicals under stated design temperature and pressure conditions. 2. ** Use of ceramic/ glass flake filler is advantageous for increased strength and rigidity. 3. *** One or more coats of paint may be required to achieve the required DFT. 4. **** Coating repairs shall be carried out by brush application. 5. ***** Total coating DFT could vary from 600 to 1,000 microns, depending upon product used. 6. The full coating shall be confirmed to be free from pinholes by H.V. holiday detection testing. 7. Relative humidity in vessel shall not exceed 60% during blast cleaning & painting (Appendix C) 8. Coating schedule shall ensure full curing with good ventilation before it is put into service. 9. Unless otherwise authorized by the QP Engineer , the Paint Manufacturer‟s recommendations for paint application and curing, including the provision of adequate ventilation, shall apply. Doc. File No.: SPC.L.002.R2

Page 57 of 88

Custodian Dept.: ST


Rev. 2

COATING SCHEDULE 8B (Addition) INTERNAL SURFACES OF VESSELS IN CORROSIVE SERVICE AT HIGH PRESSURE / TEMP. Internal lining of vessels and exchangers for service at design pressures in excess of 15 barg and/or temperatures above 70 C that are subject to corrosive process chemicals. 

SURFACE PRETREATMENT Remove all oil, grease and other contamination using a water-soluble degreasing agent, followed by low pressure fresh water washing. SURFACE PREPARATION NEW CONSTRUCTION

Blast clean to Sa 3 standard as per ISO 8501-1 plus Supplement using a suitably sized abrasive to give a surface profile of 75-100 microns and remove all abrasive and dust by vacuum cleaner. REPAIR OF DAMAGED COA TING (See Clause 11.4) Vacuum or spot blast clean to ISO 8501-1 plus Supplement using a suitably sized abrasive to give a surface profile amplitude of 75-100 microns. Power tool cleaning is not acceptable for even local repair of this coating. Abrade partially damaged coatings with emery paper and solvent wipe them. MAINTENANCE

Unless no visible coating breakdown is evident, blast clean the surfaces to Sa 3 standard as per ISO 8501-1 plus Supplement using a suitably sized abrasive to give a surface profile amplitude of 75-100 microns. Power tool cleaning is not acceptable for this Schedule . GENERIC CLASSIFICATION OF COATING PRIMER COAT

Two component high-build solvent-free modified epoxy*/** FINAL COAT

Two component high-build solvent-free modified epoxy*/** APPLICATION OF COATING *** PRIMER COAT Apply solvent-free modified epoxy by airless spray**** *** FINAL COAT Apply solvent-free modified epoxy by airless spray**** TOTAL DRY FILM THICKNESS

MICRONS @

300-500

@

300-500

=

600-1,000

NOTES :

1. * Assurance shall be obtained from Paint Manufacturer that the specified coating has proven resistance to all process chemicals under stated design temperature and pressure conditions plus demonstrable resistance to explosive decompression from the maximum stated pressure. 2. ** Use of ceramic/ glass flake filler is advantageous for increased strength and rigidity. 3. *** One or more coats of paint may be required to achieve the required DFT. 4. **** Coating repairs shall be carried out by brush application, 5. The full coating shall be confirmed to be free from pinholes by H.V. holiday detection testing. 6. Relative humidity in vessel shall not exceed 60% during blast cleaning & painting. (Appendix C) 7. Coating schedule shall ensure full curing with good ventilation before it is put into service. 8. Unless otherwise authorized by the QP Engineer , the Paint Manufacturer‟s recommendations for paint application and curing, including the provision of adequate ventilation, shall apply. Doc. File No.: SPC.L.002.R2

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Rev. 2

COATING SCHEDULE 9 (Revision 1) ZINC COATED STEEL SURFACES New and weathered galvanized and zinc spray coated (to structural steelwork, pipework, ladders, handrails, fencing and other components*/**/*** SURFACE PRETREATMENT Remove all oil, grease and other contamination using a water-soluble degreasing agent, followed by thorough fresh water washing. SURFACE PREPARATION NEW CONSTRUCTION

Remove soluble zinc corrosion products by scrubbing with a stiff bristle brush during fresh water washing. At QP Engineer‟s discretion, lightly roughen the surface by sweep blast cleaning using a fine abrasive or, if pretreatment primer is to be applied, abrade with emery paper. REPAIR OF DAMAGED COA TING (See Clause 11.4) If zinc is intact, remove soluble zinc corrosion products by scrubbing with a stiff bristle brush during fresh water washing. If rusting of the steel is evident, remove the rust by lightly abrading affected areas with emery cloth before scrubbing with a stiff bristle brush during fresh water washing. MAINTENANCE

As for Repair of Damaged Coating but lightly sweep blast clean rusted areas to Sa 2.5 standard. GENERIC CLASSIFICATION OF COATING ****/***** PRIMER COAT High-solids two-component polyamide-cured surface-tolerant epoxy primer****** FINAL COAT

Two-component aliphatic polyurethane enamel APPLICATION OF COATING

MICRONS

PRIMER COAT

Apply surface-tolerant epoxy primer by airless spray or brush

@

125

@

50

=

175

FINAL COAT

Apply aliphatic polyurethane enamel by airless spray or brush **** TOTAL DRY FILM THICKNESS

NOTES : 1. * Zinc coated components shall be galvanized to ISO 1461 and sprayed to BS EN ISO 2063. 2. ** Galvanised steel open mesh grating and treads shall not be painted for safety reasons. 3. *** For the requirement for zinc coated components to be painted, refer to Clause 8.3. 4. **** Locally damaged areas of the zinc coating shall be repaired with a 50 micron thick brush-applied coat of zinc-rich epoxy primer containing 90% minimum of zinc by weight in the dry film and a full coat of this primer may be applied if zinc coating is in poor, partly consumed condition. 5. ***** Polyvinyl butyral etch primer or acid mordant solution shall be applied thinly as a pretreatment, if surfaces are not sweep blast cleaned or if specified by the Paint Manufacturer. 6. ***** Written assurance shall be obtained from the Paint Manufacturer that the primer used is suitable for direct application to freshly galvanized steel surfaces, even if sweep blast cleaned. 7. Unless otherwise authorized by the QP Engineer , the Paint Manufacturer‟s recommendations for paint application shall apply.


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Rev. 2

COATING SCHEDULE 10 (Revision 1) HELIDECK & WALKWAY NON-SKID SURFACES Helidecks, chequer plate walkway surfaces, including escape routes, and lay down areas. SURFACE PRETREATMENT Remove all oil, grease and other contamination using a water-soluble degreasing agent, followed by low pressure fresh water washing. SURFACE PREPARATION NEW CONSTRUCTION

Blast clean to Sa 3 standard as per ISO 8501-1 plus Supplement using a suitably sized abrasive to give a surface profile amplitude of 75-100 microns. REPAIR OF DA MAGED COATING (See Clause 11.4)

Vacuum or spot blast clean to ISO 8501-1 plus Supplement using a suitably sized abrasive to give a surface profile amplitude of 75-100 microns. Power tool cleaning to St 3 standard is only acceptable by agreement for areas that are inaccessible or impractical for blast cleaning. MAINTENANCE

Blast clean areas of coating breakdown or, at QP Engineer‟s discretion, fully blast clean surfaces to Sa 2.5 standard as per ISO 8501-1 plus Supplement using a suitably sized abrasive to give a surface profile of 75-100 microns. Power tool cleaning to St 3 is only acceptable for small areas. GENERIC CLASSIFICATION OF COATING * PRIMER COAT Two-component high-build solvent-free epoxy coating incorporating aggregate particles ** **** FINAL SEAL COAT Two-component high-build solvent-free epoxy (if recommended by Manufacturer) APPLICATION OF COATING

MICRONS

PRIMER COAT

Apply solvent-free epoxy plus aggregate by airless spray***

@

1500

@

300

=

1800

FINAL SEAL COAT

Apply solvent-free epoxy by airless spray**** ****/***** TOTAL DRY FILM THICKNESS

NOTES : 1. * Epoxy primer shall be used on power tool cleaned areas and may by agreement be used on blast cleaned surfaces, subject to provision of data confirming compatibility with the epoxy paint. 2. ** Aggregate particles shall be 0.4-1.5mm (average 1.0mm) diameter aggregate for helidecks and 0.21.2mm (average 0.8mm) diameter aggregate particles for walkways. 3. *** Aggregate shall be pre-mixed into the paint used for helidecks prior to application. 4. **** Coating thickness will depend upon density and size of aggregate used, as specified by Manufacturer, with seal coat thickness being the minimum to fully seal aggregate particles. 5. ***** Helideck markings to CAP437 shall be made with brush-applied aliphatic polyurethane topcoat paint, applied over the epoxy seal coat. 6. Full helideck coating shall be confirmed as free from pinholes by H.V. holiday detection 7. Unless otherwise authorized by the QP Engineer , the Paint Manufacturer‟s recommendations for paint application, based on adequacy of coating properties for the service, shall apply


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Rev. 2

COATING SCHEDULE 11 (Revision 1) BURIED/FULLY IMMERSED PIPELINES (FIELD JOINT COATING/MAINTENANCE PAINTING) Pipelines buried or fully immersed in seawater but not subsea pipelines (see QP-SPC-L-004) SURFACE PRETREATMENT Remove all oil, grease and other contamination by primary factory degreasing, followed by controlled furnace preheating in a production line. SURFACE PREPARATION NEW CONSTRUCTION (FACTORY COA TING)

Blast clean to Sa 2.5 standard* as per ISO 8501-1 plus Supplement under controlled factory production conditions using a suitably sized abrasive to give a surface profile of 75-100 microns. REPAIR OF DAMAGED COA TING AND WEL DED JOINTS

Vacuum or spot blast clean to Sa 3 standard as per ISO 8501-1 plus Supplement using a suitably sized abrasive to give a surface profile amplitude of 75-100 microns. Power tool cleaning to St 3 standard is not acceptable for this coating system . MAINTENANCE

When pipeline is accessible for maintenance, blast clean areas of coating breakdown or, at QP Engineer‟s discretion, fully blast clean all accessible surfaces to Sa 2.5 standard as per ISO 85011 plus Supplement using a suitably sized abrasive to g ive a surface profile of 75-100 microns. GENERIC CLASSIFICATION OF COATING PRIMER/FINAL COAT (FACTORY COA TING A ND OPTIONAL FIELD TOPCOA T)***

Fusion-bonded epoxy powder** JOINT/REPAIR/MA INTENANCE COATING (FIELD COA TING)

Field-applied fusion-bonded epoxy powder OR Two-component cold-curing high-build solvent-free amine adduct-cured epoxy APPLICATION OF COATING

MICRONS

*** PRIMER/FINAL COAT (FACTORY COATING) Apply fusion-bonded epoxy by electrostatic spray and thermally cure (at factory)

@

550

FIELD JOINTS

Apply fusion-bonded epoxy by electrostatic spray and thermally cure on site**** OR Apply compatible cold-curing high-build solvent-free epoxy by airless spray***** @

550

REPAIR/MAINTENANCE COA T

Apply compatible cold-curing high-build solvent-free epoxy by trowel/airless spray @ *** = TOTAL DRY FILM THICKNESS

550 550

NOTES :

1. * Sa 2.5 standard is the highest preparatory standard guaranteed for factory blast cleaning. 2. ** Epoxy powder / factory-applied F.B.E. coating shall meet requirements of QP-SPC-L-005. 3. *** 50 micron thick aliphatic polyurethane topcoat is required for above-ground pipe sections down to a minimum depth of 300mm below grade. 4. **** Field-applied, thermally-cured F.B.E. coating shall meet requirements of QP-SPC-L-006. 5. ***** Use of shrink wrapped polyethylene or polypropylene sleeves , applied to QP-SPC-L-007, may also be considered for field joints, subject to field trials on the product and Contractor. 6. Full coating shall be subjected to a high voltage holiday detection test prior to factory dispatch and after pipeline fabrication to ensure it is free from pinholes. A maximum of five site coating repairs per pipe section shall be permitted 7. F.B.E. Coating QC and test reports shall be approved prior to acceptance of the coated pipe. 8. Concrete weight coating may be applied to submerged pipe sections to counteract buoyancy.


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Rev. 2

COATING SCHEDULE 12 (Revision 1) STAINLESS STEEL AND NON-FERROUS METAL SURFACES Uninsulated and insulated stainless steel, aluminium, copper and nickel alloy pipework, vessels and components with a design temperature of up to 120 C. 

SURFACE PRETREATMENT Remove all oil, grease and other contamination using a water-soluble degreasing agent, followed by thorough fresh water washing.

SURFACE PREPARATION NEW CONSTRUCTION Blast clean to “white metal” finish (equivalent to Sa 3 s tandard as per ISO 8501-1) using suitably sized nonmetallic and low chloride abrasive to give a surface profile amplitude of 35-50 microns.* REPAIR OF DA MAGED COATING (See Clause 11.4)

Vacuum or spot blast clean to “white metal” finish (equivalent to Sa 3 standard as per ISO 8501-1) using suitably sized non-metallic abrasive to give a surface profile of 35-50 microns.* Power tool cleaning to “white metal” is only acceptable by agreement for impractical areas to blast clean.** MAINTENANCE Dependent upon condition of existing paintwork. 1. If no visible paint breakdown, abrade surfaces with emery paper for good paint adhesion. 2. For patch or variable paint breakdown, locally blast clean degraded areas to “white metal” or, a t the QP Engineer‟s discretion, fully blast clean the surfaces with a suitable abrasive as for new. 3. For extensive paint breakdown, fully blast clean the surfaces to “white metal” as for new. Power tool cleaning with suitable tools is only acceptable by agreement for small isolated areas.

GENERIC CLASSIFICATION OF COATING PRIMER COAT

Two-component zinc-free polyamide-cured epoxy primer MID COAT

High build two-component polyamide-cured micaceous iron oxide (MIO)-pigmented epoxy***/***** **** FINAL COAT Two-component aliphatic polyurethane high gloss enamel APPLICATION OF COATING

MICRONS

PRIMER COAT

Apply zinc-free epoxy primer by brush or airless spray

@

50

@

125

@

50

=

225

MID COAT

Apply MIO-pigmented epoxy by brush or airless spray FINAL COAT

Apply aliphatic polyurethane enamel by brush or airless spray TOTAL DRY FILM THICKNESS NOTES :

1. * For copper alloys, a fine, round shaped abrasive shall be used to avoid surface distortion and expansion. 2. ** Power cleaning tools shall be constructed from the same metal as that being cleaned. 3. *** The epoxy midcoat paint pigment shall contain a minimum of 80% lamellar MIO by weight. 4. **** No topcoat is required for insulated components other than at protruding areas. 5. ***** Alternative use of a125 micron thick epoxy phenolic midcoat may be considered for insulated stainless steel items. 6. Requirement to paint non-pressurised stainle ss steel and nickel alloy items and all aluminium and copper alloy items (such as for colour coding) shall be stated in the Contract. 7. Unless otherwise authorized, Paint Manufacturer‟s application recommendations shall apply


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Rev. 2

COATING SCHEDULE 13 (Revision 1) SELF-ADHESIVE TAPE WRAPPING FOR BURIED AND IMMERSED PIPELINES/STEELWORK Buried vessels and pipelines with design temperatures up to 70 C and steelwork buried (including crossings), immersed in water or subject to seaspray but not subsea pipelines (QP-SPC-L-004). 

SURFACE PRETREATMENT Remove all oil, grease and other contamination using a water-soluble degreasing agent, followed by thorough fresh water washing. SURFACE PREPARATION (See Clause 12.2) NEW CONSTRUCTION

Preparation and painting prior to tape primer or adhesive application as follows. For splash zone conditions, blast clean to Sa 3 standard per ISO 8501-1 and spray apply one coat of Schedule 5 high-solids glassflake-reinforced polyamine-cured epoxy paint to 500 microns DFT. For buried and fully immersed conditions, blast clean to Sa 3 standard per ISO 8501-1 and spray apply one coat of Schedule 11 cold-curing high-build solvent-free amine adduct-cured epoxy Maintenance paint to 300 microns DFT. MECHANICAL REPAIR (See Clause 12.4)

Remove damaged or defective tape and primer/adhesive from affected areas or, for extensive damage, whole component, roughen underlying paint, re-prime and rewrap with good overlap. MAINTENANCE

When items are accessible for maintenance, remove defective tape and primer/adhesive, blast clean areas of paint breakdown as Schedule 11 Maintenance and patch/fully repaint, re-prime and rewrap. GENERIC CLASSIFICATION OF WRAPPING SYSTEM WRAPPING PRIMER COAT*

Rubber or asphaltic/heavy hydrocarbon primer/adhesive. TAPE WRAPPING **/***

Heavy-duty PVC-backed wrapping tape. APPLICATION OF PRIMER AND WRAPPING WRAPPING PRIMER COAT (where requ ired)

Apply rubber or asphaltic/heavy hydrocarbon primer/adhesive by brush or spray. TAPE WRAPPING

Apply heavy-duty PVC-backed wrapping tape by hand or machine to give smooth uniform profile. NOTES : 1. * Some Tape Manufacturers do not require a primer for application of their tape to painted s urfaces 2. ** Above-ground sections of tape wrapped pipelines and steelwork that will be exposed to sunlight down to a depth of 300mm below grade shall be overwrapped with an approved U.V.-resistant outer wrapping 3. *** Buried sections of wrapped pipelines shall be protected against stone and mechanical damage during burial using a physically tough grade of tape. A protective wrapping sleeve may also be applied. 4. Pipework installed in culverts and covered trenches, which is vulnerable to inadvertent water immersion and/or soil burial, shall be coated and wrapped as per this Schedule unless FBE coated. 5. Tape shall be applied to give a smooth uniform profile with 55% minimum tape layer overlap. 6. Prior to and after application of the wrapping tape , the paint coating shall be subjected to a low or high voltage holiday detection test, to ensure the absence of pinholes. 7. Concrete weight coating may also be applied to subsea pipework to counteract buoyancy. 8. Unless otherwise authorized , Tape Manufacturer‟s application and testing recommendations shall apply


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Rev. 2

18.0 COLOUR CODING & IDENTIFICATION SCHEDULES 18.1

The finishing colours of the paint coatings that are to be applied to the various items of equipment and facilities shall be in accordance with those specified in the Colour Coding Schemes given in Tables 6 to 9 and Appendix D. The use or acceptance of different colours to those specified for various items of equipment is subject to the QP Engineer‟s approval.

18.2

The colours used for intermediate coats of paint shall be based upon the Paint Manufacturer‟s recommendations. Wher e a multi-coat paint system is specified, it is desirable for different intermediate coats to be tinted to sufficiently contrasting colours to distinguish between and identify the individual coats during paint application and inspection (see Sub-clause 11.3.3). However, the colour contrasts should not be so great as to make it difficult to completely obliterate the previous coat.

18.3

Where environmental considerations make it necessary to select an alternative colour to that recommended, this should be agreed in writing with the QP Engineer prior to commencement of the work.


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19.0

APPENDICES

19.1

APPENDIX A: TABLES

Rev. 2

19.1.1 The following Tables should be read in conjunction with sections of text and Schedules to which they relate. 19.1.2 The International Standards referenced in the Tables should also be consulted, where further clarification of the Table contents is required. 19.1.3 Particular attention should be paid to the Notes accompanying many of the Tables.

TABLE 1A. CORRESPONDING DEGREES OF PAINT RUSTING STANDARDS BASIC DESCRIPTION No visible rusting of coating Localised rusting of 0.05% of coated surface area Localised rusting of 0.5% of coated surface area Marked localised rusting of 1% of surface area Widespread localised rusting of 10% surface area Extensive rusting of up to 50% of surface area

ISO 4628-3 EURO SCALE ASTM D610 Ri 0 Ri 1 Ri 2 Ri 3 Ri 4*** Ri 5

Re 0 Re 1 Re 2 Re 3 Re 5 Re 7

No. 10 No. 8* No. 7** No. 6 No. 4 No. 1

NOTES: 1. European Scale of Rusting is the same as SIS 18 51 11 2. ASTM D610 Standards have been adopted by SSPC Standard Vis 2 3. *No.8 Standard actually specifies 0.03% to 0.1% of coated surface area rusted 4. **No. 7 Standard actually specifies 0.1% to 0.3% of coated surface area rusted 5. ***Ri 4 Standard actually specifies 8% of coated surface area rusted

TABLE 2A. CORRESPONDING SURFACE PREPARATION STANDARDS BASIC DESCRIPTION

ISO 8501-1

Solvent cleaning Thorough hand and power tool cleaning Very thorough power tool cleaning Light or brush-off blast cleaning Thorough or commercial blast cleaning Very thorough or near white metal blast cleaning Visually clean or white metal blast cleaning Pickling to white metal Clean to bare substrate water jetting Very thorough water jetting Thorough water jetting Light water jetting

St 2 St 3 Sa 1 Sa 2 Sa 2.5 Sa 3

SSPC SP 1 SP 2 SP 3/11 SP 7 SP 6 SP 10 SP 5 SP 8 SP 12 WJ-1 SP 12 WJ-2 SP 12 WJ-3 SP 12 WJ-4

NACE

No. 4 No. 3 No. 2 No. 1 No. 5 WJ-1 No. 5 WJ-2 No. 5 WJ-3 No. 5 WJ-4

NOTES: 1. ISO 8501 Part 1 is the same as BS 7079 Part A1 and SIS 05 59 00 2. SSPC and NACE Standards are given in Steel Structures Painting Manual, Volume 2 Doc. File No.: SPC.L.002.R2

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Rev. 2

TABLE 3A. TYPICAL PAINTING AND WRAPPING QUALITY INSPECTION AND TEST PLAN CHECKLIST This Checklist assumes that the painting and wrapping will be carried out by a Sub-Contractor. If it is carried out by the Contractor, the “Sub-Contractor” Actions shall be carried out by the Contractor.

(SUB) CONTRACTOR WORK LOCATION PROJECT TITLE CONTRACT NO. ITM.

COATING SCHEDULE DOCUMENT REF. NO. EQUIPMENT DATE

DESCRIPTION OF ITEM

INSPECTION REQ’D

ACTIONS BY S/CON

COMMENT

CON QP/TPI

A THROUGHOUT WORKING DAY 1 2

Safety/condition of equipment/machinery Visual inspection Correct PPE is worn by all personnel Visual inspection

H H

H H

W W

3 4

Atmospheric relative humidity/dewpoint Metal surface temperature

I I

W/R W/R

M/R M/R

H H

H H

R R

Psychrometer/record Contact therm./record

B BEFORE PREPARATORY CLEANING 1 2

Work mthds./QC system/safety measures Document prep/review Permit to work in order and authorised Document prep/review

3 4

Control/inspection instruments/calibration Coating Release Note for components 5 Presence of surface-breaking defects 6 Defects found are satisfactorily removed 7 Presence of gross surface contamination 8 Rust grade/degree of coating breakdown 9 Brand of degreasing agent/type of water 10 Presence of residual oil or grease 11 Presence of residual chlorides* 12 Type, brand & grade of abrasive used

Visual/record inspection Document prep/review Visual inspection/record Visual inspection/record Visual inspection/record Visual inspection/record Visual inspection/record Water spray test/record Salt contam. meter/recrd Visual inspection/record

H H I I I I I I I I

H H R W/R R W/R R R R W/R

W/R W/R R M/R R M/R R R R M/R

13 Agreement for power/hand tool cleaning

Document review

H

R

R

C DURING PREPARATORY CLEANING 1

Batch number & date of abrasive used

Visual inspection/record

I

W/R

M/R

2 3

Presence of oil/water in compressed air Air pressure used for blast cleaning

Exhaust air test/record Needle gauge/record

I I

R W/R

R R

4 5 6 7 8 9 10 11 12

Blast cleaning surface cleaning standard Profile height of blast cleaned surfaces Residual dust and matter on surfaces Type/condition of power/hand tools used Standard of power/hand tool cleanliness Presence of residual millscale* Presence of iron salts* Presence of residual chlorides* Presence of residual oil or grease*

Visual vs. Stds./record Replica tape/record Tape,microscope/record Visual inspection/record Visual vs. Stds./record Co. sulphate test/record Cyanoferrate test/record Salt contam. meter/recrd Water spray test/record

H H I H H I I I I

H/W H/W W/R W/R H/W R R R R

W/R W/R R M/R W/R R R R R


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Rev. 2

TABLE 3A. TYPICAL PAINTING AND WRAPPING Q. I. & T. PLAN CHECKLIST (CON.) D DURING AND AFTER PAINT AND WRAPPING TAPE APPLICATION 1 2 3

Types, brands, dates, condition of paints Paint storage conditions Paint mixing procedure & control

Visual inspection/record Visual inspection Visual inspection

I I I

W/R W W

M/R W M

4 5 6

Rust present on blast cleaned surfaces Time between blast cleaning & priming Paint application technique & quality

Visual inspection/record Establish interval/record Visual inspection

I I I

R R W

M/R R M

Stripe priming of edges, corners, crevices Full primer coat thickness Primer profile & appearance Time between primer & first midcoat First midcoat & stripe thickness First midcoat & stripe profile/appearance Time between first & second midcoat

Visual inspection/record Wet/dry film tkns./record Visual inspection/record Establish interval/record Wet/dry film tkns./record Visual inspection/record Establish interval/record

I H H I I I I

W/R H/W H/W R W/R W/R R

M/R W/R W/R R M/R M/R R

14 Second midcoat & stripe thickness Wet/dry film tkns./record 15 Second midcoat /stripe profile/appearance Visual inspection/record 16 Time between second midcoat & topcoat Establish interval/record

I I I

W/R W/R R

M/R M/R R

17 Complete paint coating thickness Wet/dry film tkns./record 18 Complete paint coating profile/appearance Visual inspection/record

H H

H/W H/W

W/R W/R

19 Time between final midcoat/tape adhesive Establish interval/record 20 Adhesive/primer thickness Wet/dry film tkns./record 21 Adhesive/primer profile & appearance Visual inspection/record

I H I

R H/W W/R

R W/R M/R

22 23 24 25 26 27 28 29 30 31

I H H I H H I H H H

R H/W H/W R H/W H/W W/R H/W R H

R W/R W/R R W/R W/R M/R W/R R W/R

7 8 9 10 11 12 13

Time between adhesive & tape wrapping Complete paint and wrapping thickness Wrapping profile & appearance Final curing time for coating system Presence of holidays in coating/wrapping Adhesion of coating &/or wrapping* Identification of areas for repair Coating/wrapping appearance after repair Complete QIT form & associated docs. Delivery Release Note

KEY: * I R M W H

Establish interval/record Dry film tkns./record Visual inspection/record Establish interval/record L/H voltage test/record Dolly pull-off test/record Mark repair areas/record Visual inspection Full inspection records Final inspct./doc. review

Subsidiary inspection test to be carried out at discretion of Corporation's Engineer Inspection item to be carried out where operation involved forms part of Contract workscope Inspection reports and records to be fully reviewed and approved Inspection activity to be randomly monitored against records and acceptance criteria Inspection activity to be witnessed and approved Mandatory Hold Point in schedule beyond which work shall not proceed without formal approval SUB-CONTRACTOR

CONTRACTOR

Q.P. / T.P.I.

Signature Name Position Date Doc. File No.: SPC.L.002.R2

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Rev. 2

TABLE 4A. TYPICAL PAINTING AND WRAPPING DAILY INSPECTION REPORT (SUB) CONTRACTOR PROJECT TITLE SPECIFICATION & REV. COATING SCHEDULE WORK LOCATION

CONTRACT NO. DOCUMENT REF. NO. ITP & REV./TDR’S ITEMS COATED DATE

WEATHER CONDITIONS Time Rel. Humidity (%) Dewpoint ( C) Metal Temp. ( C) SURFACE CONDITION AND DEGREASING Original Status Coated Metal Condition Defect-free Metal Rust Grade A Coating Breakdown Ri 0 Contamination Heavy Degreasing Agent …………………….

(Circle as necessary) Wrapped Bare Laminated Ground B C Ri 3 Ri 4 Light Degreased Swabbed Sprayed

Rejected D Ri 5 Water Washed Water Tested

SURFACE PREPARATION (Circle as necessary) Method Dry Blasting Sweep Blasting Wet Blasting Power Tool Hand Tool Abrasive Used Type………………. Brand………………. Batch No…………... Size Range……….. Prep. Standard Sa 3 Sa 2.5 Sa 2 St 3 Other…………. Profile Ht. (um) 35-50 50-75 75-100 Range………... Using…………. Residual Matter Class………… Rating………. Other Tests Millscale …..…Yes/No Chlorides…..…. Yes/No Iron Salts…..….Yes/No PAINT AND WRAPPING TAPE APPLICATION (Circle as necessary) Method Airless Spray Air Spray Brush Trowel Other…………. When Priming Time Since Cleaning………………….. Visible Surface Rusting…..……….Yes/No Product Details Product Colour Base Additive Overcoat WFT Range DFT Range Batch No. Batch No. Period (um) (um) Stripe Coat Primer First Midcoat Second Midcoat Topcoat Tape Adhesive Wrapping Tape FINAL TESTING AND REPAIR (Circle as necessary) Thickness/Appearance DFT - Accept/Reject Appearance - Accept/Reject Holiday Detection Test LV/HV Tester ………… Test Voltage…………….. Pass/Fail Coating Adhesion Test Adhesion Tester……… Pull Off Stress…………… Accept/Reject Repaired Areas % of Total Area……….. Primary Locations………. Rejected Because………. GENERAL COMMENTS: SUB-CONTRACTOR

CONTRACTOR

Q.P. / T.P.I.


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Rev. 2

TABLE 5A. TYPICAL PAINTING AND WRAPPING CLOSE OUT INSPECTION REPORT (SUB) CONTRACTOR PROJECT TITLE SPECIFICATION & REV. COATING SCHEDULE WORK LOCATION

CONTRACT NO. DOCUMENT REF.NO. ITP & REV./TDR’S EQUIPMENT COATED CLOSE OUT DATE

ITEM COATED SURFACE PREPARATION Abrasive Brand / Size Other Cleaning Cleaning Standard Profile Height Date

PAINTING First Coat Product DFT / Colour Date Second Coat Product DFT / Colour Date Third Coat Product DFT / Colour Date Fourth Coat Product DFT / Colour Date

WRAPPING Adhesive Product DFT Date Wrapping Tape Date

TESTING AND REPAIRS Holiday Test Voltage Adhesion Test Repaired Areas (%)

GENERAL COMMENTS

SUB-CONTRACTOR

CONTRACTOR

Q.P. / T.P.I.


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Rev. 2

TABLE 6A. COLOUR CODING SCHEME FOR EQUIPMENT

ITEM Structural steelwork, fences & pipe supports Facility gates Marine platforms from lower deck to 15 feet below M.S.L. Painted platform floors & decks (steel & exposed concrete)*

COLOUR

BS 4800 REF. NO

Light grey or white*

10-A-03 or 00-E-55

Golden yellow Black Light grey

08-E-51 00-E-53 10-A-03

Helidecks** Dark grey Helideck guards & markings Light grey Platform accommodation, living spaces, stores & workrooms Light grey Stairways & walkways forming escape routes Canary yellow Other stairways & walkways Light grey Galvanised vertical ladders & handrails Canary yellow Overhead obstructions, travelling cranes & crash barriers Yellow with black stripes Storage tanks, pressure vessels, towers & exchangers, including skirts & saddles*** Light grey or white* Pipework, process valves & fittings Service related (Appx. D) Pumps, compressors, generators & drivers Electrical & mechanical equipment & instrumentation, including control panels & supports Insulation when not clad with aluminium or st. steel sheet Safety valves (SRV, PRV & TRV) & overpres. protn. devices Dangerous exposed machinery Fire fighting installations & equipment First aid equipment QP Logo Hazards & fire & safety systems & signs Industrial gas cylinders

18-B-25 10-A-03 10-A-03 10-E-53 10-A-03 10-E-53 08-E-51 & 00-E-53 10-A-03 or 00-E-55

Light grey or white*

10-A-03 or 00-E-55

Light grey or manf. finish

10-A-03

Light grey Navy blue

10-A-03 20-D-45

Signal red Signal red Grass green

04-E-53 04-E-53 14-C-39

Emerald green/navy blue Type related (Table 8A) Product related (Table9A)

14-E-51 & 20-D-45

NOTES: 1. * The same colour shall used for all the components within a particular plant or facility. 2. ** Components to be finished with a non-skid topcoat. 3. *** Colour coding in the form of banding per BS 1710 may be used on the exterior surface of tanks and vessels for content identification purposes. Where used, the identification bands and colours shall be the same as those used for pipework identification (see Appendix D). The QP Engineer shall advise whether such colour coding is required for particular tanks and vessels. 4. The Tag or Identification No. shall be stencil painted in black upper case Arial font letters of minimum size 100mm width by 100mm height and minimum spacing of 30mm on a readily visible area of the external surface of tanks, vessels, other equipment and structures and the base plate of pumps, compressors and motors. Requirements of Clauses D9.1, D11.1 and D11.2 shall apply.

TABLE 7A. COLOUR CODING SCHEME FOR PIPEWORK, VALVES AND FITTINGS The Pipework and Valve Colour Coding Scheme previously detailed in Table 7 has been superceded by the Pipework Colour Coding and Identification System, colour coding combinations and marking arrangements detailed in Appendix D. Table 7A has therefore been deleted in its entirety. Doc. File No.: SPC.L.002.R2

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Rev. 2

TABLE 8A. COLOUR CODING SCHEME FOR HAZARDS AND FIRE / SAFETY SIGNS HAZARD OR SIGN Safety Attention Danger Mandatory Alert Electrical equipment Moveable hazards Traffic lines

COLOUR

BS 4800 REF. NO.

Grass green

14-C-39

Golden yellow Signal red Cobalt blue

08-E-51 04-E-53 18-E-53

Canary yellow Orange Golden yellow and black stripes White

10-E-53 06-E-51 08-E-51 & 00-E-53 00-E-55

NOTE: All hazards and fire and safety signs shall have a gloss finish.

TABLE 9A. COLOUR CODING SCHEME FOR INDUSTRIAL GAS CYLINDERS NAME / FORMULA OF GAS

Acetylene (C2H2) Air (no formula) Ammonia (NH3)

BASE COLOUR COLOUR BS 4800 REF. Maroon Light grey Black

RAL 3009* 10-A-03 00-E-53

Carbon monoxide (CO) Chlorine (Cl2) Coal gas (C2H2CH4)

Navy blue Black, alumin. or white Signal red Golden yellow Signal red

Ethyl chloride (C2H3Cl) Ethylene (C2H4) Helium (He2) Hydrogen (H2) Nitrogen (N2)

Argon (Ar) Carbon dioxide (CO2)

Oxygen (O2) Phosgene (COCl2) Propane (Commercial) (C3H8) Sulphur dioxide (SO2)

BAND COLOUR COLOUR BS 4800 REF.

20-D-45 00-E-53 00-E-55 04-E-53 08-E-51 04-E-53

None None Signal red Golden yellow None White None Golden yellow None Orange

N/A N/A 04-E-53 08-E-51 N/A 00-E-55 N/A 08-E-51 N/A RAL 2002*

Light grey Dark violet Mid brown

10-A-03 22-C-37 08-C-37

Signal red Signal red None

04-E-53 04-E-53 N/A

Signal red Light grey

04-E-53 10-A-03

None Black

N/A 00-E-53

Black Black

00-E-53 00-E-53

None Navy blue Golden yellow

N/A 20-D-45 08-E-51

Signal red Pale green

04-E-53 14-C-35

Mid brown Golden yellow

08-C-37 08-E-51

NOTES: 1. * Colour coding to B.S. 381C. 2. All gas cylinders shall have a gloss finish.


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Rev. 2

TABLE 10A. RESPIRATORY PERSONNEL PROTECTIVE EQUIPMENT EQUIPMENT

OPERATION OR HAZARD BLAST CLEANING

Air-fed blasting helmet*/** Air-fed hood* Breathing apparatus Air-fed mask(pos pres)* Air line (constant flow)* Lt./wt. dust respirator Twin filter respirator Lt./wt. disposable mask

PAINT SPRAYING

TOXIC DUST

NONTOXIC DUST

CONFINED SPACES

X X X X

X

X

X X X

X X X X

NOTES: 1. * Air to be supplied from a remote compressor via a line fitted with a carbon monoxide detector 2. ** Blasting helmets shall be certified as meeting the requirements of BS EN 271 and CE marked

TABLE 11A. EYE AND FACE PERSONAL PROTECTIVE EQUIPMENT EQUIPMENT


WATER JETTING

X

X X

Air-fed blasting helmet*/** Fibre glass hood Full view safety goggles Swing-back face shield Clip-on face shield

X X

GRINDING X X X X

METAL SPRAYING

NONTOXIC DUST

X X X X

NOTES: 1. * Air to be supplied from a remote compressor. 2. ** Blasting helmets shall be certified as meeting the requirements of BS EN 271 and CE marked 3. Sweat bands shall be worn inside vessels after blast cleaning, to minimize sweat contamination of the blast cleaned surfaces prior to and during paint application.

TABLE 12A. FOOT AND BODY PERSONAL PROTECTIVE EQUIPMENT EQUIPMENT


WATER JETTING

GRINDING

X X

X

X

Coveralls Leather apron Cloth gloves Rubber gauntlets Chrm. leather gauntlets Rubber thigh boots Rubber ankle boots Leather boots

HANDLING PAINT TINS/BAGS SPRAYING X

X X

X X

X

X

X X X

X

X

NOTES: 1. Rubber ankle boots shall be worn on slippery surfaces, irrespective of the work carried out. 2. Elasticated soft disposable overshoes shall be worn for vessel entry after the internal vessel surfaces have been blast cleaned. Doc. File No.: SPC.L.002.R2

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19.2

Rev. 2

APPENDIX B: FIGURES

FIGURE 1B ZONES OF OFFSHORE STRUCTURES FOR CORROSION PROTECTION


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19.3

Rev. 2

APPENDIX C: MINIMUM FORCED VENTILATION REQUIREMENTS FOR ENCLOSED SPACES DURING PAINT APPLICATION AND CURING This requirement shall be applicable to all enclosed spaces, including tanks and vessels, during paint application and throughout the coating curing period. To avoid fires and explosions, the flammable vapour concentration must be maintained below the lower explosive limit (L.E.L.). As a guide, the required level of ventilation can be calculated using the following formula. N = Q X 125 V where

N = Number of air renewals per hour Q = Quantity (average) of paint applied in litres per hour V = Volume of enclosed space in cubic metres

EXAMPLE A 1000 cubic metre capacity tank is being lined with a paint that is being applied at an average rate of 1.5 litres per minute. N = 1.5 (litres) x 60 (minutes) x 125 1000 (cubic metres) = 11.25 The minimum level of air ventilation should therefore be 11.25 air changes per hour. NOTES: 1. The ventilation requirements and efficiency are affected by such variables as the types of fans and/or eductors used and the presence of dead spaces. It is therefore often advisable to request that an explosivity meter test is carried out. 2. Even when ventilation meeting the above requirements is provided, it is still possible for a fire or explosion to occur if the air flow to the actual paint spraying areas is insufficient. It is therefore advisable to eliminate all possible sources of ignition in addition to providing the required level of forced ventilation. 3. In addition to maintaining the flammable vapour concentration below the L.E.L., the air ventilation equipment used for tanks and vessels shall be adequate to maintain the relativity humidity of the air inside them below 60% during both blast cleaning and paint application and curing. This will generally require the use of suitably sized industrial dehumidifiers for the inlet air supply.


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19.4

Rev. 2

APPENDIX D: COLOUR CODING AND IDENTIFICATION SYSTEM FOR PIPEWORK, VALVES AND VALVE ACCESS MANHOLE COVERS TABLE OF CONTENTS

Page No. D1

OBJECTIVE

76

D2

INTRODUCTION

76

D3

COLOUR CODE IDENTIFICATION BAND SYSTEM

76

D4

PRIMARY IDENTIFICATION BAND COLOURS

77

D5

SECONDARY IDENTIFICATION BAND COLOURS

77

D6

PIPEWORK COLOUR CODE IDENTIFICATION BAND SIZE AND LOCATION

77

D7

VALVES AND VALVE ACCESS MANHOLE COVERS

78

D8

CONTENT IDENTIFICATION AND HAZARD LABELS

79

D9

LINE NUMBERING SYSTEM

79

D10

LETTERING AND FLOW DIRECTION ARROW SIZE

80

D11

PAINT SPECIFICATION

80

TABLE D1. PRIMARY IDENTIFICATION COLOURS TABLE D2. COLOUR CODE IDENTIFICATIONS FOR PIPEWORK

82 83

FIGURE D1. PIPEWORK COLOUR CODING BAND LAYOUT FIGURE D2. VALVE COLOUR CODING LAYOUT FIGURE D3. VALVE ACCESS MANHOLE COVER COLOUR CODE LAYOUT

84 84 85-88


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D1

Rev. 2

OBJECTIVE The objective of this Appendix is to specify a Colour Coding and Identification System for Pipework, Valves and Manhole Covers, which specifies the mandatory colours that shall be adopted for all QP and Joint Venture Facilities for the identification of the contents of the pipework, valves and valve manholes and the number of each line. The system is intended to address fire and safety concerns within all on-plot and off-plot facilities and provide clear line identification for plant operators, inspectors, maintenance staff and other parties.

D2

INTRODUCTION Pipework is the essential means by which liquids, gases, steam and air are conveyed from one location to another within a facility and between facilities. It is not, however, possible to establish the contents of pipework or a pipeline from its external appearance. As the number and complexity of pipework installations within any facility increase, so does the need for a system to clearly and reliably identify the pipework or pipeline contents and the individual line numbers. Failure to correctly identify the service and number of a line or its valves can cause safety incidents and even lead to plant upsets. Hence, in line with the QP Corporate Fire and Safety Philosophy and to avoid such safety incidents and unnecessary plant upsets, it is required that all pipework, valves and valve access manholes shall be clearly colour coded and labelled, in accordance with this identification system.

D3

COLOUR CODE IDENTIFICATION BAND SYSTEM

D3.1

FOR PIPEWORK SYSTEMS BELOW 2" NPS DIAMETER AND FIREWATER PIPEWORK OF ALL SIZES, the topcoat paint over the whole external surface shall be in Primary Identification Band Colour specified in Table 1D.

D3.2

FOR PIPEWORK SYSTEMS 2” NPS DIAMETER AND LARGER IN SIZE, the topcoat paint along the entire length of the external surface shall be coloured light grey to BS 4800 Code Reference Number 10-A-03 or white to BS 4800 Code Reference Number 00-E-55. This shall be referred to as the Decorative Colour.

D3.3

The nature of the pipe contents shall be identified by means of a Three Band Colour Code Identification Band System (CCIB), as specified in BS 1710. The outer bands, which shall be in the same colour, are the Primary Identification Bands (PIB) and the central band is the Secondary Identification Band (SIB). The band arrangement shall be as shown in Figure 1D.

D3.4

The colour of the Primary Identification Band (PIB) shall identify the type of fluid, e.g. Oil, Gas, Chemical or Water, conveyed. BS 1710 suggests Primary Identification Colours for different types of fluid. These colour conventions have with a few e xceptions been adopted, as detailed in Clause D4.2 and Table 1D.

D3.5

The colour of the Secondary Identification Band (SIB) added to the middle of the PIB shall identify the fluid conveyed more specifically. The combination of the SIB in conjunction with the PIB is designed to provide a unique Colour Code Identification Band (CCIB) for each fluid that is being conveyed. These colour combinations are shown in Table 2D.


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D3.6

All PIB and SIB Colours used shall comply with the appropriate BS4800 Colour Code Reference Numbers that have been specified in Tables 1D and 2D. Colour names are given for guidance only.

D3.7

The PIB and SIB width requirements for all pipe sizes over 6” dia meter and narrower band width requirements for pipe sizes between 2“ and 6” diameter shall be as specified in Clauses D6.3 and D6.4, respectively. Where required for pipe below 2” diameter and for fire fighting pipework of all sizes, the SIB width requirement shall be as specified in Clause D6.5.

D3.8

The locations at which CCIB‟s are required on pipework shall be as detailed in Clauses D6.6 and 6.7.

D4

PRIMARY IDENTIFICATION BAND COLOURS

D4.1

The Primary Identification Band (PIB) colour shall identify the basic type of fluid conveyed.

D4.2

BS 1710 specifies blue as the PIB colour for air, green for water, brown for oils, ochre for gases, purple for acids and alkalis, silver grey for steam, black for drainage systems and red for fire fighting systems. These colour conventions have been adopted apart from that for steam pipework, which is generally insulated and fitted with silver coloured metal cladding. Crimson red has therefore been specified for this service. An additional basic colour of orange has also been added for treatment chemicals. The complete PIB colour list, with BS 4800 colour reference numbers, is shown in Table 1D.

D5

SECONDARY IDENTIFICATION BAND COLOURS

D5.1

BS1710 does not specify SIB colours for all fluids. It only provides limited details of a SIB System. There are so many possible fluid identification requirements for different types of facility that it would in reality be impossible to specify SIB colours that would satisfy all BS1710 user requirements. The User Authority is required to allocate a specific SIB colour, to provide the unique CCIB for each fluid in its facilities.

D5.2

It has therefore been necessary to allocate a specific SIB colour for each individual fluid within a fluid type or PIB, so as to provide a unique CCIB combination for that fluid.

D5.3

The complete Colour Code Identification List, as allocated to date, is shown in Table 2D but the system is sufficiently flexible that further SIB colours can be added to each PIB colour as necessary, to enable additional fluids to be identified in future.

D6

PIPEWORK COLOUR CODE IDENTIFICATION BAND SIZE AND LOCATION

D6.1 All CCIB‟s shall be applied over the full pipework paint system, which shall be in accordance with the relevant Coating Schedule of QP-SPC-L-002 for the appropriate exposure environment, service temperature and constructional material. D6.2

Pipework 2" diameter and larger, other than Fire Fighting System pipework, shall be painted a Decorative Topcoat colour of light grey or white along its entire length and provided with a suitable number of CCIB‟s for the conveyed fluid of the following dimensions at the following locations.


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QP SPECIFICATION FOR PAINTING & WRAPPING OF METAL SURFACES (NEW CONSTRUCTION AND MAINTENANCE) Doc. No.: QP-SPC- L-002 D6.3

Rev. 2

The widths of the PIB‟s and the SIB shall be similar for all pipe sizes over 6” diameter but narrower band widths shall be used for pipe sizes from 2 ” to 6” diameter. The band widths shall be as follows. Pipe Diameter 2” to 6” inclusive Greater than 6”

Each Primary Band 75 mm 150 mm

Secondary Band 50 mm 100 mm

Complete CCIB 200mm 400mm

D6.4

From Table 2D, it can be seen that certain fluids both the PIB‟s and the SIB have been allocated the same colour. For these fluids, the pipework shall be painted with a single colour band of the full CCIB width, i.e. 400mm wide for pipework over 6” diameter and 200mm wide for 2” to 6” diameter pipework.

D6.5

Pipework below 2” diameter in size and Fire Fighting System pipework of all sizes shall be painted a Decorative Topcoat colour corresponding to the PIB colour listed in Table 1D along its entire length. For specific fluid identification for such pipework, only a 100mm wide band of the appropriate SIB colour, where required, shall be applied as required.

D6.6

CCIB‟s shall be provided on both sides of and adjacent to valves, tees, important fittings, wall entries, perimeter fences, road crossings (including culverts) and overpasses and outboard of flanges to and from equipment such as vessels, tanks, exchangers, compressors and pumps.

D6.7

CCIB‟s shall be provided at uniform intervals of not less than 30m or more than 50m, depending on the pipework complexity and run length, along horizontal and up vertical sections and at all junctions and on all expansion loops. Where multiple lines run close to each other, such as in common pipe racks, the CCIB‟s (plus line numbers and flow direction arrows) shall be located directly in line with one another at positions that are readily visible.

D7

VALVES AND VALVE ACCESS MANHOLE COVERS

D7.1

For all Valves, the full valve body shall be painted with the SIB for the conveyed fluid. The full CCIB shall be applied both sides of the valve, to the adjacent pipework, as detailed in Clause D6.

D7.2

For Control Valves, the valve bonnet and actuator or handwheel/lever, shall be painted with one of the following three colours, to indicate whether the Control Valve is designed to fail open, fail in its last position or fail closed, as per the arrangement shown in Figure 2D. Fail Open Control Valves, whether uninsulated, fireproofed or insulated, shall be painted Emerald Green, BS 4800 Ref. No. 14-E-53. Fail In Last Position Control Valves, whether uninsulated, fireproofed or insulated, shall be painted White, BS 4800 Ref. No. 00-E-55. Fail Closed Control Valves, whether uninsulated, fireproofed or insulated, shall be painted Signal Red, BS 4800 Ref. No. 04-E-53.

D7.3

Valve Access Manhole Covers and their surrounds shall be colour coded, to identify the fluid conveyed by the pipework to which they provide access. The colour coding arrangement for these components shall be as follows. A 100 mm wide PIB of the appropriate primary fluid colour shall be painted around the periphery of the topside surface of the manhole cover, with a 75mm wide SIB of the appropriate secondary colour for the conveyed fluid immediately inside and adjacent to the PIB. For those fluids which have the


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Rev. 2

same PIB and SIB colours, a 175mm wide band in the PIB colour shall be painted around the periphery of the cover. The topside surface of the access chamber slab immediately surrounding the cover shall generally be painted with a 250mm wide band of equi-spaced diagonal yellow (BS 4800 Colour Ref. No. 08-E-51) and black (BS 4800 Colour Ref. No. 00E-53) stripes, which are the specified Safety Colours for Moveable Safety Hazards in T able 8 of QP-SPC-L-002. D7.4

Arrows in the PIB on the manhole cover shall be provided, to indicate the flow direction through the pipework and the inlet and outlet locations, as shown in the arrangement in Figure 3D.

D8

CONTENT IDENTIFICATION AND HAZARD LABELS

D8.1

The additional use of Coloured Labels stating the full or abbreviated product description, temperature, pressure, and other details necessary to identify any potential hazard, together with appropriate pictorial hazard symbols, whilst not mandatory, is to be encouraged. Such labels and markings shall not, however, be considered as a substitute for CCIB‟s, which are mandatory.

D8.2

The use and extent of such labelling shall be at the User‟s discretion but they are considered beneficial in providing more detailed identification of, and differentiation between, similar products, such as different grades of lube oil.

D8.3

The background colour of the labels shall be similar to that of the appropriate PIB for the conveyed fluid, ideally with the text in the appropriate SIB colour.

D8.4

The length of the labels shall vary from 200 to 800mm and they shall be applied adjacent to the CCIB locations, as per the arrangement shown in Figure 1D. The labels shall be brief and written in English, with the text size for different pipe diameters as specified in Clause D10.1.

D8.5

Hazard symbols, where applied to highlight and warn of potential safety hazards, shall be in accordance with International Safety Signs, as specified in BS ISO 7010.

D8.6 The labels should ideally be painted directly onto the pipe surface using the specified paint, rather than being applied in the form of self-adhesive plastic labels, which tend to deteriorate in strong sunlight and can lead to localised underside corrosion in the harsh Qatari environment.

D9

LINE NUMBERING SYSTEM

D9.1

In addition to being colour coded, each pipework system, pipeline and valve shall be individually identified by marking them in accordance with the Equipment Identification and Tag Numbering System detailed in QP Engineering Standard ES.0.07.0020. The required identification markings shall include pipe size, service, design, area code and ownership code. All characters used shall be in upper case Arial font and no separators, hyphens, punctuation marks or spaces shall be allowed.

D9.2

The line number and the flow direction shall be stencilled in black paint onto the light grey or white background coating on each pipe section and pipeline, together with the CCIB, to provide the pipework with unique traceability. The nature and thickness of the background coating shall be in accordance with the appropriate Coating Schedule of this Specification for the pipework exposure environment, service temperature and constructional material.


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D9.3

The identification markings shall be located a distance of approximately 400 mm from the edge of the CCIB. The letter and arrow sizes shall be as specified in Clauses D10.1 and D10.2, respectively.

D9.4

Lines owned by other companies shall be assigned an ownership code by the QP Facility Owner.

D10

LETTERING AND FLOW DIRECTION ARROW SIZE

D10.1 The size of the identification lettering shall be as follows. Pipe Diameter

Width (mm) x Height (mm)

2” to 6” inclusive Over 6” to 50” inclusive Greater than 50”

Spacing (mm)

30 x 30 80 x 80 100 x 100

10 min. 25 min. 30 min.

Pipework below 2” diameter in size and valves shall be securely fitte d with stamped metal tags which provide the required line and valve numbering and identification information. D10.2 The shape and size of the flow direction arrow, as shown below, shall be as follows: Pipe Diameter 2” to 6” inclusive Over 6” to 50” inclusive Greater than 50”

W1 (mm) 10 40 50

W2 (mm) 30 80 100

L1 (mm) 45 90 150

L2 (mm) 135 270 450

L2 L1

W2

W1

D11

PAINT

SPECIFICATION D11.1 The areas of the painted surfaces to which the CCIB‟s, line identification numbers and flow direction arrows are to be applied shall be degreased, fresh water washed and lightly abraded in line with QP-SPC-L-002 requirements, to ensure good adhesion of the applied paint to the existing topcoat paint. Doc. File No.: SPC.L.002.R2

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D11.2 The CCIB‟s and identification markings shall be applied using an approved two-pack highgloss polyurethane paint product. The bands and markings may be applied in a single coat, although more than one coat may be required to achieve the required obliteration of the preceding paint colour. If the CCIB‟s are to be applied over aged topcoat paint, it may be necessary to initially apply a coat of a compatible tie-coat paint of a slightly contrasting colour prior to the required topcoat paint.

TABLE 1D. PRIMARY IDENTIFICATION COLOURS BASIC TYPE OF FLUID

ESSENTIAL COLOUR

BS 4800 REF. NO.

Water Steam Fire Fighting Hydrocarbon Liquids Chemicals (Treatment Additives) Gases (Hydrocarbons and Others) Acids and Alkalis Air Effluents (Drain, Vent and Flare)

Emerald Green Crimson Red Signal Red Dark Brown Orange Ochre Purple Light Blue Black

14-E-53 04-D-45 04-E-53 06-C-39 06-E-51 08-C-35 22-D-45 20-E-51 00-E-53


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TABLE 2D. COLOUR CODE INDICATION COMBINATIONS FOR PIPEWORK PIPE CONTENTS WATER Raw Sea Potable Landscaping/Irrigation Storm Water Desalinated/Distilled Industrial Brackish Produced/Formation/Brine Treated Effluent/Grey Water Effluent/Sewage Steam FIREFIGHTING Fire Water (Sea) Fire W ater (Desalinated/Industrial) Fire Foam Carbon Dioxide OILS (Combustible Liquids) Crude Oil NGL Condensate Sweet/Sour Pygas GTL Naphtha Refinery Naphtha Kerosene/Jet Fuel GTL Diesel/Gas Oil Refinery Diesel/Gas Oil Lube Oil Basestock Lube Oil/Steel Oil Fuel/Heating Oil CHEMICALS (Treatment) Glycol – Rich/Lean ADIP/MDEA – Rich/Lean Detergent Methanol Chemical Injection Chemical Additive GASES (Gaseous/Liquified) LNG - Rich/Lean Process Gas/Syngas Fuel Gas Natural Gas/Methane Ethane LPG – Propane LPG – Butane Ethylene Acetylene Ammonia – Gas/Liquid Chlorine Hydrogen Nitrogen Oxygen ACIDS AND ALKALIS Caustic Soda Naphthenic Caustic Hydrochloric Acid Sulphuric Acid AIR Air – Plant Utility & Service Air - Instrument OTHER LIQUID Molten Sulphur

CODE WR, WS WP WL SW WD WI WB PW WT, GW WE SX

PRIMARY COLOUR 150mm Emerald Green 14-E-53

SECONDARY COLOUR 100mm Emerald Green Cobalt Blue White Light Green Light Blue Pink Ochre Orange Purple Dark Brown Crimson Red

14-E-53 18-E-53 00-E-55 12-E-51 20-E-51 02-C-33 08-C-35 06-E-51 22-D-45 06-C-39 04-D-45

Crimson Red

04-D-45

WFS WFD FF CO2

Signal Red

04-E-53

Signal Red Light Blue Yellow White

04-E-53 20-E-51 10-E-53 00-E-55

OC FC, PC PG GN LN, HN KJ, JF GD, GO BD, GO LB OL, OS OF, GO, HO

Dark Brown

06-C-39

Dark Brown Yellow White Emerald Green Cobalt Blue Orange Light Green Light Blue Pink Purple Black

06-C-39 10-E-53 00-E-55 14-E-53 18-E-53 06-E-51 12-E-51 20-E-51 02-C-33 22-D-45 00-E-53

CGR, CGL AMR, AML LDF ME CI CA

Orange

06-E-51

Emerald Green Cobalt Blue Signal Red Ochre Pink Purple

14-E-53 18-E-53 04-E-53 08-C-35 02-C-33 22-D-45

LNG GP, GS GF NG ET PR BU ETY ACY NH3 CL H2 N2 O2

Ochre

08-C-35

Ochre Dark Brown Pink Light Green Emerald Green Light Blue Orange Purple Crimson Red Black Yellow Signal Red Cobalt Blue White

08-C-35 06-C-39 02-C-33 12-E-51 14-E-53 20-E-51 06-E-51 22-D-45 04-D-45 00-E-53 10-E-53 04-E-53 18-E-53 00-E-55

CS NC HCL HS

Purple

22-D-45

White Signal Red Cobalt Blue Emerald Green

00-E-55 04-E-53 18-E-53 14-E-53

Light Blue

20-E-51

Light Blue Yellow

20-E-51 10-E-53

Black

00-E-53

Yellow Ochre Signal Red Black

10-E-53 08-C-35 04-E-53 00-E-53

Gas Vent and Flare Closed Drain Header Drain (Oil) Atmospheric Vent


AU, AS AI SU

GF CD CD, VA

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Rev. 2

FIGURE 1D: PIPEWORK COLOUR CODE IDENTIFICATION BAND

Secondary Identification Band (SIB)

EXAMPLE 1: POTABLE WATER LINE

Flow Direction Arrow

150/75 100/50 150/75

Decorative Paint (Light grey/white)

POTABLE WATER

Contents Label on PIB Background Band (SIB)

LINE No.

Line No. (black letters on decorative paint)

Primary Identification Band (PIB’s)

EXAMPLE 2: SEWAGE/EFFLUENT WATER Flanges

Flow Direction Arrow

Line No. (black letters on decorative paint)

SEWAGE

LINE No.

Colour Code Identification Bands (CCIB’s) on both sides of flanges, valves and wall penetrations (light grey/white)

FIGURE 2D: VALVE COLOUR CODE IDENTIFICATION EXAMPLE : BUTANE CONTROL VALVE

Primary Body Colour – Signal Red for Fail Closed Control Valves Emerald Green for Fail Open Valves White for Fail Last (In-Position) Valves Line No. (black letters on decorative paint)

LPG - BUTANE

LINE No.

Control valve body shall be painted with SIB colour Note: Entire body of non-control valves shall also be painted with SIB colour


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Rev. 2

FIGURE 3D: MANHOLE COVER COLOUR CODE IDENTIFICATION

Colour Code Identification Band provided both sides of flanges, wall penetrations and valves


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QP-SPC-L- 002 Rev 2 , 16-05-2013

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