Painting System

 

Preparation Shotblast to SA2.5 as per ISO 8501-1 as defined in 06-A-001
Primer Coat 1 coat Zinc Rich Epoxy primer –  65 Microns DFT (Interzinc 52)
Inter Coat 1 Coat High Build Epoxy Coating – 200 Microns DFT (Intergard 475HS)
Top Coat 1 Coat High Build Epoxy Coating –   50 Microns DFT (Interthane 990)

Finish Colour : BS4800 00-A-05

PetroIneos Standards

Reference should be made to the following PetroIneos Standards

  • 06-A-001 Corrosion Protection by Coatings, Linings and Tape Wrap Common Requirements
  • 06-A-002 Corrosion Protection by Coatings, Linings and Tape Wrap Quality, Inspection and Acceptance

 Reference

Reference should be made to the following ISO and other international standards:

  • ISO 8501, 8502, 8503 & 8504
  • ISO 2808
  • ISO 2409
  • ISO 11124
  • ASTM D4541

Manufacturer Approved Vendor List

  • International
  • Jotun
  • Sherwin Williams
  • Prime coat, inter coat and top coat are to be from the same manufacturer

The painting will be carried out at the manufacture’s, Tomeco premises.

Paint Procedure

  1. The following surfaces shall not normally be painted and must be adequately protected against shot blasting, overspray, etc. during painting applications:

a. Non-insulated austenitic stainless steel materials (flexible hoses, piping, valve bodies, etc)

b. Mating faces of pipe flanges

c. Finished machined surfaces

d. External and internal threads

e. Nameplates

f. Instrumentation and electrical equipment that is pre-coated or painted to manufacturer’s standard

g. Aluminium, copper, brass and other non-ferrous materials

h. Galvanised steel

i. Plastic and plastic coated materials

j. Threads, handles and all moving parts of valves and actuators

k. Refractory, concrete or masonry (minimal overspray allowable)

Surface Preparation and Blast Cleaning 

  1. Surface preparation is to be completed in accordance with Appendix C of Petroineos Specification -06-A-001 : Corrosion Protection by Coatings, Linings and Tape Wrap Common Requirements
  2. As a minimum surface preparation shall not be carried out:

a. When ambient temperature is below 5°C

b. When relative humidity is >85%

c. When metal surface temperature is <3°C above the ambient dew point

d. When the surface temperature is greater than 40°C

e. When there is the likelihood of an unfavourable change in weather conditions within 2 hours of painting

f. When there is a deposition of moisture in the form of rain, condensation, frost, etc., on the surface

g. When the available light is less than 500 lux

  1. Blast cleaning of surfaces as a general rule, shall be done as outlined in ISO 8504-2 (unless otherwise stated on the paint manufacturer’s data sheets).
  2. All surfaces to be coated must be free from oil, grease and other contaminants. Degrease using a suitable solvent.
  3. All welds shall be relatively smooth without sharp edges and free of weld slag and spatter.
  4. Care is to be taken with all damper mechanisms to ensure full and correct operation after painting.
  5. Surface profile amplitude (finish/roughness) as measured by the method detailed in ISO 8503-5 must be at least 50μm with a maximum amplitude of 100μm
  1. Blast clean to SA2.5 visual standard in accordance with the requirements given on the Contract Data Sheet at the time of painting. Only dry abrasive blast cleaning techniques shall be employed. Normally abrasives shall be expendable copper; slag, aluminium silicate or re-usable iron and steel grit or shot or other materials producing sand / silica dust shall not be used.  However, when a preparation of aluminium or stainless steel is required the abrasives should be non-metallic and capable of producing the required surface profile without contamination of the substrate.

 

  1. Surfaces that have been blast cleaned shall be coated before rust bloom occurs. To prevent rusting the surfaces shall be painted within 2 hours of being blast cleaned.  If painting can not take place within 2 hours of being blasted, the cleaned surface should be washed off immediately after blast cleaning using fresh water containing a suitable corrosion inhibitor such as 0.3% wt sodium nitrite with 1.2% wt ammonium phosphate.  It should also be considered to include a suitable corrosion inhibitor in the water used for blast cleaning.

 

  1. The surface to be coated shall be rendered dust free prior to application. This shall be accomplished by blowing the surface with dry, clean air or by industrial vacuum cleaner.

 

Paint Application

  1. Paint application is to be completed in accordance with Appendix C of Petroineos Specification – 06-A-001 : Corrosion Protection by Coatings, Linings and Tape Wrap Common Requirements
  2. As a minimum surface preparation shall not be carried out:

 

a. When ambient temperature is below 5°C

b. When relative humidity is >85%

c. When metal surface temperature is <3°C above the ambient dew point

d. When priming cannot be completed within 4 hours of preparing the surface or before any

deterioration of the surface preparation standard

 

  1. Primers, intermediate and finish coats for any particular system, shall be from the same manufacturer to assure compatibility.

 

  1. The coating material shall be thoroughly mixed with a power mixer for sufficient time to thoroughly remix the pigment in accordance with the paint manufacturer’s data sheets.

 

  1. Coatings containing heavy or metallic pigments with a tendency to settle shall be kept in suspension in the pressure pot by a mechanical stirrer.

 

  1. Paint application and thinning shall be in accordance with the paint manufacturer’s data sheets.

 

  1. Before spraying each coat, all areas such as corners, edges, welds, small brackets, etc. shall be pre-coated to ensure that these areas have at least the minimum specified film thickness.

 

  1. Each coat is to be applied uniformly and completely over the entire surface. All runs and sags shall be brushed out immediately or the paint shall be removed and the surface re-painted.

 

  1. Each coat shall be allowed to dry / cure in accordance with the paint manufacturer’s data sheets prior to application of succeeding coats.

 

  1. Before application of any coat of material, all damage to previous coats shall be repaired. All loose paint shall be removed to a firm edge.

 

  1. Areas with inadequate coating thickness shall be thoroughly cleaned, and if necessary, abraded and then compatible coats reapplied until specification thickness is obtained. Those coats which are reapplied shall blend with the final coating on adjoining areas.

 

Inspection,Testing and Records

Before painting activities commence the contractor shall submit an inspection procedure report indicating inspections and tests to be conducted during preparation and application of the paint system for approval.

Inspection and testing of paint is to be completed in accordance with Petroineos Specification

06-A-002 : Corrosion Protection by Coatings, Linings and Tape Wrap Quality, Inspection and Acceptance

Only qualified personnel shall be used for inspecting coating operations and quality control activities. Such persons shall be trained and certified to a minimum of Level 2 under the ICorr Scheme. Recognised equivalents such as FROSIO and NACE are acceptable.

 

  1. Ambient conditions shall be established before surface preparation work commences. The following shall be measured :-

 

a. Air temperature

b. Surface temperature

c. Relative humidity

d. Dew point temperature

 

  1. Surface Preparation : The surface profile amplitude (anchor pattern, or roughness of steelwork) shall be tested regularly through the blast cleaning cycle and reported. It shall be assessed by either

 

  • Using the ISO 8503-1 ISO Comparator, or
  • Measuring by the tape method as detailed in ISO 8503-5, or
  • Measuring by stylus gauge as detailed in ISO 8503-5 or ASTM D4417-B, if using a needle gauge 10 reading to be taken

 

  1. Following surface preparation visual surface cleanliness shall be assessed in accordance with ISO8501-01. Visual inspection for surface cleanliness of blast cleaned surfaces shall also include testing for residual dust. This shall be done in accordance with ISO 8502-3 (pressure-sensitive tape method) such that : –

 

  • The particle quantity and particle size do not exceed Grade 1 or Grade 2, as specified in Standard 06-A-001, just prior to coating application.

 

  1. Wet Film Thickness Spot checks shall be carried out during the course of the painting operation to ensure that film thickness is being maintained. These shall be performed according to the procedure described in ISO 2808, Method No. 7B. These are to be included in the final report.

 

  1. Coating dry film thickness (DFT) measurement shall be in accordance with ISO 19840. Digital magnetic induction type gauges are preferred for magnetic substrates and eddy current type gauges for non-magnetic substrates.  The magnetic type ‘banana’ gauges shall not be used.

 

  1. DFT gauges shall be calibrated in accordance with section 2 of SSPC-PA-2.

 

  1. The numbers of measurements taken shall be as shown in Table 3- Sampling plan (below) –

 

Table 3- Sampling Plan

 

Size of Inspection Area Per Linear m for Pipe Per m2 Elsewhere Minimum Number of Measurements
Up to 1 5
Above 1 to 3 10
Above 3 to 10 15
Above 10 to 30 20
Above 30 to 100 30
Above 100 For sizes over 100 m of linear pipe or 100 m2 elsewhere the appropriate additional number of measurements shall be added

 

Table 3- Sampling Plan

 

For the acceptance of an inspected area the following criteria shall be fulfilled:

 

  • The dry film thickness of the completed coating system shall be equal or greater than the specified nominal dry film thickness (NDFT)
  • The dry film thickness of the individual coating layers shall be equal to or above 80% of the specified nominal dry film thickness (NDFT). The Number of readings below NDFT shall be less than 20% of the total dry film thickness measurements taken.
  • The dry film thickness of the individual coating layers shall be maximum 1.5 x the specified thickness, except for the areas such as corners where overlap are difficult to avoid. For such areas a maximum of 2.5 x the specified thickness is acceptable.

 

  1. Spot checks shall be carried out during the course of the painting operation to ensure that film thickness is being maintained. These shall be performed according to the procedure described in ISO 2808, Method No. 7B.

 

  1. The paint system should be applied with the required number of coats.

 

  1. Where the quality of the film is impaired by the excess film thickness (wrinkling, mud cracking or general softness) the unsatisfactory paint coating shall be removed and another applied.

 

  1. It is the responsibility of the nominated contractor to ensure that all equipment and procedures employed during the preparation and application of the stated paint system, comply with the relevant health and safety legislation and that the welfare of all personnel is paramount.

 

  1. Sample surface preparation test, adhesion test, painting test (final and WFT) reports are attached for reference.

 

  1. The following list of measuring equipment shall be used

 

a. Air temperature: use Sling Psychometer – Elcometer 116

b. Relative humidity: use Sling Psychometer – Elcometer 116

c. Dew point temperature: use Dew point table­­

d. Surface temperature: use Thermometer – Elcometer 214

e. Surface profile: use TestexTape method – Elcometer gauge and Replical Tape (O-Firm)

f. Visual Surface cleaning: Pressure – sensitive tape – Transparent Tape

g. Surface preparation visual surface cleanliness: Visual check following ISO 8501-01 Standard­

i. Wet Firm Thickness: use W­et Firm Thickness Gauge

j. Dry Firm Thickness: use Dry Firm Thickness Gauge – Elcometer A456

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