painting specification for storage tanks

Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1000-55-SP-9001 Date 12 Apr 2012

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Painting ( Protective Coating )

G3IR-1000-55-SP-9001_Rev 0 Page 1 of 16

Document No: G3IR-1000-55-SP-9001

Unit: General Discipline: Mechanical Document Type: Specification Document Title: Painting ( Protective Coating )

0 12-Apr-2012 Issued for RFQ AV AA VP

Revision Date Purpose Prepared By Checked By Fluor BASF

Approved By This document was prepared for BASF INDIA LIMITED by FLUOR DANIEL INDIA PVT LTD (“CONTRACTOR”) and based in part on information not within the control of either owner or contractor. Neither owner not contractor have made an analysis, verified or rendered an independent judgement of the validity of the information provided by others. While it is believed that the information contained herein will be reliable under the conditions and subject to the limitations set forth herein, neither owner nor contractor guarantee the accuracy thereof. Use of this report or any information contained herein shall be at user’s sole risk.



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Record of Revisions

This specification has been revised as indicated below and described in the revision record on the following page. Please destroy all previous revisions.

Revision

No. Date Description

0 12-Apr-2012 Issued for RFQ ( No change except document Name; FEED document G2IR is replaced by G3IR)



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G3IR-1000-55-SP-9001_Rev 0 Page 3 of 16

TABLE OF CONTENTS

1. GENERAL ...................................................................................................................................................... 5

1.1. Scope ........................................................................................................................................................... 5

1.2. Exceptions .................................................................................................................................................. 5

1.3. Terminology ................................................................................................................................................ 5

2. REFERENCES ............................................................................................................................................... 7

2.1. ASTM (American Society for Testing and Materials) .............................................................................. 7

2.2. SSPC (Steel Structures Painting Council) ............................................................................................... 7

2.3. ANSI/ASME/NEMA ...................................................................................................................................... 7

2.4. BIS ................................................................................................................................................................ 8

2.5. Manufacturer’s Application Data Sheets ................................................................................................. 8

2.6. Regulations of Governmental Agencies Related To Personnel Health and Safety As Applicable To Painting ....................................................................................................................................................... 8

3. EXECUTION ................................................................................................................................................... 8

4. GENERAL PAINTING REQUIREMENTS ...................................................................................................... 9

4.1. Items Which Do Not Require Painting ..................................................................................................... 9

4.2. Items Which Require Protection From Painting ..................................................................................... 9

4.3. Scheduling Of Work ................................................................................................................................... 9

5. SURFACE PREPARATION ......................................................................................................................... 10

5.1. Carbon Steels (Bare Metal) ..................................................................................................................... 10

5.2. Carbon Steels (Pre-painted, Primed Surfaces Requiring Further Coating) ....................................... 10

6. MATERIAL REQUIREMENTS ..................................................................................................................... 11

6.1. Environmental Compliance ..................................................................................................................... 11

6.2. Compressed Air ........................................................................................................................................ 11

6.3. Abrasives .................................................................................................................................................. 11

6.4. Cleaners And Paint Materials .................................................................................................................. 11

6.5. Paint Application Equipment .................................................................................................................. 12

7. FINISH COLORS AND IDENTIFICATION ................................................................................................... 12

8. APPLICATION OF PRIMERS AND FINISHES ........................................................................................... 12

9. COATING REPAIRS .................................................................................................................................... 13



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9.1. Repairs to primed, finish painted surfaces shall be as follows: ......................................................... 13

10. QA/QC (QUALITY ASSURANCE AND QUALITY CONTROL) ................................................................. 13

10.1. Documentation .................................................................................................................................... 13

10.2. Instruments .......................................................................................................................................... 14

10.3. Minimum Inspection Required Prior To and During Surface Preparation .................................... 14

10.4. Minimum Inspection Required Prior To Painting ............................................................................ 14

10.5. Minimum Inspection Required During Painting ............................................................................... 15

10.6. Minimum Inspection Required After Painting .................................................................................. 15

11. SUPPLIERS & PRODUCTS .................................................................................................................. 16

12. ATTACHMENTS .................................................................................................................................... 16



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1. GENERAL

1.1. Scope

This specification covers external painting of aboveground plant facilities exposed to weather and operating at temperatures less than 538 °C (1000°F).

1.2. Exceptions

This Specification is not applicable to architectural components and buildings. This specification does not cover Galvanizing.

1.3. Abbreviation and Terminology

APPLICATION DATA shall mean application instructions, recommendations and guidelines described in the published literature of the coating materials' Manufacturer, referenced industry standards and any specific requirements noted in this specification and any drawings issued to the CONTRACTOR. In case of conflicting requirements between the documents, CONTRACTOR shall submit all conflicting information to the ENGINEER for resolution. If the published literature of the Manufacturer does not contain required information, CONTRACTOR shall obtain additional information from the parent corporate office if the local Manufacturer is a licensee or a subsidiary of a multinational organization. Any deviations from or changes to Manufacturer's published literature shall be subject to ENGINEER's review, acceptance or rejection without comment, explanation and/or justification.

Note: Where recommendations, instructions and guidelines are given in permissive language such as “May,” “Should,” and “Recommended,” compliance with those recommendations, instructions and guidelines shall be considered mandatory unless otherwise instructed by the ENGINEER.)

Approved Equal shall mean a product approved by the ENGINEER as equal to the product specified in this specification.

Carbon steels shall mean carbon steels including alloy steels with chromium content of 9¼ % or less.

Coat shall mean one full layer of the specified material applied to the specified thickness. Multiple passes including initial mist pass are necessary to form a coat. A mist pass is not considered a full coat. The cost of a coat shall include the cost of mist pass (es).

Note: Mist coats are the same as mist passes.

CONTRACTOR shall mean the painting contractor.

CUI is Corrosion under Insulation.

ENGINEER shall mean the FLUOR corrosion engineer responsible for the development or maintenance of this Specification.

Dew point The temperature of a given air/water-vapor mixture at which, under atmospheric pressure, condensation starts.



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DFT (Dry Film Thickness) shall mean the thickness of the dry film of the coating. In the absence of a specified range, the value stated shall mean a minimum value and the maximum value shall not be more than 1.5 times the stated value.

DFT Measurement shall mean the average value of three readings recorded by dry film thickness gage. The readings shall be within a 6 inch radius and evenly spread out from a given spot.

Catalog Equipment shall mean catalog items or assemblies of catalog items such as control instruments, electrical equipment, compressors, motors, pumps and similar items which are not specifically designed and custom fabricated for the project.

Custom Equipment shall mean equipment specifically designed and fabricated for the project, such as process equipment, skid units, boilers, heat exchangers, heaters, heat recovery steam generators (HRSGs), vessels, drums, shop fabricated tanks, stacks, made-to-order equipment and related items including structural components.

Insulated surfaces shall mean steel surfaces which will be insulated.

Manufacturer shall mean the manufacturer of the specified paint.

Operating temperature shall mean the maximum temperature of the substrate surface exposed to weather (indoor and outdoor) during operating conditions. For example, operating temperature of refractory lined equipment for painting purposes shall be the temperature of the metal surface exposed to the weather during operation. The steam out temperature of piping and equipment shall not be considered as a basis for paint system selection unless specifically instructed in writing by the Owner and acknowledged in writing by FLUOR.

Owner shall mean the Owner of the Project or its authorized representative.

Piping shall mean piping, pipe fittings, valves, pipe supports and accessories unless a particular item and/or size limitation is stated.

Stainless Steel shall mean austenitic stainless steel such as Type 304, 316, 321 and 347.

Structural steel shall mean structural steel other than the structural steel which is an integral part of fabricated equipment by the SUPPLIER. (Example: Structural steel of a boiler structure shall be painted in the same manner as the boiler's other surfaces.)

SUPPLIER shall mean fabricator and/or supplier of pipe, equipment, structural steel, and other items to be painted.

Tanks shall mean field fabricated above ground storage tanks (AST).

Uninsulated surfaces shall mean carbon steel surfaces which will not be insulated.



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Work shall mean all labor, supervision, installed and consumable materials, services, equipment, instruments, tools, and each and every item of expense necessary for preparing the surfaces for paint application, application of paint materials, repairs, quality control, and cleanup thereafter.

RAL & DB color code are widely used color shade matching systems.

SIS is Swedish Standard Institution. SSPC is Steel Structures Painting Council.

2. REFERENCES

The latest revision, including addenda, of the following references in effect on the latest date of this Specification form a part of this Specification. Except as modified by the requirements specified in this Specification or on the drawings, all Work performed shall comply with the following references. Any conflicts between the following references and this Specification shall be resolved by the ENGINEER.

2.1. ASTM (American Society for Testing and Materials)

B117 Standard Test Method of Salt Spray (Fog) Testing D3276 Standard Guide for Painting Inspectors (Metal Substrates) D4541 Standard Test Method for Pull-off Strength of Coatings Using Portable Adhesion Testers D3359 Standard Test Method for measuring by tape test D4285 Test Method for indicating oil or water in Compressor Air D4752 Standard Test Method for measuring MEK resistance of ethyl silicate (inorganic) Zinc-Rich

Primer by Solvent Rub. NACE RP0287 Field Measurement of Surface Profile of Abrasive Blast Cleaned Steel Surfaces Using

Replica Tapes

2.2. SSPC (Steel Structures Painting Council)

SSPC-SP1 Solvent Cleaning SSPC-SP2 Hand Tool Cleaning ( Equivalent SIS St 2) SSPC-SP3 Power Tool Cleaning ( Equivalent SIS St 3) SSPC-SP5 White Metal Blast Cleaning ( Equivalent SIS Sa 3) SSPC-SP6 Commercial Blast Cleaning ( Equivalent SIS Sa 2) SSPC-SP10 Near White Blast Cleaning ( Equivalent SIS Sa 2. ½) SSPC-SP11 Power Tool Cleaning To Bare Metal SSPC-Vis1 Visual Standard For Abrasive Blast Cleaned Steel (Standard Reference

Photographs) SSPC-VIS 3 Visual Standard for Power and Hand-Tool Cleaned Steel SSPC-TR3/ NACE 6A192 Dehumidification and Temperature Control during Surface Preparation,

Application and Curing for Coatings/ Lining of Steel Tanks, Vessels and other Enclosed Spaces.

SSPC-PA2 Measurement Of Dry Paint Thickness With Magnetic Gages

2.3. ANSI/ASME/NEMA

A13.1 Scheme for the Identification of Piping Systems



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Z535.1 Safety color code ISO 11127 Parts 1-7 Paints and Varnishes – Preparation of Steel Substrates before application of

paints and related Products. Test methods for non-metallic blast-cleaning abrasives.

2.4. INDIAN STANDARDS (BIS)

IS 2379 : 1990 Pipelines-Identification-colour code

2.5. Manufacturer’s Application Data Sheets

2.6. Regulations of Governmental Agencies Related To Personnel Health and Safety as Applicable To Painting

3. EXECUTION

The SUPPLIER shall perform all Work related to surface preparation, priming and finish painting of the CATALOG EQUIPMENT including all attachments thereto in accordance with the SUPPLIER's standard paint system subject to the Owner's choice of finish colors, semi-gloss finish and minimum corrosion protection level of 2000 hours (salt fog resistance) when tested in accordance with ASTM B117.

The SUPPLIER shall perform all Work related to surface preparation and priming of the following items including all attachments (excluding pre-painted shelf items) thereto in accordance with the Painting Schedule of this specification:

Custom Equipment

Piping

Structural steel (non-galvanized) and miscellaneous items except tank plates for field erection

The CONTRACTOR shall perform all Work related to the following tasks, by way of example but not by limitation, necessary to complete the application of all painting systems in accordance with this specification.

Cleaning of surfaces to remove all dirt, foreign matter, grease, oil, etc. with fresh water and/or degreaser.

Repair of damaged surfaces of shop coating.

Surface preparation and priming of bare metallic surfaces.

Finish painting of primed surfaces.

Repainting of custom equipment with damaged finish paint.

Application of safety color coding and pipe identification.



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4. GENERAL PAINTING REQUIREMENTS

4.1. Items Which Do Not Require Painting

The following items do not require any surface preparation or painting unless otherwise specified.

Non-metallic items such as concrete, glass, plastic, wood and etc.

Non-ferrous metals such as aluminum, copper, brass and etc.

Galvanized surfaces except for safety color coding or coating repair.

Insulation weatherproofing.

Uninsulated stainless steel surfaces ( For insulated surfaces refer to Attachment 1)

4.2. Items Which Require Protection from Painting

Surfaces which could be damaged by abrasives, dust, or paint overspray shall be protected by wrapping, taping, or other means to prevent damage. Such surfaces shall include, by way of example, but not by limitation, the following:

Alloys (Monel, Incoloy, or Hastelloy) Bearings Conduit Control panels Control valves Couplings Equipment nameplates Expansion joint bellows Fire sprinkler heads Flange and nozzle facings Glass, rubber, gasket materials etc. Identification tags Instrument glasses and gauge dials Machined surfaces (threads, valve stems, pump and cylinder rods, shafts, etc.) Screws Spring hanger graduations Stainless steel surfaces (except as specified) Valve stems and position indicators

Note: Stainless steel surfaces shall be protected from zinc and aluminum rich coatings. Any accidental overspray of zinc and aluminum, including trace amounts, over stainless steel surfaces must be completely removed.

4.3. Scheduling Of Work

Unless otherwise stated in the APPLICATION DATA and approved by the ENGINEER, painting shall be done when:



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G3IR-1000-55-SP-9001_Rev 0 Page 10 of 16

Pressure testing is complete Ambient temperature is above 10°C Metal surface temperature is at least 5°C above the dew point Relative humidity is less than 85% There is no likelihood of rain within 24 hours after painting Protection of surfaces, not required to be painted e.g., stainless steel, is in place

5. SURFACE PREPARATION

5.1. Carbon Steels (Bare Metal)

Surfaces shall be thoroughly washed with potable water to remove all water soluble salts, dirt and dust. The water washing shall be considered critical especially if the surfaces are exposed to salty environment. If any grease and oils are present on the surface, the surfaces shall be further washed with biodegradable non-ionic detergent solution until the surfaces are completely free of all surface contamination. There shall be no smudge on the surface when rubbed with a clean cloth. Surfaces cleaned with detergent shall be thoroughly rinsed with potable water to remove traces of detergent. Solvent Cleaning methods shall be as outlined in SSPC SP-1. Under no circumstances, shall the substrate remain without a primer coat for more than 4 hours.

Welded areas shall be blast cleaned or ground to remove burrs, mill scale, weld spatter, flux, or protrusions. Weld reinforcement shall not be removed and base metal shall not be ground below the surface. Surface profile measurements for abrasive blast cleaned surfaces shall be made with a Keane Tator profile comparator, clemtec anchor profile chips, Testex Press-O-Film or other Contractor accepted method suitable for abrasive being used.

Surface preparation and anchor pattern (surface profile) shall be as specified for each individual paint system. Profile of the abrasive blasted surfaces shall comply with the requirements provided by the paint system and measured in accordance with standard NACE RP0287.

Only grit blasting shall be used for surface preparation. All rough welds shall be rounded and contoured. Sharp edges shall be rounded, chamfered and broken. The surface profile depth shall be achieved by using a medium that has good angularity of form, sharp cutting edges and is substantially free from “half rounds”.

Before applying any coating, blast cleaned surfaces shall be vacuumed and wiped with a clean cloth to remove all traces of dust.

Cleaned surfaces shall be coated within eight hours and before occurrence of any trace of rust. If rust is noticed, the surface shall be blast cleaned again. Where the item to be painted is large, it shall be cleaned and primed in sections.

The maximum allowable level of water soluble salt contamination shall be 20mg/m2. Surfaces that do not meet this criterion shall be reprocessed.

5.2. Carbon Steels (Pre-painted, Primed)

All surfaces shall be thoroughly degreased and washed in the manner stated for bare carbon steels above.

The washed surfaces shall be completely dry prior to further application of paint materials. Any additional surface preparation, such as sanding, required by the coating manufacturer shall be followed prior to top-coating.



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6. MATERIAL REQUIREMENTS

6.1. Environmental Compliance

All cleaners, primers, finishes and solvent materials shall be environmentally safe products and shall not contain hazardous materials such as CFCs, lead, chromates and etc. which cause air, soil and water pollution. Products which do not comply with the pollution regulations of the local governmental agencies are not allowed for use on this Project. The SUPPLIER and the CONTRACTOR are responsible for verifying the product compliance with local environmental regulations. Disposal of residual materials ( spent abrasives, coating materials, solvents etc.) shall be performed fully in accordance with rules, regulations and laws in force in the country where the coating work is performed.

6.2. Compressed Air

The compressed air shall be passed through a cooler.

All air compressors shall be of a sufficient size to deliver atleast 100 PSI at the nozzle. In no circumstance, shall the compressed air temperature more than 100 C. Each compressor shall have two coalescing oil/moisture removal filters, one located at the discharge of the after-cooler and one close to the blast/spray gun. Filters must remove 99.999% of oil from the compressed air. Compressed air used for blasting and lining application must be clean, oil free and dry.A compressed-air cleanliness test (blotter test) as described in ASTM D4285 shall be used for checking air cleanliness.

6.3. Abrasives

Abrasives shall be composed of clean, dry, hard particles free of foreign substances such as dirt, oil, grease, toxic substances, organic matter, mill scale and water soluble salts. The pH of the abrasive materials shall be 6.0 to 8.5. Abrasives shall be sharp garnet or grit of Rockwell hardness (40 to 50 HRC) and properly graded. Abrasive particle size shall be suitable for producing an angular sharp anchor profile. Shot is not acceptable. Conductivity measured according to ISO 11127-6 shall not exceed 300 microSiemens/cm measured at 20°C and chloride content shall be less than 25 ppm. In no circumstance shall silica abrasive be used.

6.4. Cleaners and Paint Materials

The degreaser shall be non-toxic and non-ionic biodegradable water based cleaner.

Petroleum, kerosene, diesel oil or other fatty solvents shall not be used.

Primer and finish paint materials shall be those listed in Attachment.

Primers and finishes shall be factory tinted, sealed, and labeled products and approved by the ENGINEER. Each label shall show the product name, number, type of paint, lot or batch number, color and instructions for mixing and/or thinning. Solvents shall be products of the same manufacturer and be used in accordance with the APPLICATION DATA.

All finish paints shall be semi-gloss finishes.



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6.5. Paint Application Equipment

Spray equipment shall be as recommended in the APPLICATION DATA. Sufficient number of spare parts shall be made available at the work site.

7. FINISH COLORS AND IDENTIFICATION

Finish colors shall match RAL code colors shown in Attachment 3 (Plant colors and identification). Each SUPPLIER shall furnish samples of available colors to FLUOR for items finish painted in the shop.

8. APPLICATION OF PRIMERS AND FINISHES

Proper functioning of the in-line moisture and oil traps shall be evaluated daily by allowing the air supply (downstream of the traps) to blow against a clean, white cloth in accordance with ASTM D4285. No moisture or oil should be deposited on the cloth. If contaminants are detected, the equipment deficiencies shall be corrected and the air stream shall be retested. Cleaned surfaces determined to have been blasted since the last successful test shall be degreased and re-blasted with clean air and abrasive. Primers and finishes determined to have been applied using contaminated air shall be removed and recoated using clean air.

All painting shall be in accordance with this specification and the APPLICATION DATA; Attachment 1, Primers and Finishes and Painting Schedule, unless otherwise approved in writing by the ENGINEER.

Storing; thinning; mixing order; mixing procedure, including the mixer speed and mixing time; handling; and application of paint materials shall be in accordance with the APPLICATION DATA.

Pigmented and catalyzed materials shall be thoroughly mixed and strained before applying. Materials which have not been applied within the pot-life times shall be discarded and properly disposed off.

Coatings and primers shall be delivered to the jobsite in the original containers bearing manufacturer’s name, product designation, batch number, shelf life and date of manufacture.

Paints with metallic pigments such as zinc and aluminum shall be continuously agitated to prevent settling of the pigment while being applied.

Ends of pipe, and edges of structural steel items that will require welding shall be masked off after blast cleaning and left unpainted 1½" from the edge to facilitate welding. The masking material shall be removed as soon as possible after painting.

Paint shall be airless spray applied if the adjacent property can be protected from overspray. Otherwise, the paint shall be applied by roller or brush.

Weld lanes, bolt heads, corners, and edges require an initial brush coat before the application of the paint system to assure wetness of the surface.

Paint materials shall be uniformly applied in even, parallel passes overlapping each pass 50% immediately followed by cross-spray passes to obtain a continuous film without bare spots, pinholes or holidays. The coated surface shall have no runs, sags, solvent blisters, dry spray or other blemishes. All irregularities shall be removed or repaired and recoated.



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Intercoat contamination shall be minimized by maintaining proper cleanliness and by applying all coatings within the time period stated in the APPLICATION DATA. If contaminants are present, they shall be removed before applying subsequent coats.

9. COATING REPAIRS

9.1. Repairs to primed, finish painted surfaces shall be as follows:

Damaged coatings shall be removed unless they are tightly bonded to the substrate metal. The surface shall be wiped with a clean rag to remove all dust and loose materials. If there is any oil, grease or other foreign matter, it shall be washed with water based non-ionic, biodegradable detergent followed by further rinsing with potable water to remove all traces of the detergent. The surface shall then be dried.

Products used for repair of defects and damages shall be supplied by the same paint manufacturer of the original paint system.

Areas with spot rust, burnt residue, weld spatter and other solid adherent foreign matter shall be cleaned per SSPC-SP11, Power Tool Cleaning to Bare Metal, using 3M ScotchBrite surface conditioning discs.

Existing coating shall be feathered and roughened at the edges with sandpaper or rotary discing.

All dust shall be removed from the surface by vacuuming, brushing and wiping with a clean cloth.

Repair materials shall be as follows:

1. Modified epoxy for operating temperatures ambient through 120°C.

2. Silicone acrylic for operating temperatures 121°C through 260°C.

3. Silicone aluminum for operating temperatures 260°C through 480°C.

4. Any repair shall be performed according to the instructions listed in the PDS (product data sheet) published by the paint manufacturer.

Primer repair material shall not overlap the existing adjacent finish. However, the finish repair material shall overlap the adjacent existing finish a minimum of two inches.

10. QA/QC (QUALITY ASSURANCE AND QUALITY CONTROL)

10.1. Documentation

The SUPPLIER and CONTRACTOR are solely responsible for all QA/QC activities regardless of any QA/QC activities performed by FLUOR. The SUPPLIER and CONTRACTOR shall maintain documentation to comply with the guidelines of ASTM D3276 with the exception that the Inspection Checklist in the Appendix shall be considered mandatory. Inspection shall also comply with the following additional requirements. Any approvals for products and procedures submitted by the SUPPLIER and CONTRACTOR shall be considered additional to the requirements stated in the specification and shall not be considered as a substitution to the requirements of this specification.



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All QA/QC documentation for work performed shall be made available to FLUOR on demand and without notice. If the SUPPLIER and CONTRACTOR are unable to produce the QA/QC documentation to the satisfaction of FLUOR, such absence of documentation shall be sufficient cause for FLUOR to reject the work performed.

When work is completed, SUPPLIER shall prepare a final report including the following data: surface preparation characteristics, Trade name and characteristics of each paint system applied, Sequence of the coats applied for each paint system, Atmospheric and thermo-hygrometric conditions, inspections and tests performed and the relevant results, including final acceptance reports; Repairs, if any and corrective actions undertaken.

FLUOR's review (or lack thereof) of quality control documents shall not be construed as acceptance of omissions or defective work. Nor shall it in any way lessen the SUPPLIER's responsibilities to provide a completely operative system or component in full compliance with this specification.

10.2. Instruments

The SUPPLIER and CONTRACTOR shall supply, calibrate and maintain the following instruments for inspection. Alternate instruments may be approved by the ENGINEER.

Temperature and Humidity Gardner Certified Hygrometer and Temperature Indicator

Surface cleanliness SSPC-Vis 1 or NACE blast cleaned panels

Surface profile Elcometer surface profile gauge (Model 123), Keane-Tator Surface Profile Comparator or Testex Press-O-Film

Wet Film Thickness Elcometer Model 154 or Nordson Wet Film Thickness Gauge

Dry Film Thickness Elcometer Inspector Model 111 or Mikrotest Dry Film Thickness Gauge, Elcometer Paint Inspection Gauge Model 121 (required for inspection of multiple coats)

Bond or adhesion strength Elcometer Adhesion Tester Model 106

10.3. Minimum Inspection Required Prior To and During Surface Preparation

Verify that nearby inlets of air intake and vacuum systems equipment are properly protected before initiation of blast cleaning operations.

Verify that items requiring protection from abrasives and dust are properly protected.

Verify that the surface temperature is 5°C above the dew point and rain is not forecasted within the scheduled painting time plus 24 hours.

Check abrasive quality, air quality and surface profile.

Verify that cleaned surfaces are free of contamination.

10.4. Minimum Inspection Required Prior To Painting

Verify that the storage, shelf life, mixing, thinning and application of primers and finishes are in accordance with the APPLICATION DATA.



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All surfaces shall be visually inspected to assure that the proper surface conditions necessary for painting exist.

Document the temperature, humidity and substrate surface temperature.

Verify that surfaces not to be coated are masked off or otherwise protected prior to painting of adjacent surfaces. Stainless steel must be protected from zinc and aluminum rich coatings.

10.5. Minimum Inspection Required During Painting

Verify that the recoating time is in accordance with the APPLICATION DATA.

Verify that the paint materials are applied within the shelf life and pot life.

Verify that the materials are properly strained and mixed in the recommended order and that the reaction time as necessary was allowed.

Verify that the moisture and oil filters, of the air lines, are functioning properly.

Check for initial mist pass of the coating to avoid bubbling.

Check for criss-cross spray pattern to assure proper film buildup.

Check for proper atomization and avoid dry spray.

Verify the wet film thickness of primer and finish coats. The wet film shall be uniform without runs or sags.

10.6. Minimum Inspection Required After Painting

Verify that the paint film is free of defects. The painted surface shall be free of blisters, bubbles, craters, sags, runs, dry spray, lap marks and unnecessary brush marks.

Verify the bond strength of primer and finish coats. The adhesive bond between the substrate and the prime coat (except silicone aluminum) shall be at least equal to or better than Grades 4A and 4B when tested per ASTM D3359 Standard Test Method for Measuring Adhesion by Tape Test. The number of tests shall be at least TEN (10) for each batch of bulk items and FIVE (5) for each piece of equipment at random locations selected by the ENGINEER. In case of failure, the number of tests shall be increased to the level approved by the ENGINEER.

Verify that all masking tape has been removed.

Verify that the coating is cured as specified in the APPLICATION DATA. Cure of catalyzed materials may be determined by exposure to a suitable solvent as recommended by the coating manufacturer. Inorganic zinc primers may be tested for cure by burnishing the surface with a dull metal object such as a coin or paper clip and/or testing by exposure to a suitable solvent as noted above.

Nondestructive dry film thickness gauges shall be calibrated in accordance with the gauge manufacturer's instructions at the beginning of each day. Type I (magnetic pull-off) gauges shall be calibrated using Certified Coating Thickness Calibration Standard of National Institute of Standards and Technology (NIST). Type II (magnetic flux) gauges shall be calibrated by using plastic shim standards supplied by the gauge manufacturer.



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The DFT measurement of each layer of coating at any given spot shall be within the minimum and maximum values specified for the individual coating layer of the coating system. The number of nondestructive DFT measurements shall be at least five per item or at the following rate whichever is higher.

Pipe and Structural steel: 1 for each 20 lineal feet Equipment (except tanks): 1 for each 100 ft2 Tanks: 5 for each 1000 ft2 The ENGINEER may require thickness measurement of individual coats of a multi-coat system. Such destructive measurements of coating thickness shall be performed by the SUPPLIER and CONTRACTOR when directed by the ENGINEER.

10.7. Certification of Personnel

All personnel involved in the inspection process defined above shall be NACE Level 3 or FROSIO Certified, and shall have adequate experience.

11. SUPPLIERS & PRODUCTS

Refer Attachment 02 “Paint Materials for Client Approval”.

12. ATTACHMENTS

Attachment 01 Primers and Finishes & Painting Schedule

Attachment 02 Paint Materials for Client Approval

Attachment 03 Plant Colors and Identification



Attachment 01 Page 1 of 3


G3IR-1000-55-SP-9001_ Attachment 1_ Rev 0 Page 1 of 3

Primer and Finishes & Painting Schedule Piping, equipment and tanks specified to be insulated shall not be primed or finish painted. However, all protrusions through the insulation and portions not covered by insulation (such as flanges, nozzles, supports, clips, manways, and saddles) shall be painted in accordance with the paint system specified for uninsulated surfaces. The painting requirements specified in the Painting Schedule below pertains to all uninsulated surfaces including uninsulated surfaces of partially insulated piping and equipment.

Painting System

Surface Preparation

Application Method

Operating Temperature Range

Primer (1st coat) Finish (2nd coat) Finish (3rd coat)

From To Thickness Thickness Thickness

Vessels, Exchangers, Tubular equipment and Piping - Uninsulated

System - A1 For CS & LAS (Uninsulated)

SSPC-SP10 Spray

Ambient

120°C

Inorganic Zinc Silicate

2.5 – 3.0 mils ( 63 – 75 DFT)

Modified Epoxy 5 – 8 mils

( 125 – 200 DFT)

Acrylic urethane 3 – 4 mils

( 75 – 100 DFT)

Alternative


2.5 – 3.0 mils ( 63 – 75 DFT)

Epoxy Based Micaceous iron

oxide (MIO) 4 – 8 mils

( 100 – 200 DFT)


( 50 – 75 DFT)

System - A2 CS & LAS

(Uninsulated)

SSPC-SP10 Spray

121°C 260°C


2.5 – 3 mils ( 63 – 75 DFT)

Silicone Acrylic ( Note 4 )

1.5 – 2 mils ( 37 – 50 DFT)

Silicone Acrylic 1.5 – 2 mils

( 37 – 50 DFT)

Alternative Inorganic Zinc

Silicate 2.5 – 3 mils

( 63 – 75 DFT)

Heat resisting Aluminum

1.5 to 2 mils ( 37 – 50 DFT)

Heat resisting Aluminum

1.5 to 2 mils ( 37 – 50 DFT)

System – A3 CS & LAS

(Uninsulated)

SSPC-SP10 Spray

260°C 480°C


2.5 – 4 mils ( 63 – 100 DFT)

Silicone Aluminum1 – 2 mils

( 25 – 50 DFT)

Silicone Aluminum1 – 2 mils

( 25 – 50 DFT)

System-A4 Stainless Steel ( Uninsulated)

( Note 9)

Not Applicable

Not Applicable

All temperature ranges

None None None






Painting System

Surface Preparation

Application Method

Operating Temperature Range

Primer (1st coat) Finish (2nd coat) Finish (3rd coat)

From To Thickness Thickness Thickness

Vessels, Exchangers, Tubular equipment and Piping - Insulated

System - B1 For CS & LAS

(Insulated)

SSPC-SP 10 Any

Ambient 149°C

Phenolic Epoxy 5 to 7 mils

( 125 – 175 DFT)

Phenolic Epoxy 5 to 7 mils

( 125 – 175 DFT) None

System – B2 For CS & LAS

(Insulated)

Not Applicable

Not Applicable

150°C Above None None None

System - B3 SS

(Insulated) ( Note 8 , 9)

Not Applicable

Any

Ambient 149°C Epoxy phenolic

4 to 6 mils ( 100 – 150 DFT)

Epoxy phenolic 4 to 6 mils

( 100 – 150 DFT) None

System - B4 SS

(Insulated) ( Note 8 , 9)

Not Applicable

Not Applicable

150°C Above None None None

Custom or catalogue equipment, valves and instruments

System - C1 (Uninsulated)

Supplier Standard Paint System

System - C2 (Insulated)

Supplier Standard Paint System

Storage Tanks ( Field Erected )

System - D1 For CS

Uninsulated SSPC-SP 10

Not Applicable

Ambient 120°C Inorganic Zinc Silicate

2.5 – 3.0 mils ( 63 – 75 DFT)

Modified Epoxy5 – 8 mils

( 125 – 200 DFT)


( 75 – 100 DFT)

System - D2 For CS

Insulated SSPC-SP 10

Not Applicable

Ambient 120°C Epoxy phenolic

4 to 6 mils ( 100 – 150 DFT)

Epoxy phenolic 4 to 6 mils ( 100 – 150

DFT)

None






Painting System

Surface Preparation

Application Method

Operating Temperature Range Primer (1st coat)

Thickness

Finish (2nd coat)

Thickness

Finish (3rd coat) Thickness From Thickness

System - D3 For SS

( Uninsulated) ( Note 9)

Not Applicable

Not Applicable

Ambient 120°C None None None

System –D4 For SS

( Insulated) ( Note 8, 9)

Not Applicable

Any Ambient 120°C Epoxy phenolic

4 to 6 mils ( 100 – 150 DFT)

Epoxy phenolic 4 to 6 mils ( 100 – 150

DFT)

None

Structural Steel ( Paint system for structural steel in place of Galvanizing )

System – E3 ( Only Carbon Steel )

SSPC- SP3 Any Ambient 120 C Inorganic Zinc Silicate

2.5 – 3.0 mils ( 63 – 75 DFT)

Epoxy Based Micaceous iron

oxide (MIO) 4 – 8 mils ( 100 –200

DFT)

Acrylic urethane 1.5 – 2 mils

( 37 – 50 DFT)

1) Blast cleaning requirement applies to first (prime) coat only. Refer to section 5 for surface preparation requirement before applying as a finish coat.

2) Paint materials containing zinc and aluminum shall not come in contact with stainless steel surfaces to avoid embrittlement.

3) Deleted.

4) Non heat curing silicon acrylic paint or silicon acrylic paint having heat curing temperature 120 C shall be used.

5) The average surface profile shall be 1.5 to 2.0 mils for inorganic zinc rich, urethane and epoxy paints, and 0.50 to 0.75 mils for silicone paints.

6) Exterior painting, except inorganic zinc spray application, within plant is restricted to brush or roll application unless a written exception signed by the owner.

7) DFT listed is nominal range. Consult individual supplier data sheets for recommended thickness.

8) Painting under insulation is required to prevent corrosion under Insulation due to presence of chloride.

9) All Stainless Steel surfaces shall be pickled and passivated as per Manufacturer Standard.






Paint Materials for Client Approval Materials specified or referenced by a manufacturer's name and/brand are intended to describe the type and quality level of the material desired and are not intended to be restrictive or to exclude similar items by other manufacturers. Alternate materials require approval from the ENGINEER before being used. Any approval given by the ENGINEER for alternate materials and/or application methods is subject to change if the performance of the alternate materials or application method is later found to be inferior to the specified materials and methods. In such cases, the SUPPLIER and CONTRACTOR shall remove and replace the applied coatings and revert the materials and application to comply with this Specification at no cost to FLUOR.

Approval is limited to application over surfaces operating at and application conditions less severe than the conditions stated in the published literature of the paint material manufacturer.

Equipment fabricator shall refer paint supplier product datasheet before applying painting. They shall also confirm the painting product as required per painting schedule in Attachment 1.

Indian Manufacturer:

Type & Paint Supplier

Inorganic Zinc

Silicate

Epoxy Mastic

Acrylic urethane

Phenolic Epoxy

Silicone Acrylic

Silicone Aluminum

Modified Epoxy

Epoxy MIO

Shalimar Paints

Tuffkote Silicate –

CGC / Epigard

Zinc Rich Primer

Supplier to

provide detail to contract

or / owner

Shalithane Finish

Supplier to provide detail to

contractor / owner

Supplier to

provide detail to

contractor / owner

Lustotherm MC 550


contractor / owner

Epigard HB MIO

Asian Paints Apcosil 605

Rust-o-cap

aluminium 90 %

Apcothane CF 678

Apcoguard CF 707

Acrysil HR

finish

Heat resisting silicone

aluminum paint

Apcodur EHB

Apcodur epoxy MIO

paint

Nerolac Nerosil 118

Supplier to


or / owner

Nerothane Enamel

PU

Neropoxy Phenolic

Supplier to

provide detail to

contractor / owner

Nerotherm 538


contractor / owner

Neropoxy 266 MIO






Sigma Coatings


contractor / owner

Supplier to


or / owner


contractor / owner


contractor / owner

Supplier to

provide detail to

contractor / owner


contractor / owner


contractor / owner


contractor / owner

Bombay Paints

Zinc-O-Sil 75

Pentadur Mastic 5515

Pentathane FP 4510

Pentadur HB

phenolic 5540

Supplier to

provide detail to

contractor / owner

Kangaroo HHR Aluminum 4950- 400C, Pentolite HHR Aluminum 500C

Supplier to provide detail to contractor / owner

Supplier to provide detail to contractor / owner

Berger Paints


contractor / owner

Supplier to


or / owner


contractor / owner


contractor / owner

Supplier to

provide detail to

contractor / owner


contractor / owner


contractor / owner


contractor / owner

International Manufacturer:

Type & Paint Supplier

Inorganic Zinc

Silicate

Epoxy Zinc Rich

Epoxy Mastic

Acrylic urethane

Phenolic Epoxy

Silicone Acrylic

Silicone Aluminum

Epoxy MIO

Carboline

CarboZinc 11

Carbo Zinc 859

Carboguard 890

Carbothane 134 HG

Phenoline 1205

Thermaline 4900

Thermaline 4700


contractor / owner

Akzonobel / International

Paint

Inter zinc 22

Inter zinc 52

Interseal 670 HS

Interthane 990

Intertherm 228;

Interline

Intertherm 875

Intertherm 50


contractor






850 / owner

PPG Amercoat

Dimetcote 9 Series

Amercoat 68 HS

Amerlock 400/2

Amercoat 450H Series

Amercoat 90 HS

Amercoat 874HS

Amercoat 878


contractor / owner






PLANT COLORS AND IDENTIFICATION

Painting colors on equipments & structural steel shall be as per Table 1.

Structures shall be color coded to warn personnel of potential physical hazards for safety. Safety identification color coding shall be in accordance with the Table 2.

The identification of piping color systems (Ground color for piping, Color bands, Color codes for general service, Color codes for industrial gases, Color codes for hydrocarbons, Labels, Labels dimensions, Lettering, Visibility marks), except colors listed in Table 3, shall be done in accordance with IS 2379 : 1990, PIPELINES-IDENTIFICATION COLOR CODE.

Except for safety color coding and unless otherwise stated in following tables, the finish colors shall be light ivory for equipment, piping and structural steel.

TABLE 1: COLORS FOR EQUIPMENTS & STRUCTURAL STEEL:

This table describes the color & color shade of the top coat of equipments and structural steel.

GENERAL

ITEM TO BE PAINTED COLOR RAL CODE / DB COLOR SHADE

Structural steel ( Open Area ) Dark Grey DB 703 / 701

Basalt Grey ( Alternative if Dark grey is not available )

RAL 7012

Structural Steel ( Covered Area)

Squirrel Grey RAL 7000

Pure White ( Alternative if Squirrel grey is not available )

RAL 9010

Columns, drums, vessels, pumps, heat exchangers T<120C

Light Grey RAL 7035

Columns, drums, vessels, pumps, heat exchangers T>120C

Aluminum RAL 9006

Steps and handrails except top and bottom (Top and bottom color as per table 2)

Jet Black RAL 9005

Spheres and storage tanks White RAL 9010

Outdoor Machines Silver Green DB 601






Roofed Machines Blue Grey RAL 7031

Reseda Green RAL 6011

Instrument, panels consoles, panel boards and cabinets

MS Manufacturer’s standard

TABLE 2: COLORS FOR SAFETY IDENTIFICATION:

This table describes the colors required for safety of Operators.

SAFETY IDENTIFICATION COLORS

ITEM TO BE PAINTED COLOR RAL CODE

Dangerous obstructions Black/Yellow Lines sloped at 45 minimum 50% of surface yellow

RAL 9005/1021

Dangerous or exposed parts of machinery

Alert Orange RAL 2003

Fire-Fighting equipment Fire Red RAL 3000

First aid equipment Dark Green RAL 6028

Rigging/Lifting items: Davits, Lifting beams, overhead traveling cranes and portal cranes

Static parts Yellow/Black Lines sloped at 45 minimum 50% of surface yellow

RAL 1021/9005

Moving parts Alert Orange RAL 2003

Top & Bottom of handrails for ladders and stairways, where indicated

Yellow/Black stripes RAL 1021/9005

Road Marking White RAL 9010

Identification for “Stop” and “Danger”,e.g. flammable liquid containers, emergency stop switches, fire protection equipment and apparatus

Red RAL 3002

Identification for marking hazardous parts of machines which may cut,

Alert Orange RAL 2003






crush, or other wise injure

Identification for “Safety” and location of “First Aid”, and “Safety Equipment

Dark Green, White lettering RAL 6028,

RAL 9010

TABLE 3: COLORS FOR PIPING:

This table describes the color & color shades of pipelines as per the type of fluid.

PIPING COLOR TABLE

ITEM TO BE PAINTED GROUND COLOR

(RAL CODE)

COLOR

OF FIRST BAND

(RAL CODE)

COLOR

OF SECOND BAND

(RAL CODE)

General Services ( Water)

Boiler Feed Water Sea Green Gulf Red

Condensate Sea Green Light Brown

Drinking / Low Pressure process water

Sea Green French Blue Signal Red

Fire Water Fire Red Crimson Red

Domestic, Hot ( 40 °C to 50 °C) Sea Green Light Grey

Warm Water / Temper Water Sea Green Light Grey Canary Yellow

Cold Water down Services from Storage Tank Sea Green French Blue

Canary Yellow

Chilled Water Sea Green Black Canary Yellow

Cooling Water Sea Green French Blue

Sea, River, Untreated (Raw)Water Sea Green White

Treated Water Sea Green Light Orange

Process Water & Low Pressure Process Water

Sea Green Oxide red






Quench Water Sea Green Dark Grey

Waste Water Sea Green Canary Yellow Signal Red

Dematerialized Water Sea Green Gulf Red

General Services ( Air & Steam)

Plant Air Sky Blue Silver Grey

Instrument Air Sky Blue French Blue

Compressed Air ( ≤ 15 kg/cm2) Sky Blue

Compressed Air ( ≥ 15 kg/cm2) Sky Blue Signal Red

Dry Vacuum White

Wet Vacuum White Dark Violet

High Pressure Steam ( 40 bar) Aluminum to IS 2339

French Blue

Low Pressure Steam Aluminum to IS 2339

Canary Yellow

General Services ( Oils)

High Speed Diesel Light Brown

Transformer Oil Light Brown Light Orange

Acids

Sulfuric Acid Dark Violet Brilliant Green Light Orange

Hydrochloric Acid Dark Violet Signal Red Light Orange

Phosphoric Acid Dark Violet Silver Grey

Chemicals and Allied Products

Caustic Solution / NaOH (47%) Smoke Grey Light Orange

Sodium Carbonate Solution Dark Violet Jasmine Yellow

Hydrocarbons






Methanol Dark Admiralty Grey Deep buff

Benzene Dark Admiralty Grey Canary Yellow

Ethylene Oxide Canary Yellow Dark Violet Brilliant Green

Butadiene Dark Admiralty Grey Black

Ethylene Glycol Dark Admiralty Grey Brilliant Green Gulf Red

Other Chemical Product not listed in IS 2379 code ( SLES,SLS,MDI,PMDI, ME,CMDI, Fatty Alcohol, Hydrogen Peroxide, Ester, Citric Acid, Methanol, Dehyton, Sodium Methylate, LABSA, Texapon N70 )

OWNER TO DECIDE

(Painting Contractor shall use the color as per Owner suggestion.)

OWNER TO DECIDE

(Painting Contractor shall use the color as per Owner Suggestion.)

Industrial Gases

Ammonia Canary Yellow Dark Violet

Sulphur Dioxide Canary Yellow Dark Violet Golden Brown

Flare Gases/ Off Gases Canary Yellow

Chloro-fluoro derivative of methane & ethane

Canary Yellow Light Grey Dark Violet

Hydrogen Canary Yellow Signal Red French Blue

Nitrogen Canary Yellow Black

Oxygen Canary Yellow White

PNG / Fuel Gas Canary Yellow Grey Dark Violet

Sewage Black

Emergency Vent ( Mouth of pipe) Canary Yellow

NOTE1: For insulated pipeline, the color bands shall be applied on parts of the cover sheet.

painting specification for storage tanks

Documents