petronas technical standard (pts 30.48.0031 sept2012)

PTS 30.48.00.31 September 2012

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PETRONAS TECHNICAL STANDARDS

TECHNICAL SPECIFICATION

PROTECTIVE COATINGS AND LININGS

PTS 30.48.00.31

SEPTEMBER 2012

2012 PETROLIAM NASIONAL BERHAD (PETRONAS)

All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright owner.


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This revision of PTS 30.48.00.31 Protective Coatings and Linings has been updated to incorporate PETRONAS Lessons Learnt, Best Practice and new information issued by relevant industry code and standards. All updates in the document are highlighted in blue font.

The previous version of this PTS 30.48.00.31-P (September 2009) will be removed from PTS binder / e-repository from herein onwards.

The custodian of this PTS is: Name : Nurul Asni Mohamed Contact. No : 603 2783 6063 Please direct any questions regarding this PTS to the above-named.

Revision History

Rev No. Reviewed by Approved by Date 1 Nurul Asni Mohamed

Hasbullah Abu Hassan Zamaluddin Ali December 2011

2 Nurul Asni Mohamed

M Hawari Hasan June 2012

3 Nurul Asni Mohamed

M Hawari Hasan September 2012

PTS Circular 2012 PTS No: 30.48.00.31 PTS Title: Protective Coatings and Linings


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PREFACE

PETRONAS Technical Standards (PTS) publications reflect the views, at the time of publication, of PETRONAS OPUs/Divisions. They are based on the experience acquired during the involvement with the design, construction, operation and maintenance of processing units and facilities. Where appropriate they are based on, or reference is made to, national and international standards and codes of practice. The objective is to set the recommended standard for good technical practice to be applied by PETRONAS' OPUs in oil and gas production facilities, refineries, gas processing plants, chemical plants, marketing facilities or any other such facility, and thereby to achieve maximum technical and economic benefit from standardisation. The information set forth in these publications is provided to users for their consideration and decision to implement. This is of particular importance where PTS may not cover every requirement or diversity of condition at each locality. The system of PTS is expected to be sufficiently flexible to allow individual operating units to adapt the information set forth in PTS to their own environment and requirements. When Contractors or Manufacturers/Suppliers use PTS they shall be solely responsible for the quality of work and the attainment of the required design and engineering standards. In particular, for those requirements not specifically covered, it is expected of them to follow those design and engineering practices which will achieve the same level of integrity as reflected in the PTS. If in doubt, the Contractor or Manufacturer/Supplier shall, without detracting from his own responsibility, consult the Principal. The right to use PTS rests with three categories of users:

1) PETRONAS and its affiliates. 2) Other parties who are authorised to use PTS subject to appropriate contractual

arrangements. 3) Contractors/subcontractors and Manufacturers/Suppliers under a contract with users

referred to under 1) and 2) which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said users comply with the relevant standards.

Subject to any particular terms and conditions as may be set forth in specific agreements with users, PETRONAS disclaims any liability of whatsoever nature for any damage (including injury or death) suffered by any Company or person whomsoever as a result of or in connection with the use, application or implementation of any PTS, combination of PTS or any part thereof. The benefit of this disclaimer shall inure in all respects to PETRONAS and/or any Company affiliated to PETRONAS that may issue PTS or require the use of PTS. Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, PTS shall not, without the prior written consent of PETRONAS, be disclosed by users to any Company or person whomsoever and the PTS shall be used exclusively for the purpose they have been provided to the user. They shall be returned after use, including any copies which shall only be made by users with the express prior written consent of PETRONAS. The copyright of PTS vests in PETRONAS. Users shall arrange for PTS to be held in safe custody and PETRONAS may at any time require information satisfactory to PETRONAS in order to ascertain how users implement this requirement.


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TABLE OF CONTENTS 1 PURPOSE 4 2 SCOPE AND DEFINITIONS 5 2.1 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS 6 2.2 DEFINITIONS 6 3 WARRANTY AND PAINTING CONTRACTORS RESPONSIBILITIES 10 3.1 WARRANTY 10 3.2 PAINTING CONTRACTORS RESPONSIBILITIES 10 4 SURFACE PREPARATION 14 4.1 GENERAL 14 4.2 PRE-CLEANING 14 4.3 SURFACE PREPARATION BY BLAST CLEANING 15 5 APPLICATION 20 5.1 PRE-APPLICATION PROCEDURES 22 5.2 APPLICATION CONDITIONS 22 5.3 APPLICATION METHODS 23 5.4 REPAIRS AND TOUCH UP PAINTING 26 6 PAINTING AND COATING SYSTEMS 28 6.1 COATING SYSTEMS SELECTION 28 6.2 PAINTING AND COATING SYSTEM SCHEDULES FOR EXTERNAL APPLICATION 29 6.3 PAINTING AND COATING SYSTEM SCHEDULES FOR INTERNAL APPLICATION 36 6.4 PAINT MATERIALS STORAGE, SHELF-LIFE AND HANDLING 42 6.5 COATING SYSTEMS PRODUCT APPROVAL REQUIREMENT 42 7 QUALITY CONTROL 46 7.1 INSPECTION 46 7.2 PROJECT PRODUCTION TESTING 46 8 RESOURCE EQUIREMENT 47 8.1 PAINTING CONTRACTOR 47 8.2 PAINTING INSPECTOR 47 8.3 BLASTING AND PAINTING SUPERVISOR 48 8.4 COATING AND QUALITY CONTROL TECHNICIAN (QC) 49 8.5 THERMAL SPRAY APPLICATOR 50 8.6 BLASTER / PAINTER 51 8.7 PAINT SUPPLIER COATING ADVISOR 51 8.8 INSPECTION EQUIPMENT 52 9 HEALTH, SAFETY AND ENVIRONMENT (HSE) 53 9.1 SAFETY AND HEALTH REGULATIONS 53 9.2 ENVIRONMENT REGULATIONS 53 10 COLOUR SCHEMES 55 11 REFERENCES 56 12 APPENDICES 59


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1 PURPOSE The Purpose of this industrial standard is to standardise and to improve Protective Coating Specification to optimise cost of painting without compromising Quality and Coating Performance in accordance with the guideline stipulated in Appendix 1. This standard is also intended for use by Engineers to select Painting Systems and Coating Systems to be used and applied on metallic substrates requiring protection from corrosion. Decision to implement all works described herein shall be justified in view of its potential value creations and annual cost savings and to fulfil the philosophy stated herein:

a) To maintain the integrity of oil and gas production facilities by minimising materials

degradation caused by corrosion b) To enhance in-service performance of coating systems through proper paint

materials selection, quality control during application, continuous monitoring and proper maintenance.

c) Continuous improvement towards cost effective painting practices by acquiring, testing and utilising new coating systems and technology through :

! Collective efforts and systematic feedback by all Users. ! Centralised Committee and PETRONAS Protective Coatings and Linings

Technical Committee (PCLTC). ! Close co-operation and alliancing between PSCs, Paint manufacturers,

Independent bodies and research institutes.

d) To create high level of corporate awareness in PETRONAS OPUs/Divisions, all PSCs and other service companies on the importance of protective coating in controlling corrosion.

e) To promote Health, Safety and Environmental (HSE) awareness in the Malaysian Protective Coating industry.


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2 SCOPE AND DEFINITIONS

The scope of this specification is to provide minimum requirements for both external and internal coating of both onshore and offshore facilities in the oil and gas industry. It shall also include initial and maintenance painting guidelines. The specification is not applicable to buried and submerged structures below the splash zone. Specialised equipment supplied by vendors such as valves, pumps, compressors, etc. will be coated in compliance with the User's respective functional specification; as such they are not covered under this publication. This revision has included two types of coating system recommended for the protection of bolts and nuts. Refer to Appendix 11.

2.1 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS

Unless otherwise authorised by PETRONAS, the distribution of this PTS is confined to companies forming part of PETRONAS or managed by a Group Company, and to Contractors and Manufacturers/Suppliers nominated by them. This PTS is intended for use in oil refineries, chemical plants, gas plants, exploration and production facilities and supply/marketing installations. If national and/or local regulations exist in which some of the requirements may be more stringent than in this PTS, the Contractor shall determine by careful scrutiny which of the requirements are more stringent and which combination of requirements is acceptable as regards to safety, environmental, economic and legal aspects. In all cases, the Contractor shall inform the Principal of any deviation from the requirements of this PTS which is considered to be necessary in order to comply with national and/or local regulations. The Principal may then negotiate with the authorities concerned with the object of obtaining agreement to follow this PTS as closely as possible.

2.2 DEFINITIONS

2.2.1 General Definitions The Contractor is the party which carries out all or part of the design, engineering, procurement, construction, commissioning or management of a project or operation of a facility. The Principal may undertake all or part of the duties of the Contractor. The Manufacturer/Supplier is the party which manufactures or supplies equipment and services to perform the duties specified by the Contractor. The Principal is the party which initiates the project and ultimately pays for its design and construction. The Principal will generally specify the technical requirements. The Principal may also include the Subject Matter Expert (SME), an agent or consultant authorised to act for, and on behalf of, the Principal. The Custodian is the Owner of this specification ie. PETRONAS Group Technical Solutions. Painting system is a term intended to include, with equal emphasis, not only the well accepted components of a system such as surface preparation and paint materials but also application, inspection and safety functions. Coating system is a term which refers to the applied and cured multilayer film or to the components of a system based on non-paint type coating.


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Initial painting is a term which refers to the painting of new facility or complete recoating of existing asset during major maintenance. Maintenance painting is a term which refers to the periodic painting after initial painting (repair, touch up of corroded areas or deteriorated paintwork). The word shall indicates a requirement. The word should indicates a recommendation.

2.2.2 Specific Definitions

DFT Dry Film Thickness; the thickness of the dried/cured paint or coating film. Equipment The equipment to be painted is listed in Appendix 1 and includes piping,

vessels, columns, exchangers, reactors, structural steel, fire-fighting systems, tanks, LPG storage vessels, furnaces, stacks, flare stacks, flue ducts, offshore structures and topside facilities.

Grit Particles that are predominantly angular, have fractured faces and sharp edges and are less than half round in shape.

Operating Temperature

See PTS 01.00.01.30

Shot Particles that are predominantly round, that have a length of less than twice the maximum particle width and that do not have edges, broken faces or other sharp surface defects.

TDFT Total Dry Film Thickness; the thickness of the total number of coatings specified.

WFT Wet Film Thickness; the thickness of the uncured or wet paint or coating film. PSC Production Sharing Contractors PCLTC PETRONAS Protective Coatings and Linings Technical Committee

2.3 SUMMARY OF CHANGES This PTS is the revision of old PTS dated September 2009. Table below provides summary of changes made to this latest PTS. This includes the adoption of the latest ISO 8501-1:2007 which replaces the old standard ISO 8501-1:1988. This PTS also made reference to the latest available ISO 8502-1:2002 and ISO 8504-2:2000.

Old Section

New Section

Summary of Changes

All Change the word Owner to Principal. Revise and edit grammatical errors. Revise reference of ISO 8501-1:1988 to latest released, ISO 8501-1:2007.

1 1 Added and revised sub-topic under c) as follows:

Centralised Committee and PETRONAS Protective Coatings and Linings Technical Committee (PCLTC) ! Close co-operation and alliancing between PSCs, Paint manufacturers,

Independent bodies and research institute.

2 2 Added statement on another type of coating available for bolts and nuts as follows: This revision has included two types of coating system recommended for the protection of bolts and nuts. Refer to Appendix 11.


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2.2.1 2.2.1 Remove PRSB and rename GTS as the Custodian referred in this PTS as follows: The Custodian is the Owner of this specification ie. PETRONAS Group Technical Solutions. Rephrase the following sentences: Initial painting is a term which refers to the painting of new facility or complete recoating of existing asset during major maintenance. Maintenance painting is a term which refers to the periodic painting after initial painting (repair, touch up of corroded areas or deteriorated paintwork).

2.2.2 2.2.2 Added the following specific definition: PSC - Production Sharing Contract. PCLTC - PETRONAS Protective Coatings and Linings Technical Committee.

3.2.1 3.2.1 Rephrase the following paragraph into: Copies of this PTS, work planning and the quality plan shall be made available to the Coating Contractor's representative at site and the representative shall understand its contents.

3.2.2 3.2.2 Added the following sentence: Site safety regulations shall be adhered to.

3.2.7 3.2.7 Added a word in the following sentence: Access for coating work should be constructed bearing in mind that it should provide safe, easy and sufficient access for surface preparation, painting and inspection of all surfaces.

4.2 4.2 Rephrase a sentence as follows: For the treatment of stainless steels, the level of free halides in materials to be used shall be confirmed and reviewed by Principal. Added a sentence as follows: Flushing activity shall be less than 10ppm while the actual concentration shall be maintained between 20 to 30ppm.

4.3.1 4.3.1 Rephrase a sentence as follows: Should Thermally Sprayed Aluminium be used to coat carbon steel, low alloy steels and stainless steels, the surface profile shall be between 70 m to 110 m.

4.3.4 4.3.4 Amend Table 3 according to latest DEP. Abrasive blast cleaning SSPC ISO 8501-1 NACE emarks

White metal blast cleaning SP5 Sa 3 No. 1 Ne r white metal cleaning SP10 Sa 2.5 No. 2 Commercial blast cleaning SP6 Sa 2 No. 3 Brush-off (Sweep) blast cleaning SP7 Sa 1 No. 4 Power-tool cleaning (to bare metal) SP11 - - Commercial grade power tool SP 15 - - Power-tool cleaning SP3 St 3 - Hand-tool cleaning SP2 St 2 - Solvent cleaning SP1 - - High and ultrahigh pressure water jetting SSPC ISO 8501-1 NACE Water jet cleaning SP12 No. 5 Wet abrasive blasting TR2 6G198 WJ1-WJ4


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4.3.6 4.3.6 Revise the following sentences into: Abrasive blasting shall not be conducted in open areas close to painting operations or wet coated surfaces to prevent dust and grit contamination. Normally, grit blasting shall be permitted only during daylight hours. However, rough abrasive blasting is allowed during the night provided that the surface is subsequently blasted to the specified standard under good light conditions. The illumination of the surface during final blasting shall be at least 500 Lux and all environmental restrictions shall be observed.

4.3.7.2

4.3.7.2

Potable water was identified to be the source of water for cleaning the blasted surface under abrasive blasting and jet cleaning

4.3.7.3 4.3.7.3 Portable water was specified as the source of water to be used 6.2.5 6.2.5 Remove first coat system of Inorganic Zinc Silicate.

Added note as follows: To ensure good adhesion to the metal surface, surface tolerant aluminum paint shall be used.

6.2.11 6.2.10 Revise the sections numbering due to missing Section 6.2.10 from old PTS

6.2.12 6.12.11 Revise the sections numbering due to missing Section 6.2.10 from old PTS Added painting specification as follows: Surface preparation: Degrease as SSPC-SP1 and wash with fresh clean water, light abrade or sweep blast surface to provide anchor pattern of 25micron.

Coating System DFT 1st Coat Aliphatic polyurethane 50 Total 50

6.3.4.3 6.3.4.3 Retained PTS 2008 coating system to Epoxy instead of Amine 6.5 6.5 Remove PRSS and ANM as recognised body to conduct paintings and coatings

testing in the below paragraph and rephrase the sentence to indicate not limited to the stated laboratories/ bodies only.

6.5.2 6.5.2 Remove PRSS as approved test house as per below paragraph: The test panels shall be submitted to an approved third party testing agency for laboratory testing.

8.2.1.1 8.2.1.1 Amend certificate name to include Coating as per below: NACE International Certified Coating Inspector Level III

8.2.1.2 8.3.1 8.4.1 8.5.1 8.6.1

8.2.1.2 8.3.1 8.4.1 8.5.1 8.6.1

Added equivalent to each required certification to allow contractor with different but similar accreditation level to perform each specific task.

8.5 8.5 Revise the title from Thermal Sprayer to Thermal Spray Applicator 8.8 8.8 Added statement to indicate possible utilising other equipment to perform inspection

as follows: The painting inspection equipment shall be provided by the Inspection agency and the Contractor. The appropriate instruments with valid calibration where applicable, to be used at various inspection points are listed but not limited to the following:


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11.4 11.4 Amend specification to the latest standards as follows:

Standard /Publication No.

Description

ISO 8501-1: 2007 Preparation of steel substrates before application of paints and related products - Visual assessment of surface cleanliness - Part 1 : Rust grades and preparation grades of uncoated steel substrates and steel substrates after overall removal of previous coatings.

ISO 8502-1: 2002 Preparation of steel substrates before application of paints and related products - Tests for the assessment of surface cleanliness - Part 1 : Field test for soluble iron corrosion products

ISO 8502-3: 1992 Preparation of steel substrates before application of paint and related products - Test for the assessment of surface cleanliness - Part 3 : Assessment of dust on steel surfaces prepared for painting (pressure- sensitive tape method)

ISO 8504-2:2000 Preparation of steel substrates before application of paint and related products - Surface preparation methods - Part 2: Abrasive blast-cleaning

11.6 11.6 Add reference on Protective coatings for onshore facilities to Shell standard

12 12 Remove Appendix 10, PETRONAS Corporate Policy Statement on Health, Safety and Environment, from this latest PTS and amend the chapter number. Amend Appendix 11 title from Specification of Fluorocarbon Coating of Bolt and Nuts to Specification for Bolts and Nuts Coating

Appendix 7

Appendix 7

Added Heat Resistance test as required Coating System Testing for Coating System 5A (1), 4A and 4B.

Appendix 10 to 12

Appendix 10 to 11

Remove old Appendix 10 on PETRONAS corporate policy statement on health, safety and environment and rename section. Appendix 11: Amend Appendix 11 title from Specification of Fluorocarbon Coating of Bolt and Nuts to Specification for Bolts and Nuts Coating Revamp and added new scope according to PETRONAS Carigali Standard Procedure (July, 2012).


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3 WARRANTY AND PAINTING CONTRACTORS RESPONSIBILITIES

3.1 WARRANTY

Contractors, undertaking painting and/or coating work, which are to be carried out in accordance with this PTS, shall guarantee the quality of their coating work. Before any painting or coating work shall commence, warranty period and coating condition shall be agreed with the Principal. A minimum warranty period of five (5) years or ten (10) years is required for special coatings such as Thermally Sprayed Aluminium. The use of coating systems as described in this PTS and approved by the Principal shall not affect the warranties to be agreed by the contract parties involved. If reference areas are proposed and agreed, they shall be in accordance with requirements as specified in ISO 12944-7 Clause 7 and ISO 12944-8 Table 1, No.1.13. Surfaces that have deteriorated beyond the acceptable level of breakdown within the warranty period shall be repaired by the Contractor. The Contractor shall also bear the cost for materials, equipment, labour, onshore transport and onshore storage necessary for the repair. Only surfaces that have suffered from mechanical damage or chemical spillage as a result of operational activities fall outside this warranty. Initial acceptance of any new coating work by the Principal will not relieve the Contractor of his obligations under this section until the final inspection has been carried out and acceptance of the completed work has been agreed in writing. A final inspection shall be carried by a party to be agreed between the Contractor and the Principal before expiry of the coating work warranty period. In case of a dispute on the condition of the coating work that has been inspected, an agreed independent expert body shall conduct a review inspection at the Contractors cost. Both the Principal and the Contractor shall accept the findings of the inspection by this independent consultant.

3.2 PAINTING CONTRACTORS RESPONSIBILITIES

3.2.1 General

The Contractor, in addition to his responsibilities under the general conditions of the contract is responsible for the quality of the work which shall be performed in strict accordance with this PTS and all other relevant documents, such as site regulations, safety rules and requirements, product data sheets, referenced standards and codes. The Contractor is fully responsible for all Quality Assurance and Control activities. The contractor shall schedule a pre-job meeting to ensure that job and quality requirements are fully understood. Attendees should be a representative of the Principal, contractors job superintendent and coating supervisor, the coating inspector and the coating manufacturers representative. The Contractor shall submit for any major coating work an appropriate work planning and a quality plan for implementing this PTS for review by the Principal.


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Copies of this PTS, work planning and the quality plan shall be made available to the Coating Contractor's representative at site and the representative shall understand its contents.

3.2.2 Safety and Environment The Contractor shall be responsible for all aspects of safety and personal protection related to the painting work to be done. Environmental regulations and rules shall be met. Safe working is of the greatest importance particularly during paintwork in confined spaces such as tanks and vessels. Site safety regulations shall be adhered to. All personnel shall be provided with approved personnel protection e.g. protective clothing, safety glasses, safety shoes, hard hats, goggles, respirators, earplugs, fresh-air-fed hood and any other necessary safety equipment. All safety equipment shall be maintained to a good working condition. Adequate warning signs shall be prominently displayed on each access way to all areas where abrasive blasting and painting is in progress. Handling and disposal of hazardous waste resulting from the Contractor's painting activities shall be in accordance with regulations and specific contract requirements. However, the Principals regulations on chemical management or banned materials shall be strictly adhered to.

3.2.3 Hazardous coating components

The Contractor shall ensure that all layers of a coating system and blasting materials comply with any local and/or regional standards or regulations on banned materials such as lead, chromate, crystalline silica, and coal tar. The Principals regulations on chemical management or banned materials shall be strictly followed. Any coating system shall fully comply with any local and/or regional air quality or Volatile Organic Compounds (VOC) levels or emission standards or regulations. Coatings shall contain maximum 0.1% Monomeric Isocyanate at the time of painting. Before commencing of any surface preparation, the existing coating system shall be checked for hazardous components.

3.2.4 Personnel

Only professional skilled blasters and painters shall be employed. Blasters and painters working on every painting job shall be certified in accordance with a scheme approved by the Principal. A certified foreman shall supervise the blasters and painters. Before commencing any work or awarding a contract, the certificates shall be submitted to the Principal. Certifying bodies shall comply with ISO 17024. A skilled foreman shall supervise the blasters and painters. If not certified, the skill of all blasting and painting personnel shall be verified before commencing any painting or coating work. The blasters shall blast a representative structural steel part (min. 2m) using the equipment to be used for the actual surface cleaning. The painters shall coat a representative structural steel part (min. 2m) with an agreed coating system. The test area shall be fully coated with all coats of the agreed coating system using the tools and equipment to be used for the actual coating work. The painted test area shall be maintained for the duration of the project as a reference. The Principal shall witness all tests.


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3.2.5 Protection of equipment and structural members

The painting Contractor shall protect all equipment, structures and any other areas from mechanical damage, environmental damage, blockage or obstruction, damage caused by over blasting, paint droppings and splashes or overspray.

3.2.6 Blasting and spraying equipment

The Contractor shall demonstrate that blasting and spraying equipment to be used are in good condition and well maintained. Blasting and painting equipment shall fully comply with any local and/or regional regulation. The compressed air shall be free of water and oil. Adequate separators and traps shall be provided, installed in the coolest part of the system. The presence of oil and water shall be determined in accordance with ASTM D 4285-83 at least two (2) times per twelve (12) hours. In no case shall the temperature of the compressed air be allowed to exceed 110C. Blast cleaning air, when blown through a white cloth or onto white paper for one minute shall leave no visible residue. Blasting nozzles shall be discarded and replaced when the nozzle diameter has increased through wear by more than 50% of the original diameter. Blasting equipment, its operators and the equipment being blasted shall be properly earthed to prevent the occurrence of electrostatic discharges. Abrasive blast cleaning equipment shall of intrinsically safe construction and equipped with a remote shut-off valve triggered by the release of a dead man's handle at the blasting nozzle. Where air-operated equipment is used, the operator's hood or headgear shall be ventilated by clean, cool air supplied through a filter, to prevent blast cleaning residues from being inhaled. When working in confined spaces, ventilation and/or spark-proof lighting shall be used.

3.2.7 Access Access for coating work should be constructed bearing in mind that it should provide safe, easy and sufficient access for surface preparation, painting and inspection of all surfaces. Scaffolding shall be constructed in accordance with local regulations and the requirements of the Principal or as otherwise agreed with the Principal.

3.2.8 Handling and coated parts/components To minimise the risk of damage, no lifting, transportation, erection or fabrication operations

shall be done before the paint has been fully dried and/or cured. Welding shall not be carried out on the external surfaces of internally coated tanks or vessels. Canvas or nylon slings shall be used for lifting, and wooden blocks shall be applied during transportation.

3.2.9 Storage protection The Contractor shall supply all the necessary protection when prefab coated steel or coated

steel for climate controlled areas has to be stored in the open air prior to erection, to avoid premature failure of the applied paint layers.


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3.2.10 Weather protection Unless otherwise agreed, the Contractor shall supply all weather protection, scaffolding and any other equipment necessary to ensure that the work is carried out in accordance with this PTS and to the agreed program. This includes, for example, heating and air-drying equipment.


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4. SURFACE PREPARATION

4.1 GENERAL For optimum paint performance surfaces to be painted or coated shall be completely dry and free from burrs, weld spatter, flux, rust, loose scale, dirt, dust, grease, oil and other foreign matter before any paint is applied. If the surface has been exposed to a pollutant, e.g. salt-laden, atmosphere, it shall be washed down with clean, fresh water prior to blasting or power tool cleaning. Cleaning of surface shall, as general rule, be done by dry blast cleaning (hereafter referred to as blast cleaning) as outlined in ISO 8504-2. The surface profile and the anchor pattern shall be in accordance with the requirements in this document. Fabrication should be completed before surface preparation begins. However, surface preparation and application of the base layers of the specified coating system before assembly will be allowed. Prefabrication primers are allowed. However, after assembly these primers shall be removed by blasting and the surface shall be blasted to the initial specified surface cleanliness unless otherwise agreed by the Principal. Alternative surface cleaning is only acceptable after written approval by the Principal. Alternative surface preparation such as power tool cleaning is not acceptable for areas difficult to access such as areas exposed to water, steelwork to be insulated or to be buried and the internal surfaces of equipment and tanks. Stainless steel surfaces shall not be treated with carbon steel cleaning tools. After preparation of the substrate surface, any grit, dust etc. shall be removed and a layer of primer applied before any corrosion or recontamination occurs, normally within 4 hours after blasting. Surface preparation shall be carried out by dry blast-cleaning wherever possible. The surface preparation grades shall be as specified in Appendix 2 for the various paint systems.

4.2 PRE-CLEANING

Prior to the blast cleaning and/or prior to any painting works, the surface shall be free of any contamination and any excessive rust scale shall be removed by impact cleaning tools or high pressure water jetting. All edges shall be ground to a minimum radius of 2 mm or otherwise agreed with the Principal and flame cut areas should have been ground flush. Weld spatter shall have been ground flush. If this is not the case, the Principal shall be informed, and corrective action shall be taken prior to the application of the first layer of the coating system. All bolt holes shall be solvent cleaned prior to the commencement of blast cleaning. Solvent cleaning shall be carried out in accordance with SSPC, SP1 Solvent Cleaning. When emulsion or detergent type degreasers or Teepol/fresh water solutions are used, this treatment shall be followed by copious rinsing using fresh and clean potable water or pressure water/steam wash. These types of degreasers shall be proven to be biologically degradable.


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Maintenance coating should always start with a high pressure steam/detergent cleaning to remove dirt, grease and/or salt deposits. In addition, after a long interval prior to the application of the subsequent layers of a coating system or exposure to a storm at offshore, the surface shall be cleaned by using high-pressure water/steam or water wash before the application of the next coating layer. In the specific case of uncoated stainless steel components, water/steam cleaning shall not be allowed using water with a temperature of > 50 degrees C. However, the requirements regarding the soluble salts and other surface contaminants in this document shall be adhered to at all times. All welded areas and appurtenances shall be given special attention for removal of welding flux in crevices. Welding splatter, slivers, laminations and underlying mill scale which are not removed during fabrication shall be removed prior to painting activities by the best mechanical means and the edges smoothed or rendered flush. Before performing abrasive blast cleaning, all equipment which could be damaged by blast, dust or particulate matter shall be suitably protected by masking, wrapping, taping or other means to prevent damage. Where required, the degree of contamination shall be assessed in accordance with procedures described in ISO 8502-3. This equipment shall include but not necessarily limited to the following: Bearings Control panels Control valves Conduit Instrument dials Expansion joint bellows Machined surfaces Shafts Push buttons Tags Screws Exposed moving parts

Adequate blocking or enclosure of the work area by either canvas, tarpaulin or suitable material shall be constructed and accepted by the Principal in order to avoid damage to other areas or equipment. This enclosure shall be constructed such as to contain any waste produced from the surface preparation activity. Any necessary equipment i.e. exhaust fan, air cooler, lighting for night work and other related HSE requirement shall be installed within this enclosure. Where rectification has been necessary on blast-cleaned surfaces, the dressed areas shall be pre-cleaned as initially specified. For the treatment of stainless steels, the level of free halides in materials to be used shall be confirmed and reviewed by Principal. Particular care shall be taken to dry areas, which are not self-draining, so that water collected is removed and not allowed to evaporate leaving salt deposits on the surface. Flushing activity shall be less than 10ppm while the actual concentration shall be maintained between 20 to 30ppm. Detergents with a pH >9 shall not be used on aluminium substrates.

4.3 SURFACE PREPARATION BY BLAST CLEANING

4.3.1 General

Blast cleaning shall be carried out through ISO 8504-2 to the required visual standard in accordance with ISO 8501-1 or equivalent. The minimum requirement for successful surface preparation shall be Sa 2.5 at the time of coating, unless specified by paint manufacturer on their surface tolerant coating systems.


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The blast cleaning of stainless steel shall be carried out by sweep blasting using a fine abrasive not containing iron (e.g. garnet, Aluminium Oxide, Aluminium Silicates), glass pearls or stainless steel shots. To reduce the risk of unacceptably damaging the substrate while sweep blasting stainless steel or hot dip galvanized surfaces, it is recommended that a reduced nozzle pressure be used in combination with a small size abrasive. Blast clean shall not be done close to painting operations or wet coated surfaces to prevent dust and abrasive contamination. Environmental restrictions shall be observed. Rough grit blasting will be allowed during the night providing that the surface is subsequently blasted under good light conditions to the specified Standard. Blast clean steel surfaces shall not be touched by bare hands. If the surface being cleaned lies adjacent to a coated surface, which is not to be repaired, the blast cleaning shall overlap the coated surface by at least 50 mm. The edges of the existing coating system shall be feathered. The remainder of the existing coated surface shall be properly protected with shields or screens to prevent any over blast damage. No acid wash, cleaning solvents or other chemical treatments shall be used on metal surfaces after they have been (dry) blast cleaned. This restriction includes inhibitive washes intended to prevent rusting. The surface profile or anchor pattern for carbon steel and low alloy steels to be coated with liquid organic coatings shall be in accordance with the written recommendation of the paint manufacturer. When not specified by the paint manufacturer or when otherwise specified in this document, the surface profile shall be between 40 m and 70 m. If stainless steel, galvanised or non-ferrous metal surfaces are to be painted with liquid (organic) coating materials, blast cleaning of these surfaces shall be carried out by smooth sweep blasting, using a small size non-iron containing abrasive (e.g. aluminium oxide). On galvanised surfaces, the zinc layer shall not be damaged, a smooth uniform surface roughness shall be achieved, no defects such as break through or crisping of the zinc layer shall occur. Surface roughness shall be in the range of 20 m to 30 m or shall be agreed with paint manufacturer. After approval by the Principal, abrading with sandpaper or light grinding with a suitable (flexible) disc maybe used for surface preparation if sweep blasting is impossible. In addition, when aluminium or galvanised components have to be painted, white zinc or aluminium corrosion products and/or rust present shall be removed. Should Thermally Sprayed Aluminium be used to coat carbon steel, low alloy steels and stainless steels, the surface profile shall be between 70 m to 110 m.

4.3.2 Blast cleaning equipment The compressed air supply used for blast cleaning shall be free from water and oil. Adequate separators and traps shall be provided, installed in the coolest part of the system. They shall be emptied regularly to prevent carry-over of water and oil. Accumulations of oil and moisture shall be removed from the air receiver by regular purging. Conduct Blotter Test ASTM 4285 to check for air cleanliness at appropriate intervals. Air compressors shall not be allowed to deliver air at a temperature above 110 C. Abrasive blast cleaning equipment shall be of intrinsically safe construction and equipped with a remote shut-off valve triggered by the release of a dead man's handle at the blasting nozzle. Where air-operated equipment is used, the operator's hood or head gear shall be ventilated by clean, cool air served through a regulator filter, to prevent blast cleaning residues from being inhaled.


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4.3.3 Blasting Abrasives 4.3.3.1 International standards and characteristics of abrasives

Blasting abrasives for use in blast cleaning carbon steels and low alloy steels are specified in ISO 8504-2. Recommended blasting abrasives are as follows but not limited to: Chilled iron grit or shot Steel and malleable iron grit or shot Natural mineral abrasives Non-metallic abrasives

Where abrasives which are specified as a Scheduled Waste are used, the waste shall be collected and disposed off at prescribed premises as per the requirement of the Environmental Quality Act (EQA) 1974. Sand or other materials producing silica dust shall not be used. All metallic blast cleaning abrasives shall meet the requirements of ISO 11124 and be tested in accordance with test methods specified in ISO 11125 Part 1-7. All non-metallic blast cleaning abrasives shall meet the requirements of ISO 11126 and be tested in accordance with test methods specified in ISO 11127 Part 1-7. Product shall be sealed in hermetic packaging. Any product delivered in defective packaging shall be rejected. Products must be stored sheltered from the elements. The blast profile and angular anchor pattern shall be that recommended by the paint manufacturer to suit the minimum requirement of their respective primers and the minimum peak-to-valley height shall be 25 microns. Roughness or anchor pattern measurement shall be carried out by the painting contractor using instruments and procedures approved by the Principal. Where anchor patterns are not specified in the paint manufacturers technical data sheet, Table 1 below shall be used as a guide for determining the anchor pattern.

Table 1 - Relationship between coating thickness and anchor pattern

Dry film thickness Anchor pattern 125-200 microns (5-8 mills) 25-50 microns (1 -2 mills) 200-500 microns (9-20 mills) 50-76 microns (2-3 mills) > 500 microns (>20 mills) 75-125 microns (3-5 mills)

Abrasives for use in blast cleaning steels shall be in accordance with ISO 8504-2 and Table 2 - Abrasive specifications.

Table 2 Abrasive specifications

Type of abrasive Generic Name Characteristics Standard

Metallic Iron grit >1.7% carbon ISO 11124-2 Steel grit 0.8% to 1.2% carbon ISO 11124-3

Non-metallic Natural mineral

Olivine Magnesium/iron silicate ISO 11126-8 Staurolite Iron/aluminium silicate ISO 11126-9 Specular hematite Crystaline Fe2O3 Garnet Calcium iron silicate ISO 11126-10

Non-metallic Synthetic mineral/ Industrial by-product

Coal furnace slag Aluminium silicate ISO 11126-4 Aluminium oxide Crystalline corundum ISO 11126-7

Iron furnace slag Calcium silicate ISO 11126-6


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4.3.3.2 Selection of abrasives

There is a wide variation in performance between the products within a given generic class of abrasives. Surface anchor profile is directly proportional to the abrasive particle size (the larger the abrasive particle size, the deeper the profile). Cleaning rate is inversely proportional to the abrasive particle size (the larger the abrasive particle size, the slower the cleaning rate). A balanced mixture of particle sizes will produce the optimum level of cleanliness, cleaning rate and surface profile. Pre-qualification of the blast cleaning abrasives shall be conducted subject to acceptance and approval by the Principal prior to their use. The pre-qualification test shall be carried out in accordance with a set of procedure covering field trials and laboratory testing to determine their physical and chemical properties, efficiency and effectiveness that can support the economics for their usage. Steel or iron grit is commonly used as recyclable abrasives. In general, when steel shot is used, it shall be used together with steel grit and approved by the Principal. The abrasives shall be free from oil, grease, moisture, chloride contamination etc. Each batch of abrasive should be tested to check the abrasive meets the requirements as specified in the relevant ISO standard. The conductivity of abrasives to be used on carbon steels shall be less than 150 S/cm. The salt contamination of abrasives shall be less than 30 mg/m2.

4.3.4 Grades of surface finish

The recognized surface finish grades are summarized in Table 3.

Table 3 Surface finish grades Abrasive blast cleaning SSPC ISO 8501-1 NACE Remarks White metal blast cleaning SP5 Sa 3 No. 1 Near white metal cleaning SP10 Sa 2.5 No. 2 Commercial blast cleaning SP6 Sa 2 No. 3 Brush-off (Sweep) blast cleaning

SP7 Sa 1 No. 4 Power-tool cleaning (to bare metal) SP11 - - Commercial grade power tool SP 15 - -

Power-tool cleaning SP3 St 3 - Hand-tool cleaning SP2 St 2 - Solvent cleaning SP1 - - High and ultrahigh pressure water jetting SSPC ISO 8501-1 NACE

Water jet cleaning SP12 No. 5 Wet abrasive blasting TR2 6G198 WJ1-WJ4


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4.3.5 Removal of residual salts from pitted areas

Where pitting corrosion has been located, pressure water/steam wash with fresh water shall be performed after the initial abrasive blasting. Should instant rust-back or black-spotting occur, the pressure wash shall be repeated to remove the residual salts residing in the micro pits.

4.3.6 Techniques and Restrictions

As a guide, blast cleaning shall not be carried out when the temperature of the surfaces to be blasted is less than 3 degree C above dew point and when the relative humidity of the air is greater than 85 %. For dew point determination, refer to procedure described in ASTM E 337. In enclosed areas such as in tanks and vessels where some adverse conditions (i.e. environmental conditions outside the range of the specifications or short turnaround time allotted) may prevail, dehumidification is recommended to prevent flash rusting. In the event that dehumidification is employed. The Relative Humidity (RH) within such environment shall be maintained at a maximum of 50% except for inorganic zinc silicate. NACE publication 6A 192 may be referred to determine the types of dehumidification equipment suitable for the work. Abrasive blasting shall not be conducted in open areas close to painting operations or wet coated surfaces to prevent dust and grit contamination. Normally, grit blasting shall be permitted only during daylight hours. The illumination of the surface during final blasting shall be at least 500 Lux and all environmental restrictions shall be observed. Maximum speed and most effective cleaning are obtained by systematic even blasting. Work should be blocked out in 30cm square and each square blasted evenly until complete. Blasting shall continue a minimum of 25 mm into any adjacent coated areas, and the edges shall be feathered. Any blast cleaned steelworks on which rust develops shall be re-blasted prior to being painted.

4.3.7 Alternative Methods of Surface Cleaning

4.3.7.1 General Alternative surface cleaning is only acceptable after obtaining written approval from the Principal. Alternative surface preparation such as power tool cleaning is not acceptable for areas difficult to access such as under cellar and helidecks, areas exposed to water, steelwork to be insulated, steelwork to be buried and internal surfaces of equipment and tanks. Alternative primers such as surface tolerant primers may be required for alternative methods of surface cleaning and be in accordance with paint manufacturers recommendations. Alternative primers need the approval of the Principal.


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4.3.7.2 Wet abrasive blasting and water jet cleaning

Wet abrasive blast cleaning techniques using potable water can be used to avoid dust or in cases where fire and/or explosion risks are present. The cleaned surface should be washed off immediately after blast cleaning using potable water. Corrosion inhibitors should not be used unless written approval from the Principal has been obtained. Corrosion inhibitor such as 0.3% sodium nitrite and 1.2% ammonium phosphate may be used. However, use of Chromate inhibitor is not permitted. Disposal of corrosion inhibitor into the sea should not be allowed. The paint Manufacturer shall approve the use of an inhibitor or the removal of residues of the inhibitor before painting. The cleaned surface shall be dry at the time of painting. Particular care shall be taken to dry areas, which are not self-draining, so that water collected is removed.

4.3.7.3 Water Jetting

High-pressure and ultrahigh-pressure water jetting utilising potable water may be used, if abrasive blasting is not permitted for certain areas where dusting and over-blasting may damage process equipment. It is restricted to maintenance painting. Water jetting is a hazardous operation and requires the use of well-trained, experienced operators. Where black spots occur in pits or other surface defects, the surface shall be cleaned again at higher pressure to remove the residual salts. Only after written approval from the Principal is obtained, a suitable corrosion inhibitor such as 0.3% sodium nitrite and 1.2% ammonium phosphate may be used to prevent flash rusting. However, use of Chromate inhibitor is not permitted. The paint Manufacturer shall approve the use of an inhibitor or the removal of residues of the inhibitor before painting. The cleaned surface shall be thoroughly dry at the time of painting. Particular care shall be taken to dry areas, which are not self-draining, so that water collected is removed.

4.3.7.4 Sponge Jet Blasting

Sponge Jet blast cleaning is recognized as a dry and low dust system. This cleaning type shall only be used upon agreement with the Principal. Metallic or non-metallic abrasive used in the sponge jet media matrix shall conform to the ISO 11124 or ISO 11126 blast abrasive classification. It shall be conducted in accordance with the vendor/manufacturer recommendation which includes proper site preparation, equipment set-up, choice of media and their application. A range of surface profile 25, 50, 75 and 100 microns shall be achieved using the different sponge jet media. A recycler shall be used to segregate light debris, dust and heavy collected waste from the spent sponge jet media before being used again for blast cleaning. Personnel carrying out the blast cleaning shall be qualified and trained on the use of sponge jet equipment and operation. A vendor technical representative shall be present at the work site to assist during the execution of the blast cleaning activity.

4.3.7.5 Centrifugal Abrasive Blasting

A portable blasting machine may be used to prepare steel decks and tank floors using recyclable steel abrasives.


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4.3.7.6 Vacuum Blasting

Vacuum blasting may be used in the areas where open abrasive blasting is not permitted or desirable for spot repair of damaged or corroded areas.

4.3.7.7 Power-tool Cleaning

Power-tool cleaning should be confined to minor areas and preferable to bare metal. Unless otherwise specified, it shall be done as outlined in ISO 8504-3. Power-tool cleaning to bare metal shall be done in accordance with SSPC SP11. When power-tool cleaning to bare metal is not feasible, the surface cleanliness shall at minimum meet the visual standard St 3 in accordance with ISO 8501-2 at the time of coating. Care shall be taken to ensure that the steel surface does not become polished after power-tool cleaning. Hand-tool cleaning is permitted prior to power-tool cleaning. If the surface being prepared lies adjacent to a coated surface, the power-tool cleaning shall overlap the coated surface by at least 25 mm and the coated surface shall be feathered.


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5 APPLICATION

5.1 PRE-APPLICATION PROCEDURES 5.1.1 Materials Storage and Handling

Storing, thinning, mixing and handling of paint materials shall be in accordance with the Paint manufacturers recommendation. All paint materials and solvents shall be stored in the closed original container bearing the manufacturers label until required for use. Each container must have full identification, information including Paint manufacturers name, product identification, batch number and colour. Hazardous chemicals shall be classified, packaged and labelled appropriately in compliance with the Occupational Safety and Health (Classification, Packaging and Labeling of Hazardous Chemicals) Regulations 1997. All related safety aspects to the use of paints and associated thinners shall comply to Paint manufacturers requirement namely MSDS (Material Safety Data Sheet). The Manufacturers pot-life and induction time (if any) requirements shall be followed. Mixing of different brands or generic types of paint material is not permitted unless respective manufacturers consent has been received. Paint shall be applied to dry, clean, prepared surface under conditions recommended in the manufacturers product data sheet.

5.1.2 Material Mixing and Thinning

All materials shall be mixed by solvent proof mechanical agitator for a sufficient time in order for proper mixing of one or two packs paint so as to ensure uniformity. Sticks or similar tool shall not be used to avoid contamination. Continuous agitation type spray pots shall be used when applying heavily metal-pigmented paint such as Zinc or Aluminum loaded paint to avoid sedimentation. Thinner shall not be added to primer or paints unless necessary for proper application according to Paint manufacturers recommendation. The type of thinner used must comply with the Paint manufacturers recommendation.

5.2 APPLICATION CONDITIONS

Unless otherwise recommended by Paint manufacturer and accepted by the Principal, paints shall not be applied when:

The surface temperature is less than 3C above dew point. The surface temperature is below 5C as it could adversely affect the curing of

paints. The relative humidity is more than 85%, except for Inorganic Zinc Ethyl Silicate

which can go up to 90%. The metal surface temperature is higher than that recommended by Paint

manufacturer for application. Surface preparation has not been completed or oil, grease and dust are present on

the substrate to be painted. Poor weather conditions for painting exist or are expected within two hours of

application such as blowing sand or rain. When there is a deposition of moisture in the form of rain, condensation etc. on the

surface. Probability of condensation may be determined in accordance with procedures described in ISO 8502-4.

Where the available light is less than 500 lux.


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5.3 APPLICATION METHODS 5.3.1 General Requirements

Coatings shall be uniformly applied without runs, sags, solvent blisters, dry spray or other blemishes. All blemishes and other irregularities shall be repaired or completely removed and recoated. Special attention shall be paid to crevices, corners, edges, weld lines, bolt heads, nuts and small brackets and apply the specified minimum dry film thickness by brush application if spray is inaccessible to cover all areas. Edges of existing coating shall be feathered towards the substrate prior to over-coating to ensure good adhesion. Surface which is inaccessible after assembly, including the surface of lap joint flanges, nozzle necks, lap joint stub ends, lap rings, bolt holds and some welded joints, shall receive the complete painting system before being assembled. Contact surface of bolted connections are to be primed only. On structural steel areas subject to be assembled by high tension bolts, contact surface shall be primed only with Inorganic Zinc Ethyl Silicate. Intermediate and final coat shall not be applied. Primers should not be over coated with the second coat paint until the specified minimum over-coating time is achieved. Surface preparation is required if the over-coating time is exceeded. Contact the Paint manufacturer for the type and surface preparation required. Intercoat contamination shall be minimized by maintaining proper cleanliness and by applying the intermediate and finish coats within the over-coating time recommended by the manufacturer. If contaminants are present, they shall be removed before applying subsequent coats. Contrasting colour shall be used for each coat of paint so as to ensure different coats are applied to meet the required dry film thickness. Each coat shall be applied with acceptance limits of Dry Film Thickness (DFT) as specified in section 6. It must be ensured that solvent retention in any of the coats, caused by the application of excessive coating thickness is avoided.

5.3.2 Spray Application

Paints shall be applied by Air Spray or Airless Spray. Hose and containers shall be thoroughly cleaned before addition of new materials. The spray gun shall be held no closer than 300mm or more than 600mm from the surface to be coated. During application, the spray gun shall always be held at a right angle (90) to the substrate. Each pass shall overlap the previous one by 50%. In order to achieve a uniform application when applying large surface areas, application shall be made in two directions so that the passes are at right angles to each other i.e. cross spray at 50% over lapping. Pressures and spray fan shall be adjusted so that the optimum spray pattern is obtained for the surface being coated. Cover is to be kept on opened container of paints when not in used.


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5.3.3 Brush Application Application with brush is acceptable under the following conditions subject to Principal approval: When areas cannot be properly coated by spray for any reasons. When spray application is difficult due to accessibility. Above ground level when it is considered that loss of paint under prevailing

conditions is excessive e.g windy and progress of work has to be maintained and personnel in or near the work site or requirement property, may be affected by spray particles.

For touch-up or repair of localized damaged paint or areas of incorrectly applied paint.

For painting of stripe coat e.g when applying the initial coat of paint to corners, edges, crevices, holes, welds or other irregular surface prior to spray application.

When the substrate material to be applied are suitable for brush application. The number of coats shall be adjusted to the dry film thickness to match.

Paint brushes used shall be of a style and quality that will permit appropriate application of the material being applied. Material applied by brush shall be smooth, uniform in thickness, without any apparent surface defect such as brush marks, runs, sags, or curtains.

5.3.4 Roller Application

Roller application shall only be used with written approval from the Principal. Roller application may be used only when: Spraying is not feasible. Primer coat is applied by brush. Paint application by roller method is acceptable to paint manufacturer and is in

accordance with the application data.

5.3.5 Thermal Spray Application

Spraying process used for applying melted droplets of pure metals, alloys, plastics, carbide and various oxides to a surface. Substrate must be cleaned completely. It shall be abrasive blast cleaned by sharp edge abrasives to a degree of cleanliness of Sa 2.5 (ISO 8501:1:2007). It shall be free from grease, dust and other contaminants. The specified cleanliness shall be maintained during the spraying process. A roughness of 50 to 100m is recommended. List of typical spray methods are as follows:

! Powder Flame Spraying The coating material which is in the form of powder is fed into a gas flame either

from a small cup mounted on the nozzle or from a larger stand alone container. Flame temperature is recommended at approximately 3100C. Particle velocity shall

be in the range of 40 to 70 m/s, coating porosity within 7 to 15% (Volume) and oxide content shall be in the range of 7 to 10% (Volume).

The adhesion property is recommended between 10 to 20Mpa.


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! Wire Flame Spraying Fuel gases are mixed with oxygen to propagate the combustion for melting the

material to be applied. The temperature is recommended to be in the range of 2700C to 3100C so as to

melt the wire which is fed through the nozzle at the centre of the gas. It is necessary to add clean and dry compressed air for atomizing and transporting

the molten material to the work piece or substrate. Recommended spraying distance is within 130mm to 200mm. ! Arc Spraying The material to be applied is in the form of two wires fed through the spray gun in

such a way that they intersect at the front of the gun. Electric is transferred to the wires and an electric arc is formed at the intersection, melting the material.

The temperature in the electric arc is recommended at approximately 5500C.

! Plasma Spraying Plasma gun consists of an annular copper anode and a wolfram cathode, which are

water cooled. A gas is fed into the electric arc formed between the anode and cathode. The material in powder form is transported by a carrier gas into the plasma stream form.

The intense generation of heat up is recommended between 10000 to 25000C so

as to melt the powder at the same time as it is propelled at great velocity towards the workpiece or substrate.

Power levels up to 40kW are designated Low, whereas power levels between 40

and 80 kW are designated High. ! High Velocity Oxy-fuel Spraying The gun works in such a way that propane and oxygen flame melts and propels

molten material particles against the workpiece with a very high energy. The material to be applied is in a powder form.

The recommended velocity is approximately 1000m/s while the flame temperature is

recommended at approximately 2700C. ! Detonation Spraying Powder, by means of a carrier gas is fed into a flame barrel filled with a mixture of

acetylene and oxygen which ignited by a spark. The recommended particle velocity is 700m/s so as to produce a low porosity coating.

5.3.6 Hot Dip Galvanizing

Steel is coated with zinc by means of dipping into a molten zinc bath keeping at a recommended temperature around 450 to 460C. The recommended thickness is about 100m. The substrate should be completely clean, free from grease by degreasing in a hot alkaline solution and rinsed with clean water. Mill scale and rust are to be removed in an acid bath (pickling), followed by rinsing with water.


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After this process, it shall be dipped in flux preferably zinc ammonium chloride at a recommended temperature of 40 to 60C. It shall be dried in an oven and a thin layer of flux is left on the steel surface.

5.4 REPAIRS AND TOUCH UP PAINTING

5.4.1 General requirements

Procedure for repair and/or touch up painting for each generic coating system shall be submitted by contractor to the Principal for approval. Before application of any subsequent coat of material, all damages from previous coats shall be repaired. All loose paint shall be removed to a firm edge. All surface irregularities and contaminations shall be removed. Hard, glossy surface may require abrading to obtain a suitable surface for painting. Contact Manufacturer for the type and surface preparation required. If the surface being prepared lies adjacent to a sound coated surface which is not to be repaired, the surface preparation shall overlap the coated surface by at least 25mm. The remainder of existing coated surface shall be properly protected with shields or screens to prevent any possible damage to the coating. Inorganic Zinc primer shall not overlap adjacent intermediate and finish coats. Areas with inadequate coating thickness shall be thoroughly cleaned and if necessary, abraded, and additional compatible coats applied until meeting the specification. These additional coats shall blend in with the final coating on adjoining areas.

5.4.2 Damaged Coating Not Exposing Substrate Surface

Surface to be overcoated which has been contaminated or damaged shall be cleaned by solvent cleaning and/or lightly brush blasted to ensure that the surface is free from contaminants. Contaminants shall be removed by dry compressed air and wiped by hand with clean, dry rags. The coating around the damaged area shall be chamfered by sanding to ensure continuity of the patch coating. The full coating system shall then be reapplied strictly in accordance with this specification.

5.4.3 Damaged Coating Exposing Substrate Surface

The damaged area shall be cleaned to the original or maintenance painting system specified for that item and the full coating system reapplied in accordance with the application data. The cleaning shall carry over onto tightly adhering surrounding coating for not less than 25 mm all around and the edges shall be chamfered by sanding to ensure continuity of the patch coating.

5.4.4 Repair of Zinc Ethyl Silicate Primer

Damaged surface of zinc primer shall be cleaned to remove all loose materials and blast cleaned with a portable vacuum blast cleaning unit. The surface shall be coated with one coat of the primer which is the same as the damaged primer. If blast cleaning is not practical, power tool cleaning may be used subject to Principal and Contractor agreement. In such cases, subject to operating temperature limitations, one or two packs recoatable zinc primer may be used in lieu of zinc silicate primer subject to Principal and Contractor agreement.


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5.4.5 Repair of Fully Cured Epoxy Coating

In case of repairing damage on fully cured epoxy coatings and aged epoxy coating, the coating work shall only be carried out after the surface has been suitably abraded to provide an adequate anchor for the coating to be applied. The repair coating shall be compatible with the existing coating. A test for compatibility is described in ASTM D 5064.

5.4.6 Inadequate Coating Thickness

Areas with inadequate coating thickness shall be thoroughly cleaned and if necessary abraded and additional coats applied shall blend in with the final coating on adjoining areas.

5.4.7 Handling and Shipping of Coated Items

Coated items shall be carefully handled to avoid damage to coated surface. No handling shall be performed before the coating system is cured to an acceptable level. Packing, handling and storage facilities shall be non-metallic type.


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6 PAINTING AND COATING SYSTEMS 6.1 COATING SYSTEMS SELECTION 6.1.1 General

The coating systems generally acceptable for the intended service are listed in Section 6.2 for external application and Section 6.3 for internal application. Selection and acceptance of coating systems and products for a specific and specialised application which are not listed herein shall be the prerogative of individual Principal in consultation with the respective Paint Manufacturer. When selection an approved product for a particular project, the Contractor in consultation with the Principal shall consider the following factors:

A. Coating characteristics

! Coverage cost (RM/m2) ! Application time ! Drying time ! Curing time ! Overcoating time ! Recoating time ! Compatibility

The maintenance and touch-up coating systems shall be compatible with the Initial/New Construction coating systems. Coating system compatibility shall be tested using patch test methods described in ASTM D 5064.

B. Nature of substrate C. Basic Function of Coating on Substrate D. Accessibility (time or space) and availability of appropriate equipment for

satisfactory surface preparation and application. E. Environmental factors. F. Life Cycle Costs.

The coating systems shall demonstrate low Life Cycle Costs in combination with: ! An Ideal/Optimum Service Life of minimum one (1) year for the first 10 to 12 years

of service life and ! A Practical Service Life of minimum ten (10) years.

The dry film thickness of the coating systems specified herein is the minimum requirement to achieve the desired system performance.

6.1.2 Organic and Inorganic Zinc-Filled Coatings

The metallic zinc content in the zinc dust shall be a minimum of 94%. Zinc content by percentage weight for inorganic zinc silicate and epoxy zinc should comply with SSPC-Paint 20 (Zinc rich primer, Type I 'Inorganic ' and Type II 'Organic') requirement or equivalent. Any new formulation related to zinc coating shall be subjected to qualification testing stated in this standard. The zinc coating systems shall pass the respective tests as shown in Appendix 7. If shop primer (for temporary protection) is applied, then it must be 100% full blasted to the requirement stated in section 4 prior to the application of the full coating system.


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For primed surface secondary surface preparation: All zinc salt formation shall be sweep blasted. All other possible contaminants shall be sanded down and solvent cleaned before topcoating. For damages, welding joints and rusty area, spot blast to Sa 2.5 followed by one coat of epoxy zinc rich or power tool cleaned to St3 and followed by Surface Tolerant epoxy, subject to Principal approval.

6.1.3 Selection and Application of Top Coats

For areas to be applied with polyester glassflake, all shop primer shall be removed completely, i.e. Sa 2.5. Prior to topcoating zinc rich primers, SSPC-PS Guide 8 shall be consulted to select compatible topcoats. The selection process requires identification of the generic type of primer, compatibility considerations, and selection of compatible topcoats. The minimum volume solids for high solid epoxy shall be 75%. As an alternative, surface tolerant high solid epoxy paint can be applied. When topcoating inorganic zinc silicate primed surface, a mist coat (wet to wet technique) i s required to eliminate pinholing.

6.2 PAINTING AND COATING SYSTEM SCHEDULES FOR EXTERNAL APPLICATION

6.2.1 Carbon Steel Design Temperature < 110C Non Insulated in the Atmospheric Zone

6.2.1.1 Coating System No. 1A: Initial Painting

Surface preparation : Blast Cleaning to ISO 8501-1:2007, Sa 2.5 Coating system DFT 1st coat Inorganic Zinc Silicate / Epoxy Zinc Rich 75 2nd coat High Solid Epoxy 150 3rd coat Aliphatic Polyurethane 50 Total 275

6.2.1.2 Coating System No. 1B: Maintenance Painting for Blast Cleaned Surface

Surface preparation : Blast cleaning to ISO 8501-1:2007, Sa 2.5 Coating system DFT 1st coat Epoxy Zinc Rich 75 2nd coat High Solid Epoxy 150 3rd coat Aliphatic Polyurethane 50

Total 275

6.2.1.3 Coating System No. 1C: Maintenance Painting for Power Tool Cleaned Surface

Surface preparation : Power tool cleaning to ISO 8501-1:2007, St 3 Coating system DFT 1st coat Surface Tolerant High Solid Epoxy 125 2nd coat Surface Tolerant High Solid Epoxy 125 3rd coat Aliphatic Polyurethane 50 Total 300


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6.2.2 Carbon Steel Design Temperature


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6.2.4 Splash Zone and Spray Zone

6.2.4.1 Coating System No. 4A: Initial Painting and Maintenance Painting

Surface preparation : Blast cleaning to ISO 8501-1:2007, Sa 2.5 Coating system DFT 1st coat Polyester Glass Flake 500 2nd coat Polyester Glass Flake 500 Total 1,000

6.2.4.2 Coating System No. 4B: Initial Painting and Maintenance Painting (Alternative)

Surface Preparation : Blast cleaning to ISO 8501-1:2007, Sa 2.5 Coating system DFT 1st coat Epoxy Glass Flake 500 2nd coat Epoxy Glass Flake 500 Total 1,000

Note: For major maintenance painting, one coat application of 1000 is allowed for Polyester Glass Flake and Epoxy Glass Flake.

6.2.5 Carbon Steel Design Temperature > 110C (Insulated and Non-Insulated) in Atmospheric Zone


i) Coating System No. 5A (1): Facilities with surface temperature 110 - 250C Surface preparation : Blast cleaning to ISO 8501-1:2007, Sa 2.5

Coating system DFT 1st coat Inorganic Zinc Silicate 75 2nd coat Modified Silicone Acrylics 30 3rd coat Modified Silicone Acrylics 30 Total 135

ii) Coating System No. 5A (2) : Facilities with surface temperature 250 - 450C Surface preparation : Blast cleaning to ISO 8501-1:2007, Sa 2.5

Coating system DFT 1st coat Silicone Aluminium 25 2nd coat Silicone Aluminium 25 Total 50

Note: ! Modified Silicone Acrylics and Silicone Aluminium shall be air-drying type. ! If the operating temperature is in different range/class than the design temperature,

then the selection of the coating system shall be considered on a case by case basis. ! To ensure good adhesion to the metal surface, surface tolerant Aluminum paint shall

be used.


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6.2.5.2 Coating System No. 5B: Maintenance Painting Power Tool Cleaned Surface

i) Coating System No. 5B (1) : Facilities with surface temperature 110 - 250C Surface preparation : Power tool cleaning to ISO 8501-1:2007, St 3

Coating system DFT 1st coat Zinc Graphite 40 2nd coat Modified Silicone Acrylics 30 3rd coat Modified Silicone Acrylics 30 Total 100

ii) Coating System No. 5B (2): Facilities with surface temperature 250 - 450C Surface preparation : Power tool cleaning to ISO 8501-1:2007, St 3

Coating system DFT 1st coat Zinc Graphite 40 2nd coat Silicone Aluminium 25 3rd coat Silicone Aluminium 25 Total 90

Note: ! Applicable for isolated or spot touch up maintenance painting only. ! Modified Silicone Acrylics and Silicone Aluminium shall be air-drying type.

6.2.6 Galvanised Steel

6.2.6.1 Coating System No. 6A: Initial Painting

Surface preparation : Degrease as SSPC-SP1 and wash with fresh clean water, light

abrade or sweep blast surface to provide anchor pattern of 25. Coating system DFT 1st coat Surface Tolerant High Solid Epoxy 125 2nd coat Aliphatic Polyurethane 50 Total 175

Note: Hot dip galvanising shall be carried out in accordance with the requirements of BS 729: "Hot dipped galvanised coatings on iron and steel articles". A minimum of 610 gm/m2 (dft 86 m) of zinc shall be applied. Maintenance of galvanised steel shall be treated as carbon steel as per this section 6.2.


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6.2.7 Stainless Steel


i) Coating System No. 7A (1) : Non insulated facilities operating < 110C Surface preparation : Sweep blast with dry, non-iron containing grit or

roughen surface with emery paper to provide an anchor profile.

Coating system DFT 1st coat High Solid Epoxy (refer to Note) 125 2nd coat Aliphatic Polyurethane 50 Total 175

ii) Coating System No. 7A (2) : Insulated facilities operating < 110C Surface preparation : Sweep blast with dry, non-iron containing grit or

roughen surface with emery paper to provide an anchor profile

Coating system DFT 1st coat High Solid Epoxy (Refer to Note) 125 Total 125

(iii) Coating System No. 7A (3) : Insulated and non-insulated facilities operating 110 - 600C

Surface preparation : Sweep blast with dry, non-iron containing grit to

create an anchor profile. Coating system DFT 1st coat Silicone Aluminium 25 2nd coat Silicone Aluminium 25 Total 50

Note: High solid epoxy should be non-inhibitive and non-metallic pigmented.

6.2.7.2 Painting Guideline for Stainless Steel

Table below can be used as a guideline to select painting system for Stainless Steels.

Temp Range Martensitic/ Ferritic Austenitic Duplex Remarks 110C to 600C Coating System

# 7A(3) Coating System

# 7A(3) Coating System

# 7A (3) Insulated and non insulated

60C to 110C Coating System # 7A (2)

Coating System # 7A (2)


Insulated



No Painting Non-insulated

Up to 60C Coating System # 7A (2)



Insulated


No Painting No Painting Non-insulated


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6.2.8 Carbon Steel Storage Tank 6.2.8.1 Coating System No. 8A: Initial painting

Selection of initial painting systems for carbon steel storage tanks shall be made based on specific requirements of the relevant sections 6.2.1 through to 6.2.5.

6.2.8.2 Coating System No. 8B: Initial and Maintenance Painting for Underside of Bottom Plate (ONLY if painting is required for corrosion protection to supplement Cathodic Protection)

Surface preparation : Blast cleaning to ISO 8501-1:2007, Sa 2.5

Coating system DFT 1st coat Epoxy Zinc Rich 75 2nd coat Coal Tar Epoxy 300 Total 375

6.2.8.3 Coating System No. 8C: Shell and Roof Plate, Stairways, Stair Treads, Gangways and Others External Parts Including Piping (non-galvanised)

The maintenance painting scheme shall follow that for carbon steel design temperature at < 110C.

The recommended Tank identification system is given in Appendix 4.

6.2.9 Timber Decks

6.2.9.1 Coating System No. 9A: Initial and Maintenance Painting

Surface preparation : Light sanding to remove contaminant, sharp edges and old paints.

Coating system DFT 1st coat Aluminium Wood primer 50 2nd coat Alkyd Semi-gloss finish 50 3rd coat Alkyd Semi-gloss finish 50

Antiskid aggregate Total 150

6.2.9.2 Coating System No. 10: Markings

Surface preparation : Degrease and wash with clean fresh water. Abrade surface to provide another pattern.

Coating system DFT Marking Aliphatic Polyurethane 50 Total 50

The recommended piping identification system and legend are given in Appendix 5 and 6, respectively.


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6.2.10 Coating System No. 11: Living Quarters Pressurized Building, Control Room (Interior) Surface preparation : Blast cleaning to ISO 8501-1:2007, Sa 2.5

Coating System DFT 1st coat Surface Tolerant Epoxy 150 Total 150

6.2.11 Coating System No. 12: Fire Barriers / Passive Fire Protection (PFP) System

Approval of Passive Fire Protection (PFP) Systems shall be the discretion of Principal. Fire test report or certificate shall be submitted for validation. Fire Test Standards The minimum standard curve temperature of passive fire proofing materials for rapid rise fires follows either the following standards: ! UL1709 standard for rapid rise fire test OR ! BS 476 Parts 20 and 21 (High rise hydrocarbon type fire curve)

In addition to compliance with the above fireproofing standards, where specifically required only, manufacturers must submit the following tests: ! Gas flame impingement/Jet Fire ! High pressure water hose during fire conditions. All hydrocarbon fire PFP coating system shall be capable of preventing the passage of smoke and flame for at least 120 minutes exposure to a hydrocarbon fire. A test report simulating this capability shall be provided. Lightweight epoxy-based thin film intumescent (TFI) coating shall be preferred over cementitious PFP coating system for weight control of offshore production facilities. Water-based intumescent coating system shall be used for interior application. Externally applied PFP coating system shall include a compatible top coat for weathering-resistant performance.

6.3 PAINTING AND COATING SYSTEM SCHEDULES FOR INTERNAL APPLICATION 6.3.1 Fuel Gas (Sweet and Sour)

6.3.1.1 Coating System No. 13A : Initial painting, Maintenance Painting for Blast Cleaned

surface and Power Tool Cleaned Surface. Surface preparation : Blast cleaning to ISO 8501-1:2007, Sa 2.5, Power tool

cleaning to ISO 8501-1:2007, St 3 for minor touch-u painting

Surface to be painted : All over Service Temperature : Up to 60 C

Coating System DFT 1st coat Amine Adduct Epoxy 125 2nd coat Amine Adduct Epoxy 125 Total 250


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6.3.2 Crude / condensate (Sweet and Sour), Emulsion/Slop

6.3.2.1 Coating System No. 14A: Initial Painting, Maintenance Painting for Blast Cleaned Surface and Power Tool Cleaned Surface.

i) Coating System No. 14A (1) : Roof and Shell plate

Surface preparation : Blast cleaning to ISO 8501-1:2007, Sa 2.5, Power tool cleaning to ISO 8501-1:2007, St 3 for minor touch-up painting

Service Temperature : Up to 60 C Coating System DFT

1st coat Amine Adduct Epoxy 125 2nd coat Amine Adduct Epoxy 125 Total 250

Note: Floating roof tank plates which are subjected to excessive abrasion and wear shall be uncoated. However, if the Principal considers otherwise, suitable coating systems may be specified.

(ii) Coating System No. 14A (2) : Bottom plate and vessels Surface preparation : Blast cleaning to ISO 8501-1:2007, Sa 2.5, Power tool

cleaning to ISO 8501-1:2007, St 3 for minor touch-up painting


1st coat Amine Adduct Epoxy 100 2nd coat Amine Adduct Epoxy 100 3rd coat Amine Adduct Epoxy 100 Total 300

(iii) Coating System No. 14A (3) : Alternative system for bottom plate Surface preparation : Blast cleaning to ISO 8501-1:2007, Sa 2.5, Power tool

cleaning to ISO 8501-1:2007, St 3 for minor touch-up painting


1st coat Amine Primer 50 2nd coat Amine Glassflake 200 3rd coat Amine Glassflake 200

Total 450


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6.3.3 Light Naptha, Heavy Naptha, Treated Naptha, Reformate, Jet A-1 Fuel, Lube Oil, Fuel Oil, Gasoline (unleaded), Gasoline (leaded)

6.3.3.1 Coating System No. 14A (3) : Initial Painting, Maintenance Painting for Blast Cleaned

Surface and Power Tool Cleaned Surface Surface preparation : Blast cleaning to ISO 8501-1:2007, Sa 2.5, Power tool cleaning to

ISO ISO 8501-1:2007, St 3 for minor touch-up painting Service Temperature : Up to 60 C


6.3.4 Diesel 6.3.4.1 Coating System No. 16A: Initial Painting, Maintenance Painting for Blast Cleaned

Surface and Power Tool Cleaned Surface

Surface preparation : Blast cleaning to ISO 8501-1:2007, Sa 2.5, Power tool cleaning to ISO 8501-1:2007, St 3 for minor touch-up painting

Surface to be painted : Roof and Shell plate Service Temperature : Up to 60 C


Note: Floating roof tank plates which are subjected to excessive abrasion and wear shall be uncoated. However, if the Principal considers otherwise, suitable coating systems may be specified.

6.3.4.2 Coating System No. 16B: Initial Painting, Maintenance Painting for Blast Cleaned Surface and Power Tool Cleaned Surface

Surface preparation : Blast cleaning to ISO 8501-1:2007, Sa 2.5, Power tool cleaning to

ISO 8501-1:2007, St 3 for minor touch-up painting Surface to be painted : Bottom plate and Vessels Service Temperature : Up to 60 C

Coating System DFT 1st coat Amine Adduct Epoxy 100 2nd coat Amine Adduct Epoxy 100 3rd coat Amine Adduct Epoxy 100 Total 300


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6.3.4.3 Coating System No. 16C: Alternative System for Bottom Plate Surface preparation : Blast cleaning to ISO 8501-1:2007, Sa 2.5, Surface to be painted : Bottom plate and Vessels Service Temperature : Up to 60 C

Coating System DFT

1st coat Epoxy Primer 50 2nd coat Epoxy Glassflake 200 3rd coat Epoxy Glassflake 200 Total 450

6.3.5 Potable (drinking / aerated / non-aerated) Water, Seawater (aerated / non-aerated), Produced Water, Brackish, Demineralised Water, Brine

6.3.5.1 Coating System No. 17A: Initial painting, Maintenance Painting for Blast Cleaned Surface and Power Tool Cleaned Surface.

Surface preparation : Blast cleaning to ISO 8501-1:2007, Sa 2.5, Power tool cleaning

to ISO 8501-1:2007, St 3 for minor touch-up painting Service Temperature : Up to 60 C


Note: Coating system applied for portable water system shall be accompanied with a health certificate.

6.3.6 Steam (condensate), Boiler Feed

6.3.6.1 Coating System No. 18A: Initial Painting, Maintenance Painting for Blast Cleaned Surface and Power Tool Cleaned Surface.

Surface preparation : Blast cleaning to ISO 8501-1:2007, Sa 2.5, or Power tool cleaning

to ISO 8501-1:2007, St 3 for minor touch-up painting Surface to be painted : All over Service Temperature : Up to 100 C

Coating system DFT 1st coat Phenolic Epoxy 150 2nd coat Phenolic Epoxy 150 Total 300


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6.3.7 Utility Air 6.3.7.1 Coating System No. 19A: Initial Painting, Maintenance Painting for Blast Cleaned

Surface and Power Tool Cleaned Surface.

Surface preparation : Blast cleaning to ISO 8501-1:2007, Sa 2.5, or Power tool cleaning to ISO 8501-1:2007, St 3 for minor touch-up painting

Surface to be painted : All over Service Temperature : Up to 60 C

Coating system DFT 1st coat Amine Adduct Epoxy 125 2nd coat Amine Adduct Epoxy 125 Total 250

6.3.7.2 Coating System No. 19B: Alternative System

Surface preparation : Blast cleaning to ISO 8501-1:2007, Sa 2.5 Surface to be painted : All over Service Temperature : Up to 60 C Coating system DFT 1st coat Polyester Glassflake or

Epoxy Glassflake 400

Total 400

6.3.7.3 Coating System No. 19C: Initial painting, Maintenance Painting for Blast Cleaned Surface and Power Tool Cleaned Surface.

Surface preparation : Blast cleaning to ISO 8501-1:2007, Sa 2.5, or Power tool cleaning

to ISO 8501-1:2007, St 3 for minor touch-up painting Surface to be painted : All over Service Temperature : More than 60 C Coating system DFT 1st coat Phenolic Epoxy 125 2nd coat Phenolic Epoxy 125 Total 250

6.3.7.4 Coating System No. 19D: Alternative System

Surface preparation : Blast cleaning to ISO 8501-1:2007, Sa 2.5 Surface to be painted : All over Service Temperature : More than 60 C

Coating system DFT 1st coat Vinyl Ester Glassflake 400 Total 400


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6.3.8 Corrosion Inhibitors, Demulsifier, Oxygen Scavenger

6.3.8.1 Coating System No. 20A: Initial Painting, Maintenance Painting for Blast Cleaned Surface and Power Tool Cleaned Surface

Surface preparation : Blast cleaning to ISO 8501-1:2007, Sa 2.5, or Power tool

cleaning to ISO 8501-1:2007, St 3 for minor touch-up painting Surface to be painted : All over Service Temperature : Up

petronas technical standard (pts 30.48.0031 sept2012)

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