Indra: Field Coating Procedure For Welding Joints, Damages, and Non-Conformance Portions of Tsa Coated Items

Kuwait National Petroleum Company (K.S.C.) P6011MAA.000.10.48.
004
Clean Fuels Project (CFP) REV F1
KNPC Contract No. CFP/EPC/0054-MAA Page 1 of 22
Contractor JOB CODE : 0-6798-20-0000 S-000-1274-0001V
FIELD COATING PROCEDURE FOR WELDING JOINTS, DAMAGES, AND

NON-CONFORMANCE PORTIONS OF TSA COATED ITEMS
KNPC CFP Project DSN:

MAA Package 42733
REVIEW BY: DISCIPLINE: DATE:
CODE: 1 BF QCM 13/11/16
REVIEW CODE: 1: Approved\No Comments; 2: Minor Comments;

3: Comments as Noted; 4: Rejected
Operation Center JOB CODE 0-6798-20-0000

Operation Center Doc No. S-000-1274-0001V
F1 7-Nov-16 Issued Final KN. Jithin J. Miyashita J. Miyashita
A2 26-Oct-16 Issued for Design KN. Jithin J. Miyashita J. Miyashita
A1 4-Oct-16 Issued for Design KN. Jithin J. Miyashita J. Miyashita
O2 13-Sep-16 Issued for Comment KN. Jithin J. Miyashita J. Miyashita
O1 26-Aug-16 Issued for Comment KN. Jithin J. Miyashita J. Miyashita
Rev. Date Description Orig. Checked Approved

By By
Kuwait National Petroleum Company (K.S.C.)

Clean Fuels Project (CFP)
Kuwait
JGC Corporation / GS Engineering & Construction / SK Engineering & Construction
CONTRACT NO. DOCUMENT NO. REV NO.
CFP/EPC/0054-MAA P6011MAA.000.10.48.004 F1
CONFIDENTIAL OR PROPRIETARY INFORMATION
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Kuwait National Petroleum Company (K.S.C.) P6011MAA.000.10.48.004
Record of Revisions
Rev No Date Description
O1 26-Aug-16 Issued for Comment
O2 13-Sep-16 Issued for Comment
Incorporated comments from Company except for aluminum foil tape backing
thickness. (Aluminum backing thickness “50microns” is correct)
A1 4-Oct-16 Issued for Design
A2 26-Oct-16 Issued for Design
Incorporated comments from Company on the following project documents:
- Letter : KNPC-JGSK-CFP-MAA-L-16-11831
- Material Approval Request : P6011MAA.000.10.51.4349
F1 7-Nov-16 Issued Final
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TABLE OF CONTENTS
1.0 SCOPE OF DOCUMENT .............................................................................................................. 4

2.0 REFEREMCE ............................................................................................................................... 4
3.0 DEFINITION ................................................................................................................................. 4
4.0 GENERAL .................................................................................................................................... 5
5.0 APPLICABLE CASES FOR DUPLEX COATING ......................................................................... 5
6.0 MATERIALS ................................................................................................................................. 5
7.0 APPLICATION.............................................................................................................................. 6
8.0 INSPECTION ................................................................................................................................ 9
9.0 DOCUMENTATION .................................................................................................................... 10
APPENDIX A: PRODUCT DATA SHEET ............................................................................................ 11
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1.0 SCOPE OF DOCUMENT

This document specifies field coating procedure for welding joints, damages, and non-
conformance portions of Thermally Sprayed Aluminium (TSA) coated items for the Clean
Fuels Project (CFP) with a maximum service temperature of 316 deg-C.
A duplex coating system consisting of a liquid coating and an aluminium (Al) foil tape
wrapping is explained for the field coating for the above mentioned scope on TSA coated
items.
This document was prepared based on the agreement as per the waiver request MAA-WR-
DD-622.
2.0 REFEREMCE
2.1 Project Document
DEP 30.48.00.31-Gen. : Protective Coatings For Onshore Facilities
(January 2009)
30.48.00.31-P6000CFP- : Project Variation Painting And Coating Of New Equipment
000-PV Rev. J And Piping
P6011MAA.000.10.48.001 : Project Specification For External Coating Of Onshore
Facilities
MAA-WR-DD-622 : Waiver request for “Application of Liquid Coating for
Avoidance of TSA Application at Field”
KNPC-JGSK-CFP-MAA-L- : Letter for “Company Review on Contractor Documents
16-11831 (P6011MAA.000.10.48.004, S-000-1274-0001V)”
P6011MAA.000.10.51.4349 : Material Approval Request for “Aluminum Foil Tape 425 &
427”
2.2 International Standard

ISO 2409 : Paints and varnishes — Cross-cut test
SSPC-SP 10 : Near White Metal Blast Cleaning
SSPC-SP 11 : Power Tool Cleaning To Bare Metal
3.0 DEFINITION
PMC/Principal : The party that initiates the project and ultimately pays for its design and
construction. The PMC/Principal will generally specify the technical
requirements. The PMC/Principal may also include an agent or
consultant, authorized to act for the
PMC/Principal. For CFP, “Principal” is same with “Company” which
means Kuwait National Petroleum Company (KNPC)
Contractor : The party that carries out all or part of the design, engineering,
procurement, construction, commissioning or management of a project
or operation of a facility. The PMC/Principal may undertake all or part of
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the duties of the Contractor

Sub-contractor : The party that performs works relating to the field coatings
Duplex Coating : A two layer coating system consisting of liquid coating as the first layer
and Al foil tape wrapping as second layer
4.0 GENERAL
The requirements stated in this document shall be in conjunction with and the supplement to
the following documents:
 DEP 30.48.00.31-Gen. (January 2009)
 P6011MAA.000.10.48.001
Any discrepancy between this document and other CFP documents shall be brought to the
attention of the PMC/Principal for review and direction.
5.0 APPLICABLE CASES FOR DUPLEX COATING

TSA coating is specified to thermal insulated carbon steel and low alloy steel with the
following temperature conditions in accordance with paragraph 3.31.1 of
P6011MAA.000.10.48.001.
 Continuous temperature service: -35 to 200 deg-C
 Cyclic temperature service: -20 to 320 deg-C
Duplex Coating shall be applied to the following purposes:

 Coating for welding joints of TSA applied piping
 Repair of damages and non-conformance portions of TSA coating (Note)
Note: Applicable to damages and non-conformance portions of TSA coating
found at field after erection for piping, equipment and tank, etc.
6.0 MATERIALS
6.1 Liquid Coating
The liquid coating product listed below table shall be used. Product data sheet is attached in
Appendix A.
Supplier Product
Interbond 1202UPC
International Paint
(Note-1)
Note-1: In case of alternative materials to be used, it shall be approved by PMC/Principal
after submitting the required test data and experience details.
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6.2 Aluminum Foil Tape

The aluminum foil tape shall satisfy the requirements shown in the table below. Product data
sheet of the example of the acceptable product is attached in Appendix A.
Example of Acceptable Product
Properties Requirement Aluminum Foil Tape Aluminum Foil Tape

(No. 433 or 433L (No. 425 or 427
supplied by 3M) supplied by 3M)
Available Resistant to the

Max. 316 deg-C Below 150 deg-C
Temperature operating temperature
Aluminum Grade 1100 or Grade 1100

Dead soft aluminum
Grade equivalent (Aluminum purity 99.0%)
Minimum 64 microns
Thickness
of (Note: This required 50 microns 70 microns
Aluminum thickness may be
Layer in the achieved by adjusting (Aluminum foil backing) (Aluminum foil backing)
Tape the number of overlaps
of the aluminum tape)
Silicone or adhesive
Adhesive on
with resistance to the Silicone Acrylic
Tape
operating temperature
7.0 APPLICATION
7.1 Liquid Coating
Liquid coating shall be applied in accordance with the following requirements:
a) The following portions shall be cleaned and feathered by means of abrasive blast cleaning
in compliance with SSPC-SP 10:
 Weld joints and terminations of TSA coating
 Damages and non-conformance portions found at field after erection of piping,
equipment, and tank, etc.
However, where surface preparation or feathering by abrasive blasting is considered
impracticable within the field construction conditions, e.g., due to limited access, risks of
damage to equipment, the proximity of electrical components or instrumentation, the use of
power tool cleaning (SSPC-SP 11) is acceptable at PMC/Principal agreed locations only.
The type or combination of types of power tool shall produce a minimum surface profile as
stated in paragraph 7.1 (c) and tested as stated in paragraph 8.1.
b) The following coating application methods are acceptable depending on the contour and
position of the surface to be coated:
 Airless spray, and
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 Brush
c) Surface profile and Nominal DFT (NDFT) requirement for the liquid coatings shall be as
follows:
Item Requirement
Surface Profile Minimum 50 microns
200 microns (Max. DFT shall be 300 microns)

Minimum NDFT of Total Coating System
(Note-1 and Note-2)
Note-1: Number of coat depends on the coating application method to be applied, but
minimum 2 coats shall be ensured.
Note-2: NDFT shall be minimum 200 microns for the following two cases:
(1) Applied on the bare carbon steel substrate (thickness of the liquid coating only)
(2) Applied on the feathered area (total thickness of TSA coating and the liquid coating)
d) Liquid coating shall be applied only on the prepared and feathered areas and a minimal
overlap (approx. 10 mm) shall be applied on to the unfeathered portion of TSA coating
e) Inspection shall be performed in accordance with paragraph 8.2. Following, aluminum foil
tape shall be applied in accordance with paragraph 7.2.

Aluminum foil tape shall be applied on the liquid coating, when cured, in accordance with the
following requirements:
a) The liquid coated and TSA coated areas shall be free of mud, oil, grease or any other
foreign material. Visible oil and grease shall be removed with suitable solvent.
b) The weld joints coated by the liquid coating shall be wrapped by aluminum tape spirally with
minimum 50% overlaps. Where the wrapping starts and ends, the tape shall be adjusted, so
that the amount of overlap for the initial and last turns shall be 100% (i.e., double lap). End
of lap shall be between 3 o’clock and 6 o’clock position for horizontal piping.
On vertical/sloped piping the weld shall be wrapped from the bottom up so that the "open
edge" is always facing down.
c) The tape shall be applied with a minimum 25 mm overlap on to the TSA coating.
d) Where a single length of tape is insufficient to cover the length of piping to be wrapped, the
new tape shall overlap the end of the tape previously applied by at least 25 mm.
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e) Thickness of aluminum layer in the tape shall be minimum 64 microns. However, the
required aluminum layer thickness (min. 64 microns) may be achieved by adjusting the
number of overlaps of the aluminum tape.
f) Typical drawing of aluminum tape application for welding joints is shown in Fig.1.
Min. 25mm Min. 50% Overlap

Liquid Coating
Tape
Weld Joint
TSA Coating TSA Coating
Tape
Circumferential Turn
Fig.1 Typical drawing of aluminum tape application for welding joints (spiral wrap application)
g) The repaired areas shall be repaired by patch application as shown in shown in Fig.2. Same
application philosophy with welding joints shall be applied.
Depending on the location of the repaired areas, the aluminum tape shall be wrapped with
the seam position in such a way that the ingressed water (if any) is driven out. In other
words, edge of seams shall always face down to avoid any water ingress.
h) Inspection shall be performed in accordance with paragraph 8.3. After inspection, thermal
insulation system will be applied as required in the project specification
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TSA Coating
Liquid Coating
(Repaired Area)
Gravity
Tape
- Double lap for Initial and Last Patches
- Min. 50% Overlap
- Min. 25 mm Overlap on TSA Coating
- Total Thickness of Aluminum Layer: Min. 64 microns
- Seam position during overlap shall ensure the expulsion
of any ingressed water by keeping edges facing down.
Fig.2 Typical drawing of aluminum tape application for repaired areas (patch application)
8.0 INSPECTION
8.1 Cleaned Surface

Surface roughness shall be inspected in accordance with clause 1.6.7.4 in DEP 30.48.00.31.
8.2 Liquid Coating

The integrity of the applied liquid coating shall be confirmed by the following inspection items:
a) Visual Inspection:
The coating shall be free from defects such as runs, sags, pinholes, voids, bubbles, orange
peel, grit, dust inclusions, flaking from substrate etc, and be of a good visual appearance.
b) Film Thickness Control

Film thickness during coating application shall be controlled by wet film thickness
measurement in accordance with clause 1.6.8.2 in DEP 30.48.00.31.
c) Dry Film Thickness Measurement

Dry film thickness shall be measured in accordance with clause 1.6.8.3 in DEP 30.48.00.31.
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d) Adhesion Test
Adhesion test shall be performed in accordance with the following philosophy:
Item Requirement
Carbon steel flat test plate (Not directly on the work piece) Test
Object
plate size : e.g., 100mm x 100mm x 6mm-thickness
Method ISO 2409
Acceptance Criteria ≤ 2 for ISO 2409
1 time / day / surface preparation method to be applied

Test Frequency
(i.e., SSPC-SP10 and/or SSPC-SP11)

The integrity of the applied aluminum foil tape shall be confirmed by the following inspection item:
a) Visual Inspection:
The finished wrapping/ patches shall be free of open seam and any sign of adhesion loss.
9.0 DOCUMENTATION
Sun-contractor shall submit the following documents related to field coating activities for
Contractor’s approval, but not limited to:
1) Product details (i.e., PDS, MSDS, Batch Certificate, etc.)
2) Inspection and Test Plan (ITP) for field application
3) Inspection report
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APPENDIX A: PRODUCT DATA SHEET
1) International Paint: Interbond 1202UPC (Total page no.: 4)
2) 3M: High Temperature Aluminum Foil Tape 433 • 433L (Linered) (Total page no.: 2)
3) 3M: Aluminum Foil Tape 425 • 427 (Total page no.: 2)
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1) International Paint: Interbond 1202UPC (Total page no.: 4)
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2) 3M: High Temperature Aluminum Foil Tape 433 • 433L (Linered) (Total page no.: 2)
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3) 3M: Aluminum Foil Tape 425 • 427 (Total page no.: 2)
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Indra: Field Coating Procedure For Welding Joints, Damages, and Non-Conformance Portions of Tsa Coated Items

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Kuwait National Petroleum Company (K.S.C.) P6011MAA.000.10.48.

FIELD COATING PROCEDURE FOR WELDING JOINTS, DAMAGES, AND

KNPC CFP Project DSN:

REVIEW CODE: 1: Approved\No Comments; 2: Minor Comments;

Operation Center JOB CODE 0-6798-20-0000

F1 7-Nov-16 Issued Final KN. Jithin J. Miyashita J. Miyashita

A2 26-Oct-16 Issued for Design KN. Jithin J. Miyashita J. Miyashita

A1 4-Oct-16 Issued for Design KN. Jithin J. Miyashita J. Miyashita

O2 13-Sep-16 Issued for Comment KN. Jithin J. Miyashita J. Miyashita

O1 26-Aug-16 Issued for Comment KN. Jithin J. Miyashita J. Miyashita

Rev. Date Description Orig. Checked Approved

Kuwait National Petroleum Company (K.S.C.)

CONFIDENTIAL OR PROPRIETARY INFORMATION

CONFIDENTIAL OR PROPRIETARY INFORMATION

1.0 SCOPE OF DOCUMENT .............................................................................................................. 4

APPENDIX A: PRODUCT DATA SHEET ............................................................................................ 11

CONFIDENTIAL OR PROPRIETARY INFORMATION

1.0 SCOPE OF DOCUMENT

2.2 International Standard

CONFIDENTIAL OR PROPRIETARY INFORMATION

the duties of the Contractor

5.0 APPLICABLE CASES FOR DUPLEX COATING

Duplex Coating shall be applied to the following purposes:

CONFIDENTIAL OR PROPRIETARY INFORMATION

6.2 Aluminum Foil Tape

Properties Requirement Aluminum Foil Tape Aluminum Foil Tape

Available Resistant to the

Aluminum Grade 1100 or Grade 1100

CONFIDENTIAL OR PROPRIETARY INFORMATION

Surface Profile Minimum 50 microns

200 microns (Max. DFT shall be 300 microns)

7.2 Aluminum Foil Tape

CONFIDENTIAL OR PROPRIETARY INFORMATION

Min. 25mm Min. 50% Overlap

TSA Coating TSA Coating

CONFIDENTIAL OR PROPRIETARY INFORMATION

8.1 Cleaned Surface

8.2 Liquid Coating

b) Film Thickness Control

c) Dry Film Thickness Measurement

CONFIDENTIAL OR PROPRIETARY INFORMATION

Method ISO 2409

Acceptance Criteria ≤ 2 for ISO 2409

1 time / day / surface preparation method to be applied

8.3 Aluminum Foil Tape

CONFIDENTIAL OR PROPRIETARY INFORMATION

APPENDIX A: PRODUCT DATA SHEET

1) International Paint: Interbond 1202UPC (Total page no.: 4)

3) 3M: Aluminum Foil Tape 425 • 427 (Total page no.: 2)

CONFIDENTIAL OR PROPRIETARY INFORMATION

1) International Paint: Interbond 1202UPC (Total page no.: 4)

CONFIDENTIAL OR PROPRIETARY INFORMATION

CONFIDENTIAL OR PROPRIETARY INFORMATION

CONFIDENTIAL OR PROPRIETARY INFORMATION

CONFIDENTIAL OR PROPRIETARY INFORMATION

CONFIDENTIAL OR PROPRIETARY INFORMATION

CONFIDENTIAL OR PROPRIETARY INFORMATION

CONFIDENTIAL OR PROPRIETARY INFORMATION

CONFIDENTIAL OR PROPRIETARY INFORMATION

3) 3M: Aluminum Foil Tape 425 • 427 (Total page no.: 2)

CONFIDENTIAL OR PROPRIETARY INFORMATION

CONFIDENTIAL OR PROPRIETARY INFORMATION