_____________________________________________________________________________________

PROTECTIVE COATINGS SPECIFICATION FOR

EQUIPMENT, PIPING & STRUCTURES

Project Name: ADGAS PROJECT

HISTORY OF CHANGE

Date
Description of Change Revision No.

04/01/2017 Issued for client approval 02

Reviewed & Accepted By: Eng. Mohammed Behwashy

Prepared by : GEORGE A

Reviewed by Approved By

For DOLPHIN
For ADGAS

-1-
_____________________________________________________________________________________

CONTENTS

1.0 Scope of Work

2.0 Purpose

3.0 Objectives

4.0 References

5.0 Inspection Tools Required

6.0 Surface Preparation

7.0 Safety Requirements

8.0 General Responsibility of Painting Inspector

8.1 Inspection During Surface Preparation

8.2 Inspection During Painting

9.0 Inspection and Testing

9.1 Environmental Checks

9.2 Surface Preparation Checks

9.3 WFT / DFT Checks

9.4 Pull of Test

10.0 Attachments

-2-
_____________________________________________________________________________________

1.0 SCOPE OF WORK

Blasting and painting of Waster Heat Boiler
Client: Adgas
Equipment: Waste Heat Boiler
Equipment Tag No.7-E-201
Material : CS 9SA516 Gr.60)
Design Temperature - Tub Side: 400̊ C, Shell Side: 193̊ C
Operating Temperature-Tube Side: 385̊ C, Shell Side In/out:150/186˚C

2.0 PURPOSE
The material and procedures specifications are provide to protect Carbon
steel and stainless steel from corrosion and environment as client
requirement.

3.0 OBJECTIVES
i) To ensure that proper /approved equipment, tools consumables,
paint materials and procedures /techniques are used for painting
works (Provided in the QC Report).

ii) To ensure that all coating materials / paints are supplied in

unopened containers and properly stored in well-ventilated, covered
and cool place.

iii) To ensure that the painting work is performed as per the following
codes and standards

iv) To ensure that the painting work is performed as per the client’s
requirements, specifications and approved procedures.

v) To define the surface preparation & application of painting for

Carbon steel and stainless steel
.

-3-
_____________________________________________________________________________________

4.0 REFERENCES STANDARDS

Specification as per SOP022 Issue 1 Rev 12

ISO 8502-3
Preparation of steel surface profile, within the range of 20 μm to 200 μm
by abrasive blasting

ISO 8503-2
Preparation of steel substrates before application of paints and related
products – Surface roughness characteristics of blast cleaned steel blast
cleaned steel comparator procedure.

ISO 8504-2
Preparation of steel substrates before application of paints and related
products- Surface preparation methods- Part2, Abrasive blast cleaning.

ISO 8504-3
Preparation of steel substrates before application of paints and related
products- Surface preparation methods- Part 3, Hand and power tool
cleaning.

SSPC-SP-05
Preparation of steel substrates before application of paints and related
products- Surface preparation methods Sa 3 covers the requirements for
white metal blast cleaning of unpainted or painted steel surfaces by the
use of abrasives

-4-
_____________________________________________________________________________________
SSPC PA 2
This standard describes a procedure for determining shop or conformance
to a specified coating dry film thickness (DFT) range on ferrous and non-
ferrous metal  St.2

ASTM D 3359
Test methods cover procedures for assessing the adhesion of coating

ASTM D 4285
Determine the presence of oil or water in compressed air used for abrasive
blast cleaning, air blast cleaning, and coating application operations.

ASTM D 4417
Roughness Measurement & Blast Profiles of blasted surface with profile
gauge.

Steel Structure, Pipe line and fittings Surface Preparation / painting

Standards
- Project Drawings
- Cods and Standards
- Paint Manufacturers Technical Data Sheets

5.0 3rd PARTY CERTIFIED INSPECTION TOOLS REQUIRED

i) DFT Gauge to check dry coating thickness as specifies.
ii) Whirling Hygrometer
iii) Surface Profile Gauge
iv) Salt Contamination Meter –SCM 400
v) Hypodermic Pressure Gage
vi) Wet Film Thickness gage
vii) Testex Tape
viii) Dew Point calculator
Note: Valid 3rd party certificates available at site.

-5-
_____________________________________________________________________________________

6.0 SURFACE PREPARATION

Sa 3- Blast Cleaning to pure metal ( White Metal Blast)

Operation before blasting

Blasting activities shall not be commence until completion of all

mechanical activities & get the completion certificates prior to start.

Prior to blasting the steel surface shall be high –pressure fresh water
washed (Potable fresh wter shall not contain more than 30 ppm). following
washing down, the soluble salt level on the washed surface, prior to
painting shall be less than 20 mg/m2 when measured with SCM 400 salt
contamination meter. Above that value shall be again washed down with
the same procedure until the soluble salt levels is below 20 mg/m2.

Prior to blasting, rough welds and cut offs shall be ground to a small
radius and weld spatter shall be removed by chipping and / or grinding,
wherever is applicable.

Abrasive blasting shall be carried out on when the steel surface is at least
3 degree C above the dew point and the relative humidity is less than 85%

Items/surface not required to be painted shall be protected from damage

or contamination during surface preparation and paint application by
adequate temporary covering.

Abrasive Blasting

Abrasive media garnet shall be used for blast cleaning. The surface
profile value 50-75 microns.

All surfaces shall be degreased. High pressure water washed prior to

blasting and allowed to dry.

The blasting nozzle pressure shall not be less than 90 PSI.

Used abrasive shall be removed from blast cleaned surface by dry

brushing and blowing down with clean and dry compressed air.

Blast cleaned surface shall be primed as soon as practical after blasting

and before detriment corrosion, visible re-rusting or contamination occurs ,
or within 4 hours whichever is sooner.

Painting

-6-
_____________________________________________________________________________________

Paint Storage
All paint material shall have checked against batch certificates & recorded
in material receiving inspection report.
All paints shall be received in factory sealed drums with manufacturer
marking/ labels.

Paints and thinners shall be stored in a well ventilates area away from
direct sunlight.

Paints, which have exceeded shelf life, shall not be used.

Paint preparation
All paints shall be thoroughly mixed before application. Power stirrer shall
be used for mixing paint quantities over 5 Lit.

Continuous mixing of painting materials to get homogenous mix & avoid

any settlement in paint drum.

Paint Application

Paint equipment selection shall be as per the paint manufacture

recommendation skilled painters shall carry out the painting activities.

Surfaces to be painted shall be clean, dry and free of oil, grease or other
contaminant.

Before application of any coating, the prepared surface shall be checked

for soluble salts contamination.

Environmental conditions shall be checked and recorded at least five times

in a working shift, to ensure that the humidity and surface temp. are within
the specified limits.

Painting shall not be carried out when relative humidity is greater than
85% and or when metal temp. is below10 degree C or above 55 degree C.

Primer, intermediate coat and top coat shall be of contrasting color.

Stripe coating is mandatory for all welds, edges, bolts and nuts, nozzles &
any inaccessible area before spray application.

Paint shall be applied by airless spray Equipment.

Wet film thickness shall be checked using Elcometer thickness gauge.

-7-
_____________________________________________________________________________________

Painted surface shall be washed down between coats with fresh clean
water, the surface shall be tested for chlorides.

Re-coating intervals shall be as given in paint manufacturers data sheets.

The finished coating shall be free of runs, sags, drips, dry spray or foreign
matter.

Dry film thickness shall be checked using DFT gauge

The coating shall be allowed to cure for the full time as given in the
manufactures data sheet. As a minimum, allow curing period of 2 hours
for turning and 16 hours for lifting & transporting.

Application Method

Paints shall be applied as per manufacture recommendation, by airless

spray. Brush application is acceptable only in minor areas such as repairs
& reverse angles where spray fans will not reach.

Airless spraying

The same requirement for conventional spray application shall be followed

except the air pressure control.

Paint manufacturers instruction shall be followed.

Bruch application ( only for stripe coating)

Brushes use shall be good quality and properly selected for the job to be
carried out land shall not exceed 100 mm width.

A smooth coat by brush shall be achieved with as even thickness as

possible.

All drips, runs and sags shall be brushed away

-8-
_____________________________________________________________________________________
Repair Procedure

Spot blasting to original surface preparation in pace of power tool cleaning.

Areas less than 0.1 M2 shall be hand power tools cleaned to ST2/ST3.
Manual / power tool cleaning shall be permitted for coating repair, or can
be permitted only on case to case basis.

Areas greater than 0.1 M2 shall be blast cleaned to original surface

preparation requirement.

Feather – edge the existing coating at least 50 mm beyond bare metal

Build up the paint coat as the original paint system by brush for areas up
to 0.1. m2 and by spray for areas above 0.1. m2.

7.0 SAFETY REQUIREMENT

Following safety requirements shall be implemented by painting
supervisor, before the start painting operations:

- To be ensure that personal protective equipment are provided to all

relevant staff; including hood and face mask.

- Ventilation and access platforms are inspected and approved by the

appropriate authority.

- Proper earthling arrangements are made for all the painting tools to
avoid electric shock from static electrical charge.

- Blasting activities will operated through dead man handle.

- All pressure hose connections are incorporated with the positive

locking mechanism. Pressure vessels/compressed air tanks are
provided with the safety release valve.

-9-
_____________________________________________________________________________________
- Proper cleaning arrangements are made for daily cleaning of
nozzles and other painting equipment with the recommended type
of cleaning solvent.

8.0 GENERAL RESPONSIBILITY OF PAINTING INSPECTOR

i) Qualified Nace level 2 coating inspector will report directly to the
painting project manager.

ii) All work and materials supplied will be subject to continuous

inspection in the yard and on site .

iii) Painting inspector will inspect surface preparation and coating

materials received to ensure their conformance with the client’s
requirements and specifications.

iv) Painting inspector will carry out periodical checks to ensure that the
storage of coating materials meets with the client’s and
manufacturer’s requirements.

v) Painting inspector will carry out tests and inspections to ensure that
equipment to be used for surface preparation and coating is in good
working order and conforms to the clients and manufacturer’s
requirements and specifications.

vi) Painting inspector will regularly check climatic conditions, surface

temperature, relative humidity, etc. throughout the working day and
note the findings on a daily inspection report.

- 10 -
_____________________________________________________________________________________
8.1 INSPECTION DURING SURFACE PREPARATION
i) After blast cleaning dust level shall be checked & maximum rating is
2 as per ISO 8502-3 & Add X cut adhesion test on sample plate as
per ASTM D 3359 method A to meet not less than 3 A.

ii) Painting Supervisor will check the item to be surface prepared and
to ensure that it is free from oil and grease, there are no sharp
protrusions and all non-tightly adhered excessive weld spatter has
been removed .
iii) Painting Inspector will monitor the size, shape, dryness and
cleanliness of the abrasive.

iii) Painting Supervisor will monitor the painting .

iv) Painting Inspector will inspect surfaces to ensure compliance with

client’s specifications and job specifications.

v) Painting Inspector shall check the surfaces are free from the salt
contents. The salt contents inspection shall be performed with
information to client inspector. Chloride content below 20mg/m2

vi) Painting Inspector will check the surface profile of surfaces to

ensure a profile or anchor pattern is achieved as per the relevant
specifications and coating system.

8.2 INSPECTION DURING PAINTING:

i) Painting Supervisor will ensure that coating does not take place
during adverse weather conditions such as fog, mist, dust laden air
or rain and when the relative humidity and surface temperature is
out with the limits below:
a) Surface minimum of 3oC (5oF) above dew point.

- 11 -
_____________________________________________________________________________________
b) Maximum Relative Humidity of 85%. (95% for applying
inorganic zinc silicates).

c) Maximum Surface Temperature of 55oC

.
d) Maximum Air Temperature of 55oC.

e) Available light is less than 500 lux.

ii) Painting Inspector will periodically check wet film thickness during
coating applications.

iii) Painting Supervisor will ensure that only approved coating materials
are used and are applied as per the approved coating procedure
and paint manufacturer’s recommendations.

iv) Painting Inspector will check dry film thickness of each coat prior to
over coating by using a Elcometer Dry Film Thickness Gauge

v) The DFT gauges shall be suitably calibrated each day using a

newly blasted surface and plastic shims of a known thickness.

vi) Painting Supervisor will ensure that no over coating is carried out
prior to the time recommended by the paint manufacturer.

vii) Painting Inspector will visually check applied coat for skips, runs,
sags, drips and overspray and ensure that that they are removed.

viii) Painting Inspector will check coated surfaces for coating color,
missed spots and holidays and ensure any required corrective
action is taken.

- 12 -
_____________________________________________________________________________________
ix) Painting Inspector will ensure that each coat is clean and free from
contaminates prior to over coating.

x) Coating shall be according to specification provided by the client.

9.0 INSPECTION AND TESTING

All painting materials, equipment, and accessories shall be subject to the
instant periodic inspections by the client representatives.

Following test equipment shall be frequently used:

a. DFT Gauge to check dry coating thickness as specifies.
b. Whirling Hygrometer
c. Surface Temperature Gauge
d. Surface Profile Thickness Gauge
e. Salt Contamination Meter

All equipment shall be calibrated by authorized technical personnel.

9.1 ENVIRONMENTAL CHECKS

Before start of any painting, the atmospheric temperature and relative
humidity shall be measured to determine the dew point and not to exceed
55oC for painting works.
Readings shall be repeated depending on climate changes.

9.2 SURFACE PREPARATION CHECKS

Cleaned surfaces hall be checked for surface profile and contamination
before painting.

- 13 -
_____________________________________________________________________________________
9.3 WET FILM / DRY FILM THICKNESS

Wet film thickness shall be spot checked over all the painted areas, no
reading less than 90% shall be accepted; and maximum 10% below the
required thickness readings shall be accepted.

Revise the DFT readings shall be checked for each cot as per SSPC PA2.
Number of readings shall be as per SSPC PA 2 & recorded in separate
sheet & acceptance criteria is table 1 level 3 of SSPC PA2.

10.0 Attachments
Painting Work Method
ITP
QC Report Specimen
Paint Data Sheets

- 14 -
_____________________________________________________________________________________

TECHNICAL RECOMMENDATION
FOR PROTECTIVE COATING

WORK METHOD
PAINTING FOR CARBON STEEL STRUCTURE AS PER SYS.A-4b

* De-greasing and high pressure water washing if

required.

* Blast cleaning to Swedish Standard Sa 3.

* Application of 2 coat of Jotun’s Jotatemp 650 (Inert

Polymeric Matrix) to a thickness of 125 to 150
microns each coat . Total of 250 to 300 microns
(Two coats)

- All sharp edges, welds, corners etc. will be stripe coated

between each coat.

- Washing between coats will be done if required.

- 15 -