CAIRN ENERGY INDIA PTY LIMITED

MANGALA PROCESSING TERMINAL (MPT)

MANGALA ASSOCIATED FACILITIES PROJECT (EPC-1)

TANKS AND EXPORTS SYSTEMS - PROJECT NO: M201

M201TPL-MPT-N-PRO-8001

Issued for 28/01/1 P

A2 Client SK ROY SKROY
3 NATARAJAN
Review
Issued For
SK ROY
A1 IDC 27/01/13 P NATARAJAN SK ROY

Purpose of Date of Checked Approved

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 TATA PROJECTS LIMITED
CAIRN ENERGY INDIA PTY LIMITED
MANGALA ASSOCIATED FACILITIES
PROJECT (EPC-1)
PROCEDURE FOR SURFACE PREPARATION AND PAINTING FOR
STRUCTURAL STEEL & PIPING

SL.NO DESCRIPTION PAGE NO

1 Purpose 3

2 Scope 3

3 Reference Documents 3

4 Definitions 3

5 Health and Safety 4

6 Environmental 4

7 Training and competency of personnel 4

8 Process 7

9 Inspection 8

10 Final Inspection 8

11 Documentation 8

12 Personnel 8

M201TPL-MPT-N-PRO-8001 REV.A3
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 TATA PROJECTS LIMITED
CAIRN ENERGY INDIA PTY LIMITED
MANGALA ASSOCIATED FACILITIES
PROJECT (EPC-1)
PROCEDURE FOR SURFACE PREPARATION AND PAINTING FOR
STRUCTURAL STEEL & PIPING

1. PURPOSE
The purpose of this work procedure is to provide guide lines for surface preparation and
painting of pipes and structural items and to ensure that proper quality control and documentation
are maintained at site.
2. SCOPE

The scope of method statement describes the method for blasting, painting application, touch-
up painting and inspection on exterior surface of structural steel, above ground piping, &
Equipments at Phase II-Mangala Process Terminal ; Associated facilities project – EPC 1 Project
of CAIRN ENERGY INDIA Ltd.
3. REFERENCE DOCUMENTS
• M201TPL-MPT-Q-PLN-0001 “Project Quality Plan”
• DECO-RX-L-SP-2003 “Project General Piping Design and Materials”
• DECO-RX-M-SP-2020 “External Painting and Protective Coating”
• ISO 8501-1 “Preparation of steel substrates before
application of paints”
• ISO 2808 “Paint & Varnish – Determination of Film
Thickness”
• ISO 4624 “Paint & Varnish – Pull off test for Adhesion”
• SSPC VIS 1 “Visual Standard for Abrasive Blast Cleaned
Steel”
• SSPC PA 2 “Measurement of Dry Film Thickness with
Magnetic Gauge”
• ASTM D4541 “Standard Test Method for Pull off strength of
Coating”
• Drawing References.
4. DEFINITIONS

CEIL - Cairn Energy India Pty. Limited(Client)

EIL - Engineers India Limited (PMC)

TPL - TATA Projects Limited(EPC Contractor)

NDT - Non-Destructive Testing

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 TATA PROJECTS LIMITED
CAIRN ENERGY INDIA PTY LIMITED
MANGALA ASSOCIATED FACILITIES
PROJECT (EPC-1)
PROCEDURE FOR SURFACE PREPARATION AND PAINTING FOR
STRUCTURAL STEEL & PIPING

HSE -Health Safety and Environment

DFT - Dry Film Thickness

MSDS - Material Safety Data Sheet

ISO - Indian Standard Organisation

ASTM - American Society testing of Materials

NACE - National Association of Corrosion Engineers

SSPC - Society of Protective Coating

MTC - Material Test Certificates

5. HEALTH & SAFETY

5.1 As per HSE Plan, the following system to be followed

5.2 All relevant elements of HSE Plan shall be followed.

5.3 Emergency and response Plan shall be followed in case of any emergency. Road
Transport safety procedure shall be strictly adhered while transportation of manpower
or formwork materials by vehicles.

5.4 Daily pep talk shall be conducted prior to proceed for the work.

5.5 First Aid arrangements shall be followed as per procedure.

6. ENVIRONMENTAL
6.1 Refer to Environment Management instructions.
6.2 All activities shall comply with Environment Management Plan.
7. TRAINING AND COMPETENCY OF PERSONNEL
7.1 Daily Tool Box talk shall be conducted by job supervisor and weekly tool box
talk shall be conducted by respective area in-charge.
8. PROCESS
8.1 General
8.2 Surface Preparation
8.3 Painting
8.4 Colour coding and identification sign

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 TATA PROJECTS LIMITED
CAIRN ENERGY INDIA PTY LIMITED
MANGALA ASSOCIATED FACILITIES
PROJECT (EPC-1)
PROCEDURE FOR SURFACE PREPARATION AND PAINTING FOR
STRUCTURAL STEEL & PIPING

8.1 General
8.1.1 Material
Paint materials shall be purchased from the company approved
manufactures.
All painting materials shall be stored indoor only. Materials shall be stored
and used as per the manufacturer’s recommendation. All necessary
precautions shall be taken to prevent fire. Warning signboard shall be clearly
displayed. Thinners shall be stored in separately and in sealed containers.
8.1.2 Extent of Painting
All above ground piping and structural steel shall be painted as per the
painting system specified in DECO-RX-M-SP-2020 “External Painting and
protective Coating”. Touch-up painting shall be done for the equipments.
The following surfaces shall not be painted
• Welded joints of the pipe & ends of the pipe (During shop
painting)
• Identification mark (During shop painting)
• Machined and threaded surface like flange faces, valve stem,
sliding surfaces in equipments etc.
• Galvanized surfaces
• Name plates
8.1.3 Weather condition
Surface shall not be blasted or coated in rain, heavy wind, dusty wind, fog,
moist. When the steel surface temperature is less than 3°C of dew point,
surface temperature is below 5°C whether relative humidity is greater than
85% or when the air temperature is below 10°C, the surface shall not be
painted.
8.2 Surface Preparation
The type of surface preparation shall be in accordance with Appendix 2.0 of
DECO-RX-M-SP-2020 “External Painting and Protective Coating”.
8.2.1 Abrasive Blast Cleaning
Sand blasting or other material producing silica shall not be used. Abrasive to
be used for blast cleaning are listed below.
• Chilled Iron Grit or Shot
• Non & Metallic Iron Grit or Shot

M201TPL-MPT-N-PRO-8001 REV.A3
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 TATA PROJECTS LIMITED
CAIRN ENERGY INDIA PTY LIMITED
MANGALA ASSOCIATED FACILITIES
PROJECT (EPC-1)
PROCEDURE FOR SURFACE PREPARATION AND PAINTING FOR
STRUCTURAL STEEL & PIPING

• Non Metallic Abrasive(Aluminium, Oxide, Copper, Slag, Garnet)

• Grit Spec-Particles that are predominately angular have fractures
faces and sharp edges and are less than half round in shape.
The surfaces shall be blast at appropriate pressure, distance and right angles
to the surface maintaining constant velocity and pressure.
Compressed air shall be free from moisture, oil and other contaminations,
The compressed air temperature shall be less than 110°C.
Prior to blast cleaning of pipes and pipe spools the identification of spool shall
be covered by masking tape or Aluminium tag shall be tied to the
spools/pipes.
Machined surface such as flange faces and threaded surfaces shall be
covered by masking tape so as not to damage the surface while blasting.
Abrasive blast cleaned surface shall not be less than 25µm nor be greater
than 60 µm. Grade surface finish shall be accordance with ISO 8501-1
• Sa 1 -“Light Blast Cleaning” (SSPC SP 7)
• Sa 2 -“Through Blast Cleaning”(SSPC SP 6)
• Sa 2½ -“Very Through Blast Cleaning”(SSPC SP 10)
• Sa 3 -“Blast Cleaning to Virtually Clean Steel”(SSPC SP 5)
On completion of blasting operation, the blasted surface shall be clean and
feee from Over scale, rust, oil, grit or other foreign material and first coat of
paint shall be applied on the same day.
Surface profile shall be uniform and checked randomly by profile gauge
comparator or Anchor pattern standards.
8.2.2 Hand Tool Cleaning
Rust mill scale spatters, old coating and other foreign and other foreign
matter, shall be removed by scrapping tool, emery paper cleaning, brushing
or combination of the above methods. On completion of cleaning, loose
material shall be removed from the surface by clean rags and the surface
shall be brushed, swept, and blown off with compressed air to remove all
loose matter.
8.2.3 Power Tool Cleaning
Power Rotary Wire Brushing, Rotary Power Discing, grinding machines shall
be used for removal of rust mill scale, spatter, old coating and other foreign
matters. On completion of cleaning, loose material shall be removed from the
surface by clean rags and the surface shall be brushed, swept, and blown off
with compressed air to remove all loose matter.
Power tool cleaning shall be done at site for touch up painting.
8.3 Painting

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 TATA PROJECTS LIMITED
CAIRN ENERGY INDIA PTY LIMITED
MANGALA ASSOCIATED FACILITIES
PROJECT (EPC-1)
PROCEDURE FOR SURFACE PREPARATION AND PAINTING FOR
STRUCTURAL STEEL & PIPING

Painting system and colour coding system shall be in accordance with

Appendix 1.0 and 2.0 of DECO-RX-M-SP-2020 “External Painting and
Protective Coating”.
Paint material shall be identified as per incoming Material receipt inspection
procedure and also verification of material with respect to Specification
a) Manufacturer
b) Batch Test Certificate
c) Pot life/Expiry date
d) Storage area
The paint manufacturer’s recommendation shall be followed for mixing,
thinning, storage, application of paint, drying time and weather condition.
Surfaces that should not be painted shall be covered by masking tape.
Zinc based paints shall be agitated continuously while painting.
If there is rain just after application, before drying then protection will be
done by covering tarpaulin.
In case of air spray application, traps or separators shall be installed to
remove oil and condensed water from the air.
Blast cleaned surface shall be coated with one complete application of primer
as before flash rusting occurs soon as practicable but in no case later than
the same day as sand blasted.
Blast cleaned surface allowed to set over night shall be reblasted prior to
priming.
All paint containers shall be opened prior to utilisation and shall be carefully
closed immediately after withdrawal of material. Material which become
unserviceable during storage shall not be applied. All painting material shall
be kept in weather proof barracks and shall be kept cool and dry.
Paint materials which exceed its pot life shall be removed and destroyed
immediately.
Each pass of the spray paint shall be overlapped by 50% and the spray shall
be continuous until all paint material used up which has been taken out from
the paint containers.
Each coat shall be in proper state of dryness before the application of
succeeding coat. The curing time shall be as per the manufacturer’s
recommendations.
In case of two or more coats of painting, the successive coat shall be of
contrast dark shade to the previous coat shade.
Paint film thickness shall be maintained as indicated in painting system and
the painted surface shall be free from defects. Proper application of paint
shall be checked by measuring their WFT while painting. DFT will be

M201TPL-MPT-N-PRO-8001 REV.A3
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 TATA PROJECTS LIMITED
CAIRN ENERGY INDIA PTY LIMITED
MANGALA ASSOCIATED FACILITIES
PROJECT (EPC-1)
PROCEDURE FOR SURFACE PREPARATION AND PAINTING FOR
STRUCTURAL STEEL & PIPING

measured with the help of coating thickness gauge after curing at every
stage.
All runs and sags shall be brushed out immediately or the paint shall be
removed and surface re-painted.
After painting, paint shall be visually checked with regards to unfinished
surface, drips, wrinkles, peeling, crewing, decolourisation, strains, pinholes
and spray dust where there are no marked defects in appearance the paint is
accepted with respect to meeting the DFT.
When paint has been damaged, all damaged and loosely adhering paint shall
be removed and surface cleaned mechanically to bare metal. Surface
preparation of defective or damaged areas shall be extended over the
surrounding sound coating for a minimum of 25 mm on all sides. Priming
shall be done in the area with primer specified to the required DFT. Then 2nd
& 3rd coat paint shall be applied as per specification.
Shop coating of all members should be completed before erection.
The left out paint will be preserved in a drum with tight cover.
Scaffolding arrangement shall be done for painting of erected pipelines and
structural works and equipments.
Field painting of weld joints shall be done after the completion of applicable
NDT and hydro test.
8.4 Colour coding and Identification sign
The strip colour coding shall be in accordance with the Table M – Piping
Painting Colour code of DECO-RX-L-SP-2003 “Project General Piping Design
and Materials”.
The three strips 150mm width each shall be painted over the final coat.
The three strips shall be placed each 9 meters length whenever necessary for
identification (branches, valves, tanks, at curves, close to equipments, close
to entrance and exit of equipments and before and after crossing of
bulkhead).
All strip colours shall be painted or marked by vinyl or PVC tape, in
accordance with specified colours.
Flow direction shall be an arrow mark, colours of shall be black or white and
in contrast to the colour on which they are superimposed.
Line tags and arrows to indicate flow direction shall be painted or marked by
vinyl or PVC tape. The text height shall be 20 mm for DN 50 pipe sizes and 50
mm for pipe sizes above DN 50.
Insulated piping shall also be identified.
9. INSPECTION
Inspection of surface preparation and painting shall be carried out as per the
ITP No. M201TPL-MPT-Q-ITP-5004.
M201TPL-MPT-N-PRO-8001 REV.A3
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 TATA PROJECTS LIMITED
CAIRN ENERGY INDIA PTY LIMITED
MANGALA ASSOCIATED FACILITIES
PROJECT (EPC-1)
PROCEDURE FOR SURFACE PREPARATION AND PAINTING FOR
STRUCTURAL STEEL & PIPING

9.1 DEW POINT MEASUREMENT

Dew Point shall be measured 3 times a day as a minimum and records shall
be maintained.
Before any coating or painting activities commence, the substrate
temperature shall not 3 °C or less than the Dew point.
9.2 SURFACE PREPARATION VISUAL INSPECTION
Surface preparation shall be visually inspected in accordance with SSPC VIS 1
& 3.
The measurement of surface profile shall be as per NACE RP 0287 or ASTM D
4417 and ISO 8502.
Acceptance of the blast cleaned surface shall be made by visual comparison
with Anchor Pattern Standards’ or ‘Surface Profile Comparator’.
9.3 DRY FILM THICKNESS
Painted area shall be devoid of bare metal and is free of holiday. The DFT
requirements and colour codes shall be achieved as per the requirements.
The DFT shall be checked in the spots at random and documented.
9.4 ADHESION TEST
The adhesion Test shall be carried out in accordance with ASTM D4541 and
ISO 4624.
Each coat of a system and the complete system shall be visually inspected
for adhesion and surface imperfections. If upon visual inspection loss of
adhesion is suspected or found in a paint system, an adhesion test shall be
carried out.
Test plates shall be adhesion tested for each paint / coating system.
Where practical, to avoid damaging the paint on equipment, a test plate of
the same material as equipment shall be prepared and painted concurrent
with the Tank being painted. The adhesion test shall be done on the test
plate after paint is completely cured. The adhesion test shall be performed on
the test plate after application of the primer to the steel substrate and after
the subsequent coats.
A cross cut test or pull off test shall be used to check the adhesion of primer
to substrate or inter coat adhesion.
10. DOCUMENTATION
Documentation shall be as follow
Refer Inspection and Test Plan for Surface Preparation and Painting for
structural steel and piping M201TPL-MPT-Q-ITP-5004..
Format for surface preparation and Painting M201TPL-MPT-M-REP-3010 Rev.
C2.

M201TPL-MPT-N-PRO-8001 REV.A3
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 TATA PROJECTS LIMITED
CAIRN ENERGY INDIA PTY LIMITED
MANGALA ASSOCIATED FACILITIES
PROJECT (EPC-1)
PROCEDURE FOR SURFACE PREPARATION AND PAINTING FOR
STRUCTURAL STEEL & PIPING

Adhesion Test Report M201TPL-MPT-M-REP-6130 Rev A2.

Colour coding & identification Mark report M201TPL-MPT-M-REP-6105 REV A2.
11. PERSONNEL
Peoples involved
1. Construction Manager
2. Project QC Manager
3. QA/QC Engineer
4. Site Engineer
5. HSE Engineer
6. QC Assistant
7. Foreman
Roles & Responsibilities – Refer Project Quality Plan
M201TPL-MPT-Q-PLN-0001- Responsibility & Authority section.
12.0 EQUIPMENT FOR CONSTUCTION
• Compressor along with hose and nozzles
• Hoppers.
• Paint agitators.
• Paint spraying equipment.
• DFT gauge.
• Surface Profile Comparators.
• Cleaning tools like wire brush, scrappers, etc.
• Painting brush and rollers.
• Hygrometer.
• WFT gauge.

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