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Above Ground Piping Painting Procedure - Shop-Field Application
Above Ground Piping Painting Procedure - Shop-Field Application
Above Ground Piping Painting Procedure - Shop-Field Application
DLPS-SSSP-5-QA-PRC-
REPLACE SSSP-5 REFINED PRODUCTS SUPPLY PIPELINE 043-
Rev 00
Contract No. 6600045190 / BI-10-10056
ABOVE GROUND PIPING PAINTING
PROCEDURE – SHOP / FIELD Date: Feb-08, 2022 Page No: 1 of 15
APPLICATION
PROJECT: BI-10-10056
REPLACE SSSP-5 REFINED PRODUCTS SUPPLY PIPELINE
CLIENT:
SAUDI ARABIAN OIL COMPANY
Dhahran - 31311, Saudi Arabia
CONTRACTOR:
P.O. Box 737 Abqaiq 31992 Saudi Arabia
Web: www.dlpls.net
TABLE OF CONTENTS
1. SCOPE AND PURPOSE...............................................................................................................4
2. APPICABILTY.............................................................................................................................4
3. REFERENCES..............................................................................................................................4
4. RESPONSIBILITY.......................................................................................................................5
5. TOOLS AND EQUIPMENTS......................................................................................................6
6. PERSONNEL QULIFICATION...................................................................................................6
7. STORAGE AND HANDLING OF PAINTS AND ABRASIVE.................................................7
8. SAFETY REQUIREMENTS........................................................................................................8
9. GENERAL.....................................................................................................................................8
10. PROCEDURE................................................................................................................................9
11. QUALITY CONTROL EQUIPMENT KIT................................................................................12
12. INSPECTION PROCEDURE.....................................................................................................12
13. COATING MATERIAL SELECTION FOR PIPING AND STRUCTURE..............................14
14. ATTACHMENTS........................................................................................................................14
DIVERSIFIED LINES PETROLEUM SERVICES DOCUMENT NO
Modification History
DIVERSIFIED LINES PETROLEUM SERVICES DOCUMENT NO
This procedure will cover the surface preparation and painting works at DLPS coating
shop/ field application. Activity will cover the surface preparation and painting works for
pipe spools, flanges, saddle and wear pads which are missing coating from shop application
& field girth weld joints.
This procedure is limited to ensure the execution of surface preparation and paint
application works in accordance with project specification and paint manufacturer’s
recommendation.
The paint system to be used shall be APCS-26 for all above ground pipe spools, valves,
vent valves, valve actuators, flanges, fittings, saddle and wear pads including field girth
welds as per SAES-H-001 and project specification requirements.
2. APPICABILTY
3. REFERENCES
SAES-H-001 Coating Selection & Application Requirements for Industrial Plants and
Equipment
SAES-H-101V Approved Saudi Aramco Data Sheets – Paints and Coatings
SAES-H-002 Internal and External Coatings for Steel Pipeline and Piping
SAES-H-002V Approved Saudi Aramco Data Sheets for the Pipeline Maintenance
External Coatings
SAES-H-102 Safety Requirements for Coating Applications
SAES-H-200 Storage, Handling and Installation of Externally Coated pipe
SAEP-316 Performance Qualification of Coating Personnel
09-SAMSS-060 Saudi Aramco Material System Specification Requirements for
Coating
APCS 113A High volume solid epoxy
DIVERSIFIED LINES PETROLEUM SERVICES DOCUMENT NO
4. RESPONSIBILITY
PROJECT MANAGER
To ensure that the work described here-under is executed in accordance with all the Contract
requirements including this procedure.
QC MANAGER
Controlling and implementing of all quality construction activities in collaboration with the
Project Manager as per approved QCP & applicable SAES, SAEP & SATIP.
QC SUPERVISOR
Quality control supervisor provides an overview of the quality management aspects of surface
preparation, paint, coatings, and inspection operations.
DIVERSIFIED LINES PETROLEUM SERVICES DOCUMENT NO
PERMIT TO WORK
Permit holder/ Crew supervisor will be responsible to obtain the Permit to Work prior to
startup of any coating activity at site.
The material and equipment used for surface preparation, painting application, and
inspection shall confirm to the requirements of APCS and as per SAES-H-001.
DIVERSIFIED LINES PETROLEUM SERVICES DOCUMENT NO
Extreme care shall be taken to avoid the damage to the blasting and painting equipment’s
during handling and operating.
6. PERSONNEL QULIFICATION
All site coating crew supervisor, abrasive blasters and protective coating applicators shall
be qualified and certified as per SAEP-316 requirements.
Coating inspector shall be NACE Level II or equivalent.
Coating Inspector shall meet the required experience and certification as per SAEP-316.
Also, he shall be approved by PIESU.
7. STORAGE AND HANDLING OF PAINTS AND ABRASIVE
Paint and thinner shall be stored in well-ventilated area or shelter according with
recommended storage temperatures given in Saudi Aramco Paint data sheet, SAES-H-101V.
Shelter storage temperature shall not exceed 35C unless stated otherwise in the paint
manufacturer data sheet.
Paints which have exceed the shelf life given in the Saudi Aramco data sheet shall be set
aside and removed. Expired shelf life paint shall not be used.
Coating materials used at construction sites must be covered with appropriate canvas,
tarpaulins, or equivalent for a temporary storage period not to exceed 14 days.
Each coating container shall be clearly marked in accordance with 09-SAMSS-060.
Paint container showing signs of leakage shall be discarded and not to be used for coating.
Abrasive shall be kept dry and clean. Regardless of the type of abrasive, the sulfate content
shall be less than 50 PPM, the chloride shall be less than 50 PPM, and calcium carbonate
shall be 0.1 0% maximum by weight.
The use of reclaimed abrasives is prohibited.
Abrasives shall be stored in dry and clean areas and shall be covered with tarpaulin during
storage.
8. SAFETY REQUIREMENTS
Safety during abrasive blasting and application of coating shall meet the
requirements of SAES-H-102, Sect. 4. GI-0002.100 (Work Permit System) & GI-0006.021
(Safety Requirement for Abrasive Blasting).
All the areas shall be barricaded prior to start of abrasive blasting and coating and
necessary sign boards to be made visible near the area of work. All the personnel
involved in this process should wear proper Personal Protective Equipment.
DIVERSIFIED LINES PETROLEUM SERVICES DOCUMENT NO
Compressor hoses, air lines, and blast hoses shall be safety wired at each coupling using
proper safety pins.
Airless spray guns shall never be pointed at anyone or at any part of the body.
The trigger safety catch shall be engaged whenever the airless gun is left unattended.
Hoses, pumps, and accessories shall never be operated at pressures exceeding their rated
pressure. In no case, shall the working pressure in the paint line exceed 34.5 MPa (5000 psi).
Safety pressure relief valves shall be used on outbound side of the pressure pump(s).
Airless spray equipment shall not be operated if any of the pressure system components is
not in good condition.
9. GENERAL
The responsibility for the Process Control of the Painting Works rests primarily with the
Crew Supervisor, foreman, QC Inspectors, and QC Supervisor and audit by the QC Manager.
The discipline Engineer and the Crew Supervisor shall ensure the required work permits are
available and in place on a daily basis. Similarly, they shall ensure that utilized drawings are
latest revision.
Blasting and coating shall not be performed if one or more of the following conditions exist
unless the coating is specifically formulated for the averted condition:
The substrate temperature is less than 10°C or more than the temperature limit given in the
applicable Saudi Aramco Data Sheet.
The substrate contains oil, grease, dirt, loose coating, loose rust, or other surface
contaminants.
The substrate temperature is less than 3°C (5°F) above the dew point.
Adverse weather conditions exist such as, but not restricted to, the following:
Wind is strong enough to blow sand, salt spray, or other foreign matter onto the surface being
coated.
Wind is strong enough to cause dry spray or to otherwise seriously disturb the spray pattern
when application is by spray gun.
Surface preparation shall conform to the applicable APCS as per SAES-H-001.
The type of abrasive to be used shall be determined by the degree of cleanliness and surface
profile requirements as specified in the APCS. Silica Sand as abrasive material is prohibited
in Saudi Aramco as per GI-0006.021 requirements.
DIVERSIFIED LINES PETROLEUM SERVICES DOCUMENT NO
When required, solvent cleaning shall be carried out in accordance with SSPC-SP1. Do not
use kerosene, diesel, or other degreasers that leave an oily film unless the surface is
subsequently cleaned with a non-greasy solvent or cleaner such SAP m/n 1000186759 (s/n
26-854-642), m/n 1000022130 (s/n 45-605-875) and m/n 45-605-875/880 (s/n 1000022131).
Modifications and/or reformulations of coatings including change of names require re-
qualification.
Fasteners shall be coated with fluoropolymer coating which is applied in accordance with 09-
SAMSS-107 or Galvanizing can be used onshore.
Projecting steel items (such as grating angles, slide plates, Unistrut, steel plates, etc.) which
are attached to the formwork and cast at the concrete surface shall be hot dip galvanized in
accordance with ASTM A123 or coated with the zinc rich epoxy primer in APCS-1C of
SAES-H-001 as per requirement of SAES-Q-001 para 6.3.
Client specifications and drawings, manufacturer instructions/recommendations shall
supersede the techniques detailed in this procedure when they differ.
The following procedure is a basic outline of requirements and in all cases the relevant
SATIP (if available) shall be reviewed by QC Manager or QC Supervisor to ensure
Inspectors are fully aware of tests and documentation requirements prior to start of work.
10. PROCEDURE
All blasting pots and compressor shall be fitted with efficient water/moisture separator and
water traps etc. to maintain dry oil free air supply. Traps and filters shall be cleaned
regularly.
Sufficient dust suction Blowers shall be fitted adequately to remove dust and fine blasting
debris during the blasting operation.
The Operational remote-control valve (“Deadman”) shall be securely attached to the nozzle.
Minimum nozzle pressure acceptable for blasting steel shall be 620 kPa (90 psig) measured
at the nozzle side.
All compressed air used for abrasive blasting or coating operations shall be free of oil
moisture and contamination.
Degree of cleanliness shall be SA2.5 (SSPC-SP10) and profile shall be (40 – 65 microns) as
per applicable APCS-26 data sheet.
Spent abrasive shall be removed from cleaned external surfaces by dry brushing and blowing
down with clean, dry compressed air.
Abrasive-cleaned surfaces shall be primed or coated before the surface condition degrades
below the specified cleanliness level.
Abrasive blasted surfaces shall call for inspection prior to priming or coating if the surfaces
are hold for more than 4 hours after blasting.
The reference standard for profile measurement shall be the Clemtex Anchor Pattern
Standards.
Painting Materials
All painting materials shall be chemically pure and free from inclusions and foreign
contaminants. The age of material components shall not exceed the recommended pot-life
given by the manufactures.
Batch No and date of manufacture shall be clearly given on all painting materials.
In multi-coat applications, primer, intermediate coat, and topcoats shall be of contrasting
colors and from the same coating manufacturer.
Coatings, which have gelled, shall not be used.
Partial mixing in a two-component and multi-component coatings is prohibited.
Preparation of Coating Materials
Primer or paint shall be mixed in accordance with the paint manufacturer’s datasheet.
Prior to application, all coating shall be thoroughly mixed until it is homogeneous. For
quantities over 5L, a power stirrer shall be used.
DIVERSIFIED LINES PETROLEUM SERVICES DOCUMENT NO
If sludge has formed in the bottom of the coating container, stirring to mix shall be continued
until the coating is fully homogeneous mix. If sludge cannot be dispersed, the coating shall
not be used.
All ingredients in any container shall be thoroughly mixed and shall be agitated by
mechanically (manual agitation not allowed) frequently during application to keep the solids
in suspension.
Application of Paint Materials
The compressed air supply shall be free of oil, moisture and contamination.
Used abrasive shall be removed from cleaned surface by dry brushing and blowing down
with clean, dry compressed air. Avoid handling the blasted steel surface with bare hands.
All weld lines, edges, bolts, nuts and rivets shall be given a brush applied stripe coat prior to
all coating applications.
In case of brush application, the maximum brush size used shall be 125 mm as per SAES-H-
001.
Recoating intervals shall be follow as given in the Saudi Aramco Data Sheet.
Spraying of the paint shall be done by means of airless spray to obtain uniform and correct
film thickness as specified in the APCS-26. Wet film thickness shall be monitored to control
the required minimum dry film thickness.
Between applied coats the minimum and maximum drying time and temperature must be
observed strictly in accordance with paint manufacturer’s recommendations.
Large surfaces shall be painted with passes in two directions at right angles and spray overlap
of previous pass shall be by 50%.
Damaged area of painting during the transportation and erection shall be repaired with the
original material.
Repair Procedure for Damaged Coatings
Clean defective area by solvent or detergent wash.
For area, less than 0.1 m², grind to a rough metal surface using at least 80 grit disc sander.
Alternatively, spot blast to bare steel. Feather edge the coating at least 50mm beyond bare
metal. If the area is very less manual application of abrasive papers may be performed to
prepare the surface.
For areas, greater than 0.1 m², blast clean to obtain the metal surface pretreatment originally
specified. Feather edge the coating at least 50mm beyond bare metal.
Remove dust and debris by brush or vacuum.
DIVERSIFIED LINES PETROLEUM SERVICES DOCUMENT NO
Prior to abrasive blasting, rough welds and Sharp edges shall be ground to a minimum radius
not less than 3 mm to insure proper coating application as per SAES-H-001.
Apply coating by brush for area less than 0.1 m² and by spray for areas greater than 0.1 m² to
the original specification except that the first coat of a multi-coat system shall be thinned.
QC Inspector shall check the surface of the blasted materials as per required surface
preparation and ensure that clean surface must be free from mill scale, oil, grease, soil,
cement, salt, acid or other corrosive material, which are harmful for painting.
Surface profile shall be inspected by using Testex Tape (Press-O-Film).
Degree of surface cleaning shall be inspected visually by comparing the blasted surface with
photographic standards as per SSPC or ISO 8501.
Relative humidity, dew point and substrate temperature shall be recorded at least thrice per
day by the supervisor in daily log book and shall be transfer to inspection report. Blasting
shall not be performed if the substrate temperature is less than 10°C or less than 3°C (5°F)
above the dew point.
Before painting, paint mix ratio shall be as per paint manufacturer’s recommendations.
DIVERSIFIED LINES PETROLEUM SERVICES DOCUMENT NO
After completion of painting, dry film shall be visually examined to establish application
defects such as over spray, dirt inclusion, blister, sag, runs, adhesion, pinholes, voids, spatter
and thin spots. Adhesion strength of all coating systems shall not be less than that required in
the appropriate Saudi Aramco Materials System specification for new product approval.
The finished coating film shall have the following characteristics:
a. The dry film thickness shall be within the minimum and maximum limits (300 – 400
microns) allowed in the applicable APCS-26. Dry film thickness shall be checked in
accordance with SSPC-PA 2.
b. Generally free of application related defects such as runs, sags, drips, dry spray or
foreign matter and uniform in appearance.
c. Areas with blisters, cracks, porous or below minimum dry film thickness shall be
repaired in accordance with paragraph 10.5.
Paint thickness gauge, surface profile gauge, Digital Thermometer shall be calibrated prior to
use.
If the result of DFT is varying from the specified value or if any defect is observed on the
paint surface, it shall be rectified, before proceeding further application.
Rectified surface shall be re-inspected for its completeness.
In addition to the above, QC Inspector shall visually inspect the quality of welds after
blasting to ensure that it is free from welding defects.
The coating contractor supervisor shall fill out a log, on a daily basis, recording all problem
areas, delays non-compliances, and corrective action taken for Saudi Aramco inspector
witnessing and surveillance.
The non-conformance report shall be issued whenever any defect is resulted by coating
materials deficiencies or / and application malfunctioning.
Inspection and Testing shall be carried out as per SAES-H-001 sec.10 requirement.
QC Inspector shall record all inspections conducted for surface preparation and coating
application in the applicable SATR and SAIC as per SATIP for acceptance of coating.
Hempadur Mastic 45881, Sigma cover 410 or any approved brand shall be used.
Etc.
14. RECORDS