Specification For Protective Paint and Coatings: Minimum Works Obligations

RUM AIL A PROJECT
Specification for Protective Paint and

Coatings
Minimum Works Obligations
00102W-C-G0-G000-ML-SPC-0007 Rev 1
14 December 2011
WorleyParsons Europe Limited

Parkview, Great West Road
Brentford, Middlesex
TW8 9AZ
United Kingdom
Tel: +44 (0)20 8326 5000
Fax: +44 (0)20 8710 0220
© Copyright 2011 WorleyParsons

Worley Pa rsons
A
--- "
~~·
RUMAILA PROJECT
SPECIFICATION FOR PROTECTIVE PAINT AND COATINGS
MINIMUM WORKS OBLIGATIONS
NOTICE: "These materials are the Work Product of WorleyParsons, and no reliance on this work
product is authorized by WorleyParsons, and WorleyParsons accepts no liability for any reliance
by any person on the Work product contained herein. BP Iraq NV has expressly authorized
WorleyParsons to issue this disclaimer."
RUMAILA PROJECT 405000-00098 - DOCUMENT TEMPLATE

REV DESCRIPTION ORIG REVIEW WORLEY- DATE CLIENT DATE
PARSONS APPROVAL
APPROVAL
A Issued for Squad 13-May-2011 N/A N/A

Check M Suter R Pollington R Chapman
B Issued for Customer 16-June-2011

Review M Suter R Pollington R Chapman
0 Issued for Use 22.July-2011
1 Issued for Use 14-Dec-2011
Laughlin-
McCann
001 02W-C-GO-GOOO-ML-SPC-0007 Page 2 of 46

Rev 1 (1 4 December 2011) Rumaila Tomplato R3
RUMAILA PROJECT
REVISION DESCRIPTION SHEET
Rev. Para. Reason for Revision
0 3.2 Added - Group Defined Practices and Order of Precedence
1 Client comments incorporated (ref: 00102-CAN-0020)
Hold
Para. Description of Hold
No.
00102W-C-G0-G000-ML-SPC-0007 Page 3 of 46
Rev 1 (14 December 2011)
RUMAILA PROJECT
CONTENTS
CONTENTS ....................................................................................................................................... 4
1. INTRODUCTION................................................................................................................ 7
1.1 Scope ................................................................................................................................. 7
1.2 Definitions .......................................................................................................................... 7
1.3 Abbreviations - ................................................................................................................... 8
2. REFERENCED DOCUMENTS .......................................................................................... 9
2.1 Group Defined Practices and Order of Precedence ........................................................ 11
3. MATERIALS ..................................................................................................................... 12
3.1 Generic versus named products ...................................................................................... 12
3.2 Abrasives ......................................................................................................................... 12
3.3 Compressed Air ............................................................................................................... 12
3.4 Paint Materials ................................................................................................................. 13
4. GENERAL REQUIREMENTS .......................................................................................... 14
4.1 Extent of Painting ............................................................................................................. 14
4.2 Surfaces Not Be Painted .................................................................................................. 14
4.3 Fasteners ......................................................................................................................... 15
4.4 Protection of Stainless Steel Surfaces ............................................................................. 16
4.5 Safety Requirements........................................................................................................ 16
5. SURFACE PREPARATION ............................................................................................. 17
5.1 Items to be Protected ....................................................................................................... 17
5.2 Basic Cleaning ................................................................................................................. 17
5.3 Weld Preparation ............................................................................................................. 18
5.4 Abrasive Blasting of Carbon Steel ................................................................................... 18
5.5 Cleaning of Galvanized and Inorganic Zinc Surfaces ...................................................... 19
5.6 Cleaning and Blasting of Stainless Steel Surfaces .......................................................... 19
6. APPLICATION PROCEDURES ....................................................................................... 20
6.1 Preparation for Painting ................................................................................................... 20
6.2 Environmental Conditions ................................................................................................ 20
RUMAILA PROJECT
6.3 Paint Application .............................................................................................................. 21
6.3.1 General ................................................................................................................ 21
6.3.2 Spray Application ................................................................................................ 22
6.3.3 Brush Application ................................................................................................ 22
6.3.4 Roller Application ................................................................................................ 22
7. REPAIRS ......................................................................................................................... 23
7.1 General Requirements ..................................................................................................... 23
7.2 Coating Damage Not Exposing Substrate Surface .......................................................... 23
7.3 Coating Damage Exposing Substrate Surface ................................................................ 23
7.4 Repair of Zinc Silicate Primer .......................................................................................... 24
7.5 Repair of Fully Cured Epoxy Coating............................................................................... 24
8. EXECUTION .................................................................................................................... 25
8.1 Shop Versus Field Painting Policy ................................................................................... 25
8.2 Responsibilities of the VENDOR ...................................................................................... 25
8.3 Responsibilities of the Paint Manufacturer....................................................................... 25
8.4 Site Painting ..................................................................................................................... 25
9. INSPECTION AND TESTING .......................................................................................... 27
9.1 General............................................................................................................................. 27
9.2 Inspection Instruments ..................................................................................................... 27
9.3 Before Surface Preparation ............................................................................................. 28
9.4 Before And During Paint Application ................................................................................ 28
9.5 After Painting .................................................................................................................... 28
10. INSPECTION RECORDS AND REPORTS ..................................................................... 29
11. SHIPMENT AND PACKING ............................................................................................. 30
11.1 Handling of Coated Items ............................................................................................ 30
11.2 Coating Materials ......................................................................................................... 30
12. GUARANTEE ................................................................................................................... 31
APPENDIX 1: - PAINT SYSTEM SCHEDULE ................................................................................ 32
APPENDIX 2: COLOUR CODING AND IDENTIFICATION ............................................................ 38
A2.1 GENERAL ............................................................................................................................... 38
RUMAILA PROJECT
A2.2 PROCESS AND UTILITY PIPING IDENTIFICATION MARKING COLOUR BANDING SYSTEM 41
A2.3 TEXT SIZE AND LABELLING REQUIREMENTS .................................................................. 44
A2.4 EQUIPMENT LABELLING ...................................................................................................... 46
RUMAILA PROJECT
1. INTRODUCTION
1.1 Scope
This specification defines the minimum requirements for the surface preparation of and protective coating
application to metallic surfaces both in shop and in the field.
This specification covers the painting of exterior surfaces of all above ground equipment, piping, structural steel
and internal linings for vessels and tanks. It defines the generic coating/lining systems to be used, the minimum
properties of the coating/lining materials and the minimum application requirements.
This specification does not cover below ground coating systems and galvanizing.
The document is provided to the SUPPLIERS for the specification and definition of the CONTRACTOR’S
minimum requirements. These requirements shall be imposed by the SUPPLIER on all SUB-SUPPLIERS.
1.2 Definitions
COMPANY shall mean B.P. Iraq NV
CONTRACTOR shall mean WorleyParsons which carries out all or part of the design and engineering of the
project.
SUPPLIER shall mean the party that manufactures or supplies equipment and services to perform the duties
specified by the COMPANY or CONTRACTOR.
SUB-SUPPLIER shall mean the party supplying goods, equipment or material specified by the SUPPLIER.
INSPECTION AUTHORITY shall mean the inspection bodies which work under the supervision of the
COMPANY or CONTRACTOR. In some cases the COMPANY may also act as the INSPECTION
AUTHORITY.
OWNER - Shall mean the B.P. Iraq NV Rumaila Project.
PLANT - Shall mean permanent facilities designed, constructed and completed as a result of execution of
the WORK under the Contract, located at the Rumaila Project Iraq.
PURCHASER – the party purchasing goods, equipment or material.
SITE - Shall mean the premises and places on, under, in, over or through which the WORK is to be executed
or carried out including CONTRACTOR’S engineering office and the Plant.
WORK - Shall mean all and any of the works and / or services and / or materials required to be provided by
the CONTRACTOR under the Contract with COMPANY.
The word shall indicates a requirement
RUMAILA PROJECT
1.3 Abbreviations -
ASTM American Society for Testing and Materials
CS Carbon Steel
DFT Dry Film Thickness
EN Euro Norm
FRP Fibre Reinforced Plastic
GRP Glass Reinforced Plastic
HP High Pressure
IOZ Inorganic Zinc
ISO International
ITP Inspection and Test Plan
LP Low Pressure
MIO Micaceous Iron Oxide
NPS Nominal Pipe Size
PFP Passive Fire Protection
ppm parts per millon
PVC Polyvinyl Chloride
SS Stainless Steel
SSPC Society for Protective Coatings
TEG Tri Ethylene Glycol
TSA Thermally Sprayed Aluminium
VOC Volatile Organic Compound
WFT Wet Film Thickness
RUMAILA PROJECT
2. REFERENCED DOCUMENTS
ASTM B117 Standard Practice for Operating Salt Spray (Fog) Apparatus
ASTM D4060 Standard Test Method for Abrasion Resistance of Organic

Coatings by the Taber Abraser
ASTM D4285 Standard Test Method for Indicating Oil Water in

Compressed Air
ASTM D4541 Pull-Off Strength of Coatings Using Portable Adhesion

Testers
ASTM D5162 Discontinuity (Holiday) Testing of Nonconductive Protective

Coating on Metallic Substrates
BS4800 Schedule of paint colours for building purposes
BS6920 Specification for Suitability of non-metallic products for use in

contact with water intended for human consumption with
regard to their effect on the quality of the water.
EN 12329 Corrosion Protection of Metals - Electrodeposited Coatings of

Zinc with Supplementary Treatment on Iron or Steel
RAL 840 Standard Colours
ISO 2409 Paints and Varnishes - Cross-cut test
ISO 2808 Paints and Varnishes - Determination of film thickness
ISO 4624 Paints and Varnishes - Pull-off test for adhesion
ISO 4628 - General Title Paints and Varnishes - Evaluation of degradation of paint
coatings - Designation of intensity, quantity and size of common
types of defect.
ISO 4628 - 2 Part 2 : Designation of degree of blistering
ISO 4628 - 3 Part 3 : Designation of degree of rusting
ISO 4628 - 4 Part 4: Designation of degree of cracking
ISO 4628 - 5 Part 5 : Designation of degree of flaking
ISO 4628 - 6 Part 6 : Rating of degree of chalking by tape method
RUMAILA PROJECT
ISO 8501-1 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 - General Title Preparation of steel substrates before application of paints and
related products-Tests for the assessment of surface
cleanliness
ISO 8502 - 1 Part 1: Field test for soluble iron corrosion products
ISO 8502 - 2 Part 2, Laboratory determination of chloride on cleaned surfaces
ISO 8502 - 3 Part 3, Assessment of dust on steel surfaces prepared for

painting (pressure-sensitive tape method)
ISO 8502 - 4 Part 4, Guidance on the estimation of the probability of

condensation prior to paint application
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 – General Title Preparation of steel substrates before application of paints and
related products — Surface preparation methods
ISO 8504 - 2 Part 2, Abrasive blast-cleaning
ISO 8504 - 3 Part 3, Hand and power tool cleaning
ISO 9001 Quality management Systems - Requirements
SSPC SP-1 Solvent Cleaning
SSPC PA-1 Shop, Field and Maintenance Painting
SSPC-Vis-1 Guide and Reference Photographs for Steel Surfaces

Prepared By Dry Abrasive Blast Cleaning
SP 0274 High-Voltage Electrical Inspection of Pipeline Coatings Prior

to Installation
The edition of the Reference Documents shall be the edition current at the effective date of the agreement.
SUPPLIER shall advise CONTRACTOR of any conflict between the referenced documents and any technical
specification. CONTRACTOR shall determine which shall govern. Resolution of any conflict shall be obtained
from the CONTRACTOR in writing before proceeding.
RUMAILA PROJECT
2.1 Group Defined Practices and Order of Precedence

The following listed Group Defined Practices will be utilized and are mandatory. WorleyParsons as a BP
Global Agreement Contractor has access to the BP ETP library website and familiar with their application:
• HSSE review of projects (GP 48-01)
• Hazard and Operability Study (GP 48-02)
• Layer of Protection Analysis (GP 48-03)
• Inherently safer design (GP 48-04)
• Major Accident Risk process (GP 48-50)
• Pipeline Integrity Management Systems (GP 43-49)
• Inspection and Testing of Equipment in Service (GP 32-30)
The precedence applying for use of the Codes, Standards, Specifications and Regulatory requirements for
this project is as follows:
• Statutory Iraqi Laws and Regulatory Requirements
• International Laws, Standards and Regulations (where they do not conflict with Item 1)
• BP corporate and project standards (ETP’s) (where they do not conflict with items 1 and 2)
• Recognised Contractor, Manufacturers and Technology codes and standards (where they do not
conflict with 1,2, and 3)
• Good Engineering practice.
In the event of an inconsistency, conflict or discrepancy between any of the Standards, Specifications and
Regulatory, the most stringent and safest requirement applicable to the project will prevail to the extent of the
inconsistency, conflict or discrepancy. Any inconsistencies critical to the design shall be brought to the
attention of the Engineering Manager for resolution.
RUMAILA PROJECT
3. MATERI ALS
3.1 Generic versus named products

Equipment and materials specified or referenced by a manufacturer’s name and/or brand name are intended
to describe the type and quality level of the equipment and materials desired and are not intended to be
restrictive or to exclude similar items by other manufacturers. Alternate equipment and materials of similar
quality or better may be submitted for CONTRACTOR approval.
The CONTRACTOR reserves the right to instruct the SUPPLIER to use approved materials from paint
manufacturers other than those listed in Appendix 1. Prequalification of other manufacturers' products is
subject to compliance with CONTRACTOR procedures and requirements.
Unless otherwise approved by the CONTRACTOR, products specified in this section and Appendix 1 shall
be used.
3.2 Abrasives
• SILICA SAND AND OTHER MEDIA PRODUCING SILICA DUST SHALL NOT BE USED.
• Abrasives for blast cleaning shall be clean, dry and free of any constituent part that could be
detrimental to long term coating performance, and shall be selected to provide the required surface
profile for the coating to be applied.
• Abrasive for use on carbon steel and low alloy steels shall be in accordance with ISO 8504-2.
Abrasives shall be grit manufactured from chilled iron, steel, and malleable iron or non-metallic
abrasives such as aluminium oxide, copper slag and garnet.
• Abrasives for use on stainless steel shall be glass beads, aluminium oxide or garnet and shall be free
from chlorides, zinc, and iron/steel contamination. Copper slag shall not be used on stainless steel.
• All blast media to be used shall be submitted to CONTRACTOR for approval prior to initiation of any
surface preparation work.
3.3 Compressed Air

Compressed air shall be clean, dry, oil free, and supplied at a temperature of less than 110 °C. Moisture and
oil traps shall be used in compressed air lines for blast cleaning, conventional, or airless spray equipment.
The Inspector shall check the cleanliness of the compressed air using a white absorbent cloth (the “blotter
test“) in accordance with ASTM D4285.
RUMAILA PROJECT
3.4 Paint Materials

Materials containing cadmium or lead or any toxic material to environment/personnel shall not be used.
Paints for use over stainless steels shall not contain zinc, chlorides or other halides and shall be approved by
the paint manufacturer for use on stainless steel.
Paint materials shall be as identified in Appendix 1.
Paints shall be factory sealed in metal containers and factory labelled. Thinners and solvents shall be as
identified in the manufacturer’s data sheets. All containers shall remain closed in factory sealed containers
until required for use. Each container shall have the manufacturer’s name, the product name/identification,
the batch number, the date of manufacture, the shelf life or expiry date, identify the appropriate health &
safety data sheets, material data sheets and a contact telephone number for technical service.
Storing, thinning, mixing and handling, of paint materials shall be in accordance with the manufacturer’s
recommendations. Only thinning materials approved by the paint manufacturer shall be used.
All paint materials shall be used on a first-in, first-out basis.
Primer colours shall be manufacturer’s standard colours. Finish colours, except for silicone aluminium, shall
be as noted in the colour schedule in Appendix 2. Heat stable colours shall be used for services above
93°C.
The VOC level of the coating materials shall not exceed 420 grams/litre or the limit set by local agencies
whichever is lower.
SUPPLIER shall be completely responsible for determining the compatibility of coating materials being
applied to the same item that are the products of different manufacturers.
RUMAILA PROJECT
4. GENERAL REQUIREMENTS
4.1 Extent of Painting

Structural steel, equipment (e.g. vessels, heat exchangers and tanks) and above ground piping and pipelines
shall be externally painted in accordance with the systems summarised in Appendix 1 inclusive of this
Specification. The tables provide a summary of the items to be painted, the standards of surface preparation
to be employed, the type of primer and finish paints, the number of coats required and the final coat colour
for ambient, high temperature and low temperature service.
Requirements for painting of pipework to suit temperature conditions involved shall include the entire
pipework system comprising pipe, fittings, flanges, strainers, traps etc., together with valves where the valve
manufacturers' standard coating system does not offer sufficient protection for the environmental conditions
involved.
Ladders, stair treads, cages and platform gratings shall be galvanized and shall not be over painted.
Hand-railing (posts, mid-bars and top rail) shall be painted. The tubular top rail shall be over painted in
accordance with this specification. (This may apply to other steel items requiring application of high visibility
coating.)
All uninsulated portions of insulated equipment comprising vessel nozzles, manway covers, valves, relief
valves, etc. shall be painted to suit temperature conditions involved.
All equipment supports, including vessel skirts, legs, saddles, etc. shall be coated with the paint system
specified in Table 1 for the temperature range up to 120°C.
The paint system shall be based on the maximum operating temperature of the equipment and pipework.
Where the paint system is applied for low temperature service, the effect of lowest temperature shall also be
considered.
Process equipment shall be prepared and painted only after completion of all heat treatment, pressure
testing and non-destructive examinations.
4.2 Surfaces Not Be Painted

The following items do not require surface preparation or painting. When additional protection is considered
necessary for the surfaces listed below the CONTRACTOR Coating Specialist shall be consulted for the
specific details of the system to be applied:
• Brickwork, concrete structures and foundations, fireproofing, building floors, the underside of site
erected tank bottoms and pavement not subject to attack from corrosive substances.
• Brass, copper, slate, glass, tile, uninsulated stainless steels and similar weather resisting
materials.
• Aluminium or galvanised metal including insulation weatherproofing.
• Screwed items of valves, or gasket contact surfaces.
RUMAILA PROJECT
• Finished machined parts of machinery.
• Any equipment furnished completely primed and finish painted by the manufacturer (e.g.
Instruments, Instrument boards, Motors) unless specifically required to repair paint damage or to
match a colour scheme.
• Metallic, aluminium pigmented or light coloured insulation coating (fabric reinforcement and
mastic).
• Stainless steels when protected by guards or not covered with insulation. Aluminium fins of air
coolers
• Insulation jacketing
• Interior surfaces of equipment (except where indicated otherwise)
• Operating parts of machinery and equipment, e.g. valve stems and shafts
• Polished and machined surfaces, e.g. flange facings
• Stainless steel piping (all types) with a nominal diameter less than 26 mm
• Stainless steel surfaces directly exposed to the atmosphere (i.e. stainless steel surfaces without
thermal or acoustic insulation.
4.3 Fasteners
Shop applied coatings for fasteners (bolts, studs and nuts) shall be spun galvanized – i.e. hot dip galvanized
and centrifuged. Hot dip galvanizing shall be in accordance with the requirements of the specification for
galvanizing and centrifuged to remove all excess zinc from threads, the minimum coating thickness shall be
43 microns.
Fasteners that are not supplied shop coated shall be coated as per Appendix 1 as part of the site painting
activities.
Shop coated fasteners shall generally be utilized for the following:
• All external, shop and field assembled, flanged connections, including insulated flange bolting at or
below a service temperature of 200 ºC.
• Galvanized bolts shall not be used on austenitic SS piping/flanges (e.g. type 304L and 316L grades).
• Equipment bolting that requires removal for scheduled maintenance and inspection.
Shop coated fasteners shall not generally be utilized for the following:
• Structural bolting
• Fasteners forming part of standard equipment supplied by a SUPPLIER, miscellaneous valve

assemblies and the instrumentation. The CONTRACTOR shall review the supplied coating for
suitability on a case by case basis.
• High alloy fasteners (e.g. stainless steels, Duplex)
RUMAILA PROJECT
• Insulated flange bolting above a service temperature of 200 ºC
4.4 Protection of Stainless Steel Surfaces

Stainless steel shall be cleaned in accordance with Section 6.6 before application of any coating materials
and shall be painted in accordance with Appendix 1.
Stainless steel shall be protected from contact with galvanized or zinc coated surfaces, including zinc
coatings on flanges, support legs, pipe hangers, or clamps. Zinc primers are prohibited for stainless steel
surfaces and precautions shall be taken to prevent contact especially from accidental overspray during
nearby painting activities. This shall apply to all types of stainless steels; nickel alloys and also 9% nickel
steel components.
4.5 Safety Requirements

All necessary precautions shall be taken to ensure the safety of personnel and property. The SUPPLIER
shall comply with applicable national, state or local codes and regulations and the safety orders and
practices of the CONTRACTOR/COMPANY. This shall encompass working conditions, scaffolding, clothing,
fire and explosion hazards, safety equipment, solvents, lighting, venting and grounding of vessels.
Rags and other waste material soiled with paints, thinners or solvents shall be kept in tightly closed metal
containers while on the job or not in use.
Extreme precautions shall be used when working with paint materials, cleaning fluids, etc. especially in close
proximity to oxygen piping or oxygen equipment. Heavy concentrations of volatile or toxic fumes shall be
avoided. When working in confined areas, blowers or exhaust fans shall be used.
Abrasive blast-cleaning equipment shall be of an intrinsically safe construction and equipped with a remote
shutoff 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
served through a regulator filter, to prevent blast cleaning residues from being inhaled.
RUMAILA PROJECT
5. SURFACE PREP ARATION
5.1 Items to be Protected

Before abrasive blast cleaning, all items and equipment that could be damaged by abrasive blasting, dust or
particulate matter shall be suitably protected by wrapping, taping or other means to prevent damage.
Typically, equipment to be protected shall include, but not necessarily be limited to, the following:
• Bearings & shafts;
• Control valves;
• Couplings;
• Fire system sprinkler heads;
• Instrument dials & level gauge glasses;
• Machined surfaces;
• Screws;
• Spring hanger graduations;
• Valve stems and position indicators;
• Control panels & push buttons;
• Conduit;
• Expansion joint bellows;
• Flange facings (pipe);
• Nameplates/Code stampings;
• Tags;
• Exposed moving parts.
5.2 Basic Cleaning

The following cleaning procedure is mandatory for all surfaces prior to blast cleaning and for all shop coated
items prior to field applied coating activities.
Dust, dirt and debris shall be removed from the substrate surfaces by high pressure fresh water washing.
Stubborn deposits shall be removed by scrubbing with stiff plastic brushes. The water wash shall continue
until all water soluble salts are removed from the surfaces.
Surface contaminants such as oil, grease, hydrocarbons etc. shall be removed using water based
biodegradable cleaner in accordance with the manufacturer’s instructions and recommendations for the
cleaner.
RUMAILA PROJECT
The degreased surfaces shall be further washed with fresh water to remove all traces of the cleaner
chemicals and thoroughly dried before proceeding with any further coating work.
Bolt holes shall be solvent-cleaned prior to blast cleaning.
5.3 Weld Preparation

Welded areas shall be smoothed as required by an abrasive grinding wheel to remove sharp or rough areas.
Weld reinforcement removal is not required, as long as the reinforcement has rounded edges. Sharp edges,
fillets, corners, and weld seams shall be radiused to a minimum of 3 mm. All bolt holes shall be drilled and
ground prior to blast cleaning.
Preparation of welds shall use hand tools, powered tools and abrasive blasting as necessary to remove
burrs, weld spatter, weld flux, slivers, indentations, protrusions and other foreign matter. When grinding the
weld and base metals shall not be ground below the surface.
If stainless steel items need to be smoothed as required by an abrasive grinding wheel, then they shall be
done using a grinding wheel approved for the grinding of stainless steel. Under no circumstances shall
grinding wheels or tools used on carbon steel surfaces be used on stainless steel surfaces. Tools shall
always be kept segregated.
If grinding is to be carried out after blast cleaning, the ground surface shall be re-blasted to restore the
specified surface profile.
Supports for items to be blast cleaned shall have a configuration such that the contact points are as small as
possible to limit surface area covered.
5.4 Abrasive Blasting of Carbon Steel

Carbon steel surfaces shall be prepared by abrasive blasting as specified for the paint system. Blasting shall
only be performed when all the conditions as per Section 6.2 are met.
Surface profile or surface roughness (also called “anchor pattern”) shall comply with the requirements of the
paint system to be applied and the approved application procedure. All blasted surfaces shall be visually
inspected to confirm the surface profile has been achieved using the methods and equipment as noted in
Section 10. The results shall be recorded.
After blast cleaning, the surface shall be inspected for metal protrusions, slivers or other metal imperfections;
these shall be ground out and if bigger than 50 mm x 50 mm shall be re-blasted to restore the profile.
Surfaces shall be clean, free of dust and abrasive particles by brushing, blowing with clean compressed air
or vacuum cleaning. Care shall be taken to keep cleaned surfaces free of contamination from dirt, dust,
grease, weld slag, and any other foreign material. Surface preparation shall be subject to inspection before
the prime coat is applied to ensure all traces of dust and foreign matter have been removed.
Blast cleaned surfaces shall be primed within 4 hours of completion of surface preparation and before
occurrence of visible rusting.
RUMAILA PROJECT
5.5 Cleaning of Galvanized and Inorganic Zinc Surfaces

Hot-dip galvanized steel surfaces shall be prepared before application of any coating in accordance with the
application procedure.
Galvanized or zinc primed surfaces shall be free of all zinc salts, oil and grease before application of any
surface treatment or coating. Zinc salts, oil and grease shall be removed by fresh water washing and/or
suitable solvent. Then, surfaces shall be lightly blast cleaned with garnet or aluminium oxide abrasive to
ensure proper adhesion of subsequently applied coating. Copper slag shall not be used. Any other surface
treatment shall require CONTRACTOR approval.
5.6 Cleaning and Blasting of Stainless Steel Surfaces

Surface cleaning shall be by high pressure steam cleaning with an appropriate alkaline detergent or
thorough solvent cleaning with an approved solvent. Solvents/detergents etc. used for cleaning stainless
steel surfaces shall contain less than 50 ppm of water-soluble chlorides. The surface cleaning procedure
must be in accordance with the paint manufacturer’s recommendations and shall be subject to approval from
the CONTRACTOR.
Stainless steel surfaces shall be abrasive-blasted to an equivalent of ISO 8501-1 grade Sa2½ using a good
quality stainless steel or silica-safe non-metallic abrasive low in chlorides and heavy metal elements, such as
aluminium oxide or a proprietary abrasive based on inert aluminium silicate. Blast cleaning shall achieve a
25-40 micron profile. Surface profile shall be checked by the SUPPLIER. Where abrasive-blasting cannot
be used, the surfaces may be prepared using power-driven flexible disc sanders fitted with coarse grade
abrasive paper, e.g. P60 at CONTRACTOR discretion. Wire brushing shall only be used at weld areas and
shall use brushes with stainless steel bristles
For shop applied coatings light abrasive blasting is mandatory, the use of steam or solvent cleaning only is
not acceptable.
For site applied coatings where restrictive conditions make the abrasive blasting of stainless steel
impractical, light abrasive blasting is not mandatory. The proposed cleaning procedure shall meet the paint
manufacturer’s recommendations.
RUMAILA PROJECT
6. APPLICATION PROCEDURES
6.1 Preparation for Painting

Before painting activities commence, the SUPPLIER shall submit an application procedure for each paint
system for review by the CONTRACTOR. The application procedure shall provide:
• The identity of the paint system to be applied;
• The paint manufacturer’s data sheets for all paint materials to be used including safety data
sheets;
• The coating thicknesses to be applied;
• Individual coat thicknesses and system total DFT;
• Surface preparation method along with chloride and dust acceptance criteria
• Description of application method and equipment
Weld inspection and hydrostatic testing shall be completed prior to painting.
Ends of pipe and related components, tank plate, structural steel, and like areas of other items that will
require subsequent welding at site, shall be masked off after blast cleaning and left uncoated for a distance
of 50 mm from all areas requiring welding. The masking material shall be removed as soon as possible after
priming or painting. The SUPPLIER shall ensure that all masking material is thoroughly removed from the
equipment and any damage to the primed/painted surface is repaired prior to shipment.
Mixing of the paint shall be in accordance with the manufacturer’s requirements. All mixing shall be done
using power mixers. Mixing units of paint systems shall be as per the manufacturers’ instructions using only
complete units of measure. Mixing of approximate proportions is not permitted.
Mixing of different brands or generic types of coating materials is not allowed.
The paint manufacturer’s pot-life requirements shall be followed.
6.2 Environmental Conditions

Abrasive blasting and paint application shall only be performed when all of the following conditions are met:
• The ambient temperature is greater than 4°C;
• The relative humidity is less than 85 %;
• The surface temperature is more than 3°C above the dew point;
• The metal surface temperature does not exceed that recommended by the paint manufacturer
for application;
• Adverse weather conditions are not expected within two hours of completing the coating
application e.g. sand storms & blowing sand, fog or rain etc.
• The surface to be coated is free of all moisture e.g. rain, condensation or dampness;
RUMAILA PROJECT
• The available light level is greater than 500 lux.
• Exception to these conditions will be considered on a case by case basis only and subject to
agreement by the paint manufacturer.
6.3 Paint Application
6.3.1 General
Paint systems shall be selected from the Painting Schedule for External Surfaces (Table 1) and Paint
Systems (Table 2) all found in Appendix 1. Flanges, nozzles, clips, access ways, saddles and other
attachments which protrude through insulation shall be considered un-insulated and shall be painted
accordingly.
Primer application of the prepared surface shall begin as soon as possible after blast cleaning is complete
and before visible rusting; in all cases the period between blasting and coating application shall not exceed 4
hours.
Paints shall be applied by airless spray or a spray method as recommended by the paint manufacturer.
Brush and or roller application shall be restricted to those conditions given in Sections 7.3.3 & 7.3.4
respectively. The grade of paint shall match the application method.
All dry thicknesses as specified shall be strictly adhered to within a tolerance of -0/+20% unless otherwise
agreed by the CONTRACTOR. The dry film thickness of each coat shall be checked with calibrated film
thickness gauges, using the magnetic resistance or eddy currents principle, such as Elcometer, Micro-test,
Tinsley, etc. The equipment shall be calibrated at least twice daily in accordance with the equipment
manufacturers' recommendations. In order to achieve the specified dry film thickness, frequent checks of
wet film thickness shall be carried out during the paint application with film thickness gauges such as the
Elcometer wheel or comb type.
Paint shall be applied to dry, clean, prepared surfaces under acceptable environmental conditions (Section
7.2) and in accordance with the manufacturer’s data and application sheets.
All coatings shall be uniformly applied without runs, sags, 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, to apply the specified minimum
dry film thickness by brush application. This is known as stripe coating and shall be applied for primer,
intermediate and finish coats.
Continuous agitation type spray pots shall be used when applying metal pigmented coatings such as zinc or
aluminium loaded coatings.
A mist coat or tie coat of organic primer shall be applied over inorganic zinc primer to seal the coating prior to
application of the intermediate coat. This shall be done when the inorganic zinc primer has reached a
satisfactory level of cure. The CONTRACTOR shall exercise necessary care to ensure a smooth and
uniform coating is applied over inorganic zinc primer.
RUMAILA PROJECT
Surfaces that will be inaccessible after assembly, including the surfaces of lap joint flanges, nozzle necks,
lap joint stub ends, lap rings, bolt holes and some welded joints, shall receive the complete painting system
before being assembled. Contact surfaces of bolted connections are to be primed only.
Contamination between coats shall be minimized by maintaining proper cleanliness and by applying
intermediate and finish coats within the time period recommended by the manufacturer.
Adhesion qualification test plates shall be prepared at the same time and under the same conditions as the
production coating work.
6.3.2 Spray Application

Hose and containers shall be thoroughly cleaned at the completion of each coating activity and at any
change of materials.
The spray gun shall be held at right angles to the substrate and no closer than 200 mm or more than 600
mm from the surface to be coated. Each pass shall overlap the previous one by 50 %. For large surface
areas the direction of spray application between coats shall be at right angles to each other.
Pressures and spray fan shall be adjusted so that the optimum spray pattern is utilized for the surface being
coated.
6.3.3 Brush Application

Application with brush is acceptable under the following conditions:
• Where access for spray equipment is severely restricted or hazardous
• When the work geometry/shape prevents proper/uniform spray application
• For localized touch-up and minor repair of localized damaged paint
• When the paint system is not suitable for spray application
• When applying the stripe coat of paint to corners, edges, crevices, holes, welds or other irregular
surfaces prior to spray application.
Paint brushes used shall be of a type and quality that will permit appropriate application of the material being
applied.
Material applied by brush shall be smooth, uniform in thickness, without any surface defects such as brush
marks, runs or sags.
6.3.4 Roller Application

Roller application shall be used on a case by case basis and only with written approval from the
CONTRACTOR.
Roller application may be used only when:
• Spraying is not an option.
• Primer coat is applied by brush.

RUMAILA PROJECT
7. REP AIRS
7.1 General Requirements

The SUPPLIER shall submit a repair procedure for each coating system. Adhesion qualification tests shall
be mandatory and shall be performed to determine the compatibility for each repair method.
Before application of any further coat of material, all damage to previous coats shall be repaired.
Surface preparation shall wherever possible be carried out by dry blast cleaning. If dry blast cleaning is not
required or not feasible (e.g. due to limited access, risks of damage to equipment, the proximity of electrical
components or instrumentation) then manual cleaning shall be performed.
Manual cleaning shall be performed using hand wire brushes, or power operated tools (e.g. grinders,
chippers or wire brush) in accordance with ISO 8504-3 to provide a roughly abraded surface. A burnished
surface is not acceptable.
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 25 mm. 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 they meet this Specification. These additional coats shall blend in
with the final coating on adjoining areas. Colour match shall be achieved.
7.2 Coating Damage Not Exposing Substrate Surface

Surfaces to be over coated shall be cleaned by solvent cleaning and/or lightly brush blasted ensuring that
the surface is free of all contaminants prior to applying the following coats. After cleaning, any residual
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, using an approved method, to ensure continuity
of the patch coating. The required number of paint coats shall be applied in accordance with this
specification to re-establish the full coating system.
7.3 Coating Damage Exposing Substrate Surface

Damaged paint and loose coating shall be removed back to metal substrate. The damaged area shall be
cleaned, prepared and the full coating system reapplied in accordance with this specification. The repair
area shall overlap onto the tightly adhering surrounding coating for a minimum of 25 mm; the edges shall be
chamfered by a method approved by the CONTRACTOR.
RUMAILA PROJECT
7.4 Repair of Zinc Silicate Primer

Where repairs are required to inorganic zinc silicate primer, either with or without topcoats, the following
procedure shall be followed:
a) Abrasive blasting of the surface to the specified standard of cleanliness and profile.
b) Light abrasive blasting of the surrounding zinc silicate primer extending a minimum distance of 25 mm,
to ensure removal of all zinc corrosion products.
c) Apply the repair primer to the steel surface and surrounding zinc silicate primer.
d) Apply topcoats to achieve the required system thickness.
The repair primer shall be a zinc-rich, polyamide epoxy primer subject to it being suitable for the intended
service temperature. In the event that the service temperature prevents the use of a zinc-rich polyamide
epoxy primer the SUPPLIER shall submit a detailed repair procedure, along with paint data sheets, for
CONTRACTOR review. The paint manufacturer should confirm the compatibility of the proposed silicate
primer and surface preparation requirements.
Surface preparation by any other method than abrasive blast cleaning shall be permitted only with the written
approval of the CONTRACTOR.
Under no circumstance shall zinc silicate primer be allowed to overlap adjacent intermediate and finish
coats, or be applied over visible zinc corrosion products.
7.5 Repair of Full y Cured Epox y Coating

All fully cured epoxy coatings shall be lightly abraded by sweep blasting to provide a suitable surface profile
prior to over coating of the damaged substrate. The timescale to attain the fully cured condition shall be as
indicated on the paint data sheets.
RUMAILA PROJECT
8. EXECUTION
8.1 Shop Versus Field Painting Polic y

Shop application of the complete coating system is preferred. If this is not possible then the primer and at
least one intermediate coat shall be applied in the shop before transport to the site. Completion of the paint
system at site shall be completed after erection and shall include minor repairs/ touch-up, additional
intermediate coats as necessary and the final topcoat application.
The SUPPLIER shall submit a Work Plan/Method Statement delineating painting work execution between
shop and field painting and obtain CONTRACTOR approval.
8.2 Responsibilities of the VENDOR

As a minimum the VENDOR at their facility shall perform surface preparation, priming and application of at
least one intermediate coat to the equipment and attachments. The paint system, surface preparation and
coating application shall comply with this Specification.
Standard paint systems offered by the SUPPLIER for standard items such as control and electrical
equipment, pumps, motors, compressors, etc must be capable of a minimum corrosion resistance of 2000
hours when tested in accordance with ASTM B117.
The SUPPLIER shall submit the paint specification/application procedures for review by the
CONTRACTOR/COMPANY REPRESENTATIVE. All SUPPLIER specification/procedures shall comply with
the requirements of this Specification and shall not be considered in lieu of or substitution for the procedures
and requirements stated in this Specification.
8.3 Responsibilities of the Paint Manufacturer

The paint manufacturer’s technical representative shall submit a periodic report to the CONTRACTOR
summarising whether painting is being carried out in accordance with their recommendations and quality of
workmanship is acceptable to them. This report shall also cover analysis of technical problems where
observed.
The manufacturer shall copy all technical correspondence with the SUPPLIER to the CONTRACTOR.
8.4 Site Painting

The SUPPLIER shall be responsible for all requirements to carry out painting at a field paint shop and site
painting in accordance with this specification. This shall include the following activities:
• Supply and application of all paint materials, labour, supervision, coating equipment, inspection tools
and each and every item of expense necessary for complete application of the paint system.
• Supply, erection and removal of scaffolding to perform the painting work. Scaffolding shall be
inspected by a qualified safety inspector and certified safe before being released for use.
RUMAILA PROJECT
• Application of the paint systems to the extent stated in the procurement documents and in accordance
with this specification and all other relevant documents such as site regulations, safety rules,
referenced standards and codes, etc.
• Removal of identification marks on bare or unfinished equipment, piping and structural steel and re-
application of the identification marks on the finished surfaces.
• Protection from abrasives and paint overspray of all items and surfaces not being painted.
• Cleaning and application of painting systems on welded and damaged surfaces.
• Collection and disposal of all toxic waste materials from the work site.
• Appropriate arrangements for technical services of the paint manufacturer before and during planning
and application of the paint systems. The SUPPLIER’S purchase order for paint materials shall include
a provision stating that the manufacturer’s technical representative shall directly report to the
CONTRACTOR regarding the acceptability and workmanship of the paint application.
• Obtaining latest paint data sheets and application procedures and maintaining the same for use by all
the parties.
• Providing qualified painting inspectors and testing instruments and tools for carrying out specified
inspection and quality control measures.
• Maintenance of the paint work until completion of the contract. This shall include the repair of damage
caused by third parties. Refer to Section 13.
RUMAILA PROJECT
9. INSPECTION AND TESTING
9.1 General
Before painting activities commence the SUPPLIER shall submit an Inspection & Test Plan (ITP) for review
by the CONTRACTOR. The ITP shall incorporate all inspection requirements, hold points and the required
inspection frequency and number of readings. For production work the checks shall include paint material
inspection, blast material inspection, environmental conditions, surface condition and cleanliness, the
surface profile, the coating thickness, a visual assessment and repairs and corrective actions taken.
Adhesion and cure tests may be carried out on test plates prepared and coated at the same time - and to the
same standard - as the work.
The SUPPLIER shall employ a qualified painting inspector whose resume shall be approved by the
CONTRACTOR.
The CONTRACTOR shall have the right to inspect coating activities at all stages and to reject any tools,
materials, equipment or work which do not conform to this Specification.
All items coated by the SUB-SUPPLIER shall be inspected on arrival and damaged areas shall be repaired
by the SUPPLIER. If repairs amount to more than 5 % of the surface areas, or the finish coat appearance is
not acceptable, then the CONTRACTOR may instruct the SUPPLIER to apply an additional finish coat to
improve appearance at no cost to CONTRACTOR/COMPANY.
9.2 Inspection Instruments

The following instruments shall be supplied, calibrated and maintained by the SUPPLIER and available for
use by the CONTRACTOR/COMPANY.
Activity Instrument
• Surface Profile Keane-Tator Surface Profile Comparator or

Testex Press-O-Film
• Surface Cleanliness SSPC-Vis-1
• Wet Film Thickness Nordson Wet Film Thickness Gage

• Dry Film Thickness Mikrotest Dry Film Thickness Gage* (with SSPC-PA-2 as a
guide)
• Temperature and Humidity Gardner Certified Hygrometer and Temperature Indicator

• Surface Temperature PTC E0092.00 (-20°C to 120°C)
• Adhesion Elcometer 106
• Salt Contamination Salt Meter SCM 400
Test instruments shall be calibrated on a routine basis determined on the frequency of use and maintained in
good working condition at all times.
RUMAILA PROJECT
9.3 Before Surface Preparation

Prior to blast cleaning, the SUPPLIER shall check that all environmental and safety requirements relating to
blast cleaning have been met.
9.4 Before And During Paint Application

Prior to painting, all surfaces shall be visually inspected to assure that the proper surface conditions
necessary for painting exist. The SUPPLIER shall carry out the following activities and record the results in
an approved tabular format:
a) Verify the required blast surface cleanliness and surface profile has been achieved. Surface profile
assessment shall be carried out in accordance with ISO 8503 2.
b) Verify the surfaces are free of contamination. Tests to indicate the presence of chlorides and dust
shall be carried out in accordance with ISO 8502-1, ISO-8502 and ISO 8502-3. The acceptance
criteria for chlorides and dust shall be detailed in the application procedure.
c) Verify that surfaces not to be coated are masked off, or otherwise protected.
d) Check the air temperature, relative humidity, and substrate surface temperature.
e) Record the actual paint materials to be applied and they match the specified coating system. Verify
that storage, mixing, thinning, and application of primer, intermediate, and finish coats are in
accordance with the Application Procedure.
f) Immediately before paint application, re-inspect the surface to confirm freedom from moisture and
other contaminants are present.
g) Take wet film thickness (WFT) measurements during paint application to ensure that the film thickness
is being achieved.
h) Take dry film thickness (DFT) measurements at each stage of the system application to ensure that
the film thickness is being achieved.
9.5 After Painting

The SUPPLIER shall measure and record the dry film thickness of each coat (i.e. the primer, intermediate,
and finish coats) of the system. The measurement method and frequency shall be detailed in the Application
Procedure and comply with one of the magnetic methods (Methods 7A/7B/7C/7D) in ISO 2808.
Visual inspection shall be carried out at each stage of the coating system. If loss of adhesion is found or
suspected then an adhesion test shall be made. The adhesion of the primer to the steel substrate and the
inter-coat adhesion of the subsequent coat(s) after curing shall be determined by the application of either a
cross-cut test in accordance with ISO 2409 or a pull-off test described in ISO 4624. Coatings applied to blast
2
cleaned carbon steel exhibiting an adhesion of less than 15 kg/cm shall be rejected.
Each painting system and repair method shall be tested on a test plate for an adhesion qualification test.
The test plate shall be coated at the same time and to the same standard as the production work.
Repairs made in the field shall be documented and inspected in accordance with this Specification.
RUMAILA PROJECT
10. INSPECTION RECORDS AND REPORTS

Prior to final acceptance of the paint work, an inspection shall be made. The SUPPLIER and the
CONTRACTOR/COMPANY, shall both be represented and they shall sign an inspection report agreed upon
by all parties. The report shall consist, as a minimum, of the following:
a) Names of the SUPPLIER applicator and the responsible personnel
b) Dates when work was carried out
c) Equipment and techniques used
d) Materials receipt condition
e) Type and calibration of inspection instruments used
f) Weather / environmental conditions
g) Painting periods
h) Condition of the surface before preparation
i) Tools and methods used for surface preparation
j) Condition of the surface after preparation
k) Information on the paint system applied
l) Mixing and testing prior to application
m) Paint application techniques
n) Agreed remedial actions
Remedial actions, if any, shall be determined based on the results of the inspection.
RUMAILA PROJECT
11. SHIPMENT AND PACKING
11.1 Handling of Coated Items

Preparation for shipment and packing will be subject to inspection and acceptance by the
CONTRACTOR/COMPANY inspectors. All costs related to rejection shall be to the account of the
SUPPLIER.
Facilities and methods of yard storage and protection of the pipe during transportation shall be subject to
approval by the CONTRACTOR.
Preparation of coated items for shipment shall be in accordance with CONTRACTOR standards and this
Specification. Procedures shall be established to prevent mechanical damage to the applied coating system
and corrosion during transit and at the jobsite. The procedures shall cover the following activities:
• Pipe end caps - Pipe ends shall be capped at all times after final coating.
The procedure shall include checking for damaged or loose fitting
caps and replacement as required.
• Handling - To prevent rolling and impact damage of coated items
• Packing & padding - To ensure sufficient support and padding to prevent movement
• Lifting - To ensure correct usage of lifting apparatus and slings that will not
damage the coating e.g. rubber straps, canvas belts.
Ropes, hooks, chains and cables shall be prohibited.
Coated items shall be treated with a solvent-based, rust preventative fluid to provide medium- to long-term
protection during storage and handling at the job site prior to use. The SUPPLIER shall submit data sheets
of the rust preventative fluid for CONTRACTOR approval.
Coated items shall be stored off the ground on padded skids that are suitably levelled and spaced to support
the coated item. Coated items shall be separated or protected from adjacent items.
Pipe end caps shall be checked and maintained up to point of welding.
Gasket contact surfaces and machined surfaces shall be protected with CONTRACTOR approved rust
preventative fluid to provide medium to long-term protection during transportation and storage.
11.2 Coating Materials

Paint materials, solvents and cleaners, abrasives and associated materials shall be protected to withstand
ocean transit and an extended period of storage at the jobsite. All materials shall be protected to safeguard
against all adverse environments, such as: heat, humidity, moisture, rain, dust, dirt, sand, mud, salt air, salt
spray, and sea water.
Storage conditions shall comply with the recommendations of the manufacturer.
RUMAILA PROJECT
12. GUARANTEE
The SUPPLIER shall guarantee the performance of the paint system – both shop and field applied - for a
period of 5 years from the date of final acceptance by the CONTRACTOR/COMPANY.
This guarantee applies to painting of carbon steel, galvanized steel, stainless steel and all items painted in
accordance with the SUPPLIER/SUB-SUPPLIER and CONTRACTOR procedures.
The SUPPLIER shall be liable for remedial actions such as spot repair and the over coating and
refurbishment of extended areas with paint failures/defects at site when:
• The estimated amounts of rust breakthrough on a coating and of total apparent rust (rust breakthrough
plus under film) rust exceeds ISO 4628-3 rust scale Ri 1(0.05% area rusted).
• Defects in the paint film such as blistering, peeling, flaking, inter-coat delamination, mud cracking, etc.
affecting the overall integrity of the coating.
The repair procedure shall be subject to approval by the CONTRACTOR. All defective spots shall be
repaired. If the area requiring repair is greater than 20% of the total surface of an individual item then the
entire item shall be refurbished.
The degree of blistering shall be evaluated in accordance with ISO 4628-2. The degree of cracking and
flaking in a coating shall be evaluated in accordance with ISO 4628-4, ISO 4628-5 and ISO 4628-6,
respectively.
The SUPPLIER shall undertake to carry out remedial painting at any time within the guarantee period as
directed and agreed by the CONTRACTOR/COMPANY, at the expense of the SUPPLIER. “Remedial
painting” shall include all site activities necessary for the removal of defective coating where necessary,
surface preparation, paint material supply and the application of paint in conformity with this Specification.
RUMAILA PROJECT
APPENDIX 1: - Paint System Schedule

Table 1 : Paint System Schedule for External Surfaces
Items to be Coated Operating temp, ºC Paint System Number
From To Non-Insulated Insulated

Surfaces Surfaces
Carbon steels and low alloy steels (Note 1)
General : -45 120 2 3

Equipment, piping, piping supports, 121 350 1 1
tanks and structural steel with the 351 550 4 NA
exception of items specifically listed
below (Note 1)
Structural steel to be fireproofed. Ambient 120 NA 5
External surfaces of buried tanks Ambient 120 6 NA

and piping. Tank floor plate
surfaces in contact with soil. (Note 2)
Temporary protection of external Ambient 7 NA
surfaces during pre-fabrication.
Galvanized surfaces
Structural steel, handrails, cable Ambient 120 8 NA

trays etc. that are galvanized but not
fire-proofed. (Note 3)
Stainless Steels
All items exposed to cryogenic -40 51 NR 9

conditions
All items exposed to atmosphere 51 300 4 4
Alternative to above 51 120 10 10
Copper and copper alloys
All items exposed to plant outside Ambient 120 8 NA

environment
Glass or Fibre Reinforced Plastic
Piping Equipment (Note 5) Ambient 90 11 NA
RUMAILA PROJECT
Notes – Table 1:
1. For painting requirements, low alloy steels shall include all Cr-Mo steels containing up to 9% Cr.
2. With regard to coating of the soil side: the tank floor plates shall be masked off 100 mm from the edge
to prevent coating application. The coating shall be holiday tested and coating repairs completed prior
to plate welding.
3. Galvanized gratings, stair treads, cages, ladders, etc shall not be painted unless otherwise specified.
4. Paint systems with IOZ or other zinc rich primers shall not be used for austenitic stainless steel piping
and pressurized equipment
5. GRP/FRP equipment exposed above ground shall be coated in accordance with the
manufacturer/supplier recommendations. For GRP/FRP piping only identification banding - as per
Appendix 2 - shall be necessary.
6. For all electrical equipment items manufacturers standard coating system and finish colour is
acceptable.
RUMAILA PROJECT
Table 2 : Paint Systems

Paint Substrate Surface Primer Intermediate Finish DFT Max
System Metal Preparation Coat Coat Coat (microns) temp
( ºC )
1 CS Sa 3 Inorganic zinc silicate − Modified aluminium silicone 80 350
(60 µ) (20 µ)
2 CS Sa2½ Zinc Rich Epoxy (75 µ) Hi-build MIO epoxy Acrylic modified polyurethane 320 120
(2 x100 µ) (60 µ)
3 CS Sa2½ Epoxy phenolic Hi-build MIO epoxy 300 120
(100 µ) (2 x100 µ)
4 CS Sa 3 Aluminium metal spray Modified aluminium silicone 170 550

(TSA) (20 µ)
(100 µ)
5 CS Sa2½ Zinc rich epoxy Red oxide epoxy tie coat 100 NA
(75 µ) (25 µ)
6 CS Sa3 Coal tar epoxy Coal tar epoxy 400 100

(200 µ) (200 µ)
7 CS Sa2 Red oxide epoxy shop 30 100

primer
OR Zinc phosphate shop
primer
(30µ)
RUMAILA PROJECT
8 Galvanised See Section 6.5 Epoxy primer Polyamide MIO epoxy Aliphatic polyurethane 155 120
Copper (40 µ) (40 µ) (75 µ)
9 SS Sa2½ Polyamide epoxy Polyamide epoxy 300 Ambient

See Section 6.6 (150 µ) (150 µ)
10 SS Sa2½ 2 pack polyurethane primer - Hi-build MIO epoxy Acrylic modified polyurethane 310 120
See Section 6.6 (50 µ) (2 x100 µ) (60 µ)
11 GRP/FRP Note 5 Aliphatic polyurethane − Aliphatic polyurethane 150 90

(75 µ) (75 µ)
Notes
a) Thickness of inorganic zinc silicate primer shall not exceed 60 microns. DFT values greater than 60 microns shall be subject to removal by blasting and re-
application of primer. The requirements of the surface preparation shall be subject to approval by CONTRACTOR.
b) Precautions shall be taken against over-thickness application of aluminium silicone resin based coats. Adhesion tests are mandatory. High temperature finish
coating must be capable of "cold curing" to handle ambient temperature.
c) Inorganic zinc silicate paints may be water based or solvent based and shall have metallic zinc of at least 85% (by weight) in the dried film.
RUMAILA PROJECT
Table 3: System Schedule for Tank Linings
Scope Specification Thickness in

microns
CS potable water tanks, Prepare - Blast ISO 8501 Sa 3
diesel storage tanks. Prime - 2 pack 100% pure epoxy* 1 x 50
Finish - 2 pack 100% pure epoxy* 3 x 125
*Shall comply with BS6920 - suitable for use Total 425
with potable water OR have an
internationally recognised potable water
certificate.
CS Oil storage tank floor + Prepare - Blast ISO 8501 Sa 3
1.5 m of tank wall shell. Roof Prime - manufacturers holding primer if 1 x 50
space for fixed roof tanks required
Finish - Two pack glass flake vinyl ester or 1 x 500
modified epoxy tank lining Total 550
Note - Includes roof and all fittings down to
1.5 m below top of upper shell strake
CS Oil storage tank floor + Prepare - Blast ISO 8501 Sa 3

1.5 m of tank wall shell. Roof Prime - Epoxy phenolic 1 x 125
space for fixed roof tanks Finish - Epoxy phenolic 2 x 200
Alternative to above Total 425
CS raw water, slops, Prepare - Blast ISO 8501 Sa 3

emulsion, produced water Prime - manufacturers holding primer if 1 x 50
<90°C required
Finish - Two pack glass flake vinyl ester 2 x 200
Total 450
CS raw water, slops, Prepare - Blast ISO 8501 Sa 3

emulsion, produced water Prime - Epoxy phenolic 1 x 125
Alternative to above Finish - Epoxy phenolic 2 x 200
<90°C Total 425
CS process oil tanks, Prepare - Blast ISO 8501 Sa 3

separators, heat exchanger Prime - manufacturers holding primer if 1 x 50
channels <90°C required 2 x 500
Finish - Two pack glass flake vinyl ester Total 1000
(1 mm)
RUMAILA PROJECT
Table 3 : Paint System Schedule for Tank Linings - continued

Scope Specification Thickness in
microns
CS process oil tanks, Prepare - Blast ISO 8501 Sa 3
separators, heat exchanger Prime - manufacturers holding primer if 1 x 50
channels >90°C required 3 x 500
Finish - Glass flake reinforced vinyl ester Total 1500
(1.5 mm)
RUMAILA PROJECT
APPENDIX 2: Colour Coding and Identification
A2.1 General
Safety colour coding and identification of equipment and piping for this project shall be in accordance with
this Specification. SUPPLIERS shall use the BS 4800 standard colours or equivalent. Equivalent German
colour standard numbers, RAL 840, may be substituted depending on the in-country availability of particular
colours, but this shall be agreed with the CONTRACTOR.
Table 4 lists basic piping systems, equipment, and the required finish colour for that particular piping system
and major equipment type. Any item that is not listed below, but is part of this project, shall be brought to the
attention of the CONTRACTOR for selection of the finish colour and exact colour coding and marking
requirements.
Table 5 lists the RAL equivalent colours.
This specification also applies to package and/or skid mounted equipment.
Components such as junction boxes / auxiliary piping etc. attached directly to the prime equipment or
equipment driver shall be painted to the same colour (as per Table 4) as the major item to which it is
attached.
Pipes shall be identified by pipe body colour and with colour coded self adhesive bands or by painting (for
cases where bands are not practical or commercially available). In such cases, pipe marking shall follow all
the coding and marking in accordance with this specification.
RUMAILA PROJECT
Table 4: Finish Colour Schedule

Item Finished Colour BS 4800 Colour Ref No
PIPING AND VALVES - Process Grey up to 120°C. Aluminium 00A05/Aluminium

above 120°C
Utilities - all other than cooling water or firewater lines Grey up to 120°C. Aluminium 00A05/Aluminium
above 120°C
Utilities - Cooling water lines Green 14E53
Toxic Lines Grey with orange banding 00A05/06E51

pitched at intervals depending
on pipe geometry
Acid alkali and other corrosive storage except toxic Grey up to 120°C or 00A05/Aluminium
contents. aluminium above 120°C 10E53
Number and description
stencilled on yellow block
Outdoor Instrumentation Items Black 00E53
e.g., control valves, transmitters, gauges. Where such
items require painting for weather protection, they shall be
black.
FIRE FIGHTING EQUIPMENT - Valves, hydrants, hose Red 04E53
boxes, firewater and foam-lines, dry risers
MOVING EQUIPMENT - Pumps, compressors, turbines, Mushroom 08B21

stirrers, blowers, rotary air locks, screw feeders, etc. (and
their concrete bases inside buildings)
ELECTRICAL EQUIPMENT - Motors and their field Orange 06E51

mounted switchgear
ELECTRICAL EQUIPMENT - General Grey 00A05
FIRED HEATERS – HEAT EXCHANGERS – STORAGE Grey up to 120°C or 00A05/Aluminium

TANKS - VESSELS aluminium above 120°C.
Number and description
stencilled straight on.
CHLORINE STORAGE - also hypochlorite storage White, number and description 00A01/ 10E53
stencilled on yellow block
RUMAILA PROJECT
ALL STRUCTURAL STEELWORK including pipe supports, Grey 00A05

etc
GALVANISED HANDRAILS, STANDARDS, LADDER 06E51

Orange
CAGES & GATES - items that are scheduled to be
overpainted
Table 5: RAL Equivalent Colours
COLOUR BS 4800 Reference RAL Reference
White 00E55 9010
Light Grey 00A05 7035
Aluminium None 9006
Mushroom 08B21 7036
Red 04E53 2002
Light Orange 06E51 2003
Green 14E53 6024
Black 00E53 9005
Dark Grey 00A09 7037
Golden Yellow 08E51 1016
RUMAILA PROJECT
A2.2 PROCESS AND UTILITY PIPING IDENTIFICATION MARKING COLOUR

BANDING SYSTEM
Each colour band system shall consist of:
• Adhesive PVC marker tape - the primary colour. This also indicates the direction of the pipe
contents flow with an arrow.
• Adhesive PVC marker tape - the secondary colour.
• Adhesive text label.
The colour bands shall be applied over the pipework coating.
UNDER NO CIRCUMSTANCES SHALL ADHESIVE BANDS BE PLACED ON UNPAINTED CARBON

STEEL OR STAINLESS STEEL.
Prior to the band application, the pipe surface shall be thoroughly cleaned of all surface contamination such
as oil, grease, scale dust etc. by the application of an approved cleaning solvent compatible with the coating
system using only clean rags or brushes. The cleaned surface shall be allowed to completely dry out before
applying the PVC colour bands.
The PVC colour bands shall be applied to the pipework immediately after the solvent cleaned surface is dry.
The banding system shall be applied as follows:
• The length of the tapes needed shall be removed by applying a length of tape around the pipework
with the backing paper still attached. An overlap of 50 mm shall be allowed for, and the tapes cut to
the required length.
• The corner edges (approx. 25 mm) shall be cut off at an angle of 45º at the overlap end of the tapes to
prevent peel-off.
• The backing paper shall be removed from the primary band tape to the extent that the arrow under
which the text strip is to be placed is clear.
• The arrow shall point in the direction of pipe contents flow and the text strip shall be applied to the
back face of the primary tape so that the text is centrally located and clearly visible within the
transparent flow arrow window.
• The tape shall be held with both hands against the pipe and the flow arrow adjusted into the best
reading position for the operations personnel. The tape shall be applied by smoothing it onto the
pipework by hand, avoiding trapping air bubbles and without stretching. It should be a snug fit on the
pipework with a 50 mm overlap.
• The two secondary plain band tapes shall be applied in the same manner as the band tape.
The PVC banding system shall be applied on all piping, oriented so that the flow directional arrow and label
text is clearly visible by operations personnel. The banding system shall be applied immediately adjacent to
the following items and additionally at approximately 5 m intervals:
• All vessels/heat exchangers / pumps etc;
• All valves;
RUMAILA PROJECT
• All pipework junctions; and
• All wall/floor/ceiling penetrations.

Table 6: Fluid Identification Colours
Service Primary Band BS 4800 REF Secondary Band BS 4800 REF.
CHEMICALS
Biocide Violet 22C37 Pink 04E49
Hypochlorite Violet 22C37 Red 04E53
Demulsifier Violet 22C37 Brown 06D45
Antifoam Violet 22C37 DK Yellow 08E51
Deoiler Violet 22C37 Yellow Ochre 08C53
Methanol Violet 22C37 Blue 20D45
Oxygen scavenger (future) Violet 22C37 Dark Green 14C39
Corrosion inhibitor Violet 22C37 White 00E55
Scale inhibitor Violet 22C37 Green 12D45
Asphaltene Disperant Violet 22C37 Light Blue 20E51
Fire fighting Foam Red 04E53
Black 00E53
PROCESS FLUIDS
Hydrocarbon Gas Yellow Ocre 08C35 Brown 06C39
Fuel Gas Yellow Ocre 08E35 Blue 18E50
Hydrocarbon Liquid Brown 06C39 Light Blue 20E51
Two Phase Hydrocarbon Brown 06C39 Violet 22C37
Produced Water Green 12D45 Yellow Ocre 08C53
UTILITIES GAS FLUID
Instrument Air Light Blue 20E51 White 00E55
Plant Air Light Blue 20E51 Brown 06C39
Nitrogen Light Blue 20E51 Red 04E53
Cooling Medium Blue 18E50 Yellow Ochre 08C53
(30% TEG / 70% Water)
Lean TEG Blue 18E50 White 00E55
Rich TEG Blue 18E50 Black 00E53
WATER
Injection Water Dark Green 14C39 Red 04E53
Seawater Green 12D45 Red 04E53
Potable Water (sterilised) Green 12D45 Blue 18E53
Fresh Water Green 12D45 Blue 18E53
RUMAILA PROJECT
Service Primary Band BS 4800 REF Secondary Band BS 4800 REF.
Sewage Green 12D45 Black 00E53

OIL AND FUEL
Diesel Oil Brown 06C53 Emerald Green 14E53
Lube Oil Brown 06C39 Pink 04 E 59

Helifuel Brown 06C53 White 00E55
HP Flare Brown 06C53 Black 00E53
LP Flare Brown 06C53 Grey 00A09
Hydraulic Oil Brown 06 C 39 Yellow Ochre 08 C 53

DRAINS
Closed Drains Black 00E53 Red 04E53
Haz Area Open Drain Black 00E53 Grey 00A09
Non-Haz Area Open Drains Black 00E53 Violet 22C37
RUMAILA PROJECT
A2.3 TEXT SIZE and LABELLING REQUIREMENTS

The size of lettering used for code indications on insulated and un-insulated piping are as follows.
Table 7: Text Size and Labelling
Item Pipe/Equipment Size Text Size
Pipe NPS ½ to NPS 1 10 mm high
Pipe NPS 1½ to NPS 2 15 mm high
Pipe NPS 3 to NPS 6 25 mm high
Pipe NPS 8 to NPS 18 40 mm high
Pipe NPS 20 and above 80 mm high
Process/Utility Equipment All sizes– See A2.5 100 to 300 mm high
Tanks and Spheres All sizes- See A2.5 500 to 1000 mm high
For insulated lines text size shall be based on pipe diameter plus (2x) insulation thickness.
Arrow size shall be relative to Text.
BAND A B B BAND A B
Figure 1
NOTE:
Band B shall be downstream side of the flow with respect to Band A.
For bi-directional flow, band B shall be on both side of band A.
RUMAILA PROJECT
Band width
1) For pipe sizes less than NPS 6
Band A = 100mm
Band B = 50mm
2) For pipe sizes NPS 6 to NPS 10
Band A = 150mm
Band B = 75mm
3) For pipe sizes NPS 12 to NPS 16
Band A = 200mm
Band B = 75mm
4) For pipe sizes greater than NPS 16
Band A = 300mm
Band B = 100mm
RUMAILA PROJECT
A2.4 EQUIPMENT LABELLING

Equipment labelling shall be in Black letters on to the equipment base colour, unless there is insufficient
contrast for identification, in which case, a white background for the label shall be provided.
The method for applying equipment labelling should be considered as painting particularly for larger text
sizes (see section A2.4). However, SUPPLIER shall propose more practical and economical alternatives
should they be considered more suitable and commercially available, for CONTRACTOR review.
A 2.4.1 Label Locations
a) Packaged / skid mounted equipment
Unit item/identification number shall be painted onto the web of structural steel base plate members on both
sides of the unit.
Equipment included in enclosures shall have the unit/identification number painted onto both sides of the
enclosure.
b) Storage tanks, Towers, Drums, Pressure vessels, Filters & exchangers
For horizontal equipment the unit item/identification number shall be painted at the equipment centre-line on
both sides of the equipment. For vertical equipment the unit item/identification number shall be painted on
both sides of the equipment at approximately one quarter of the height of the equipment, up to a maximum
elevation of 5 m.
Where applicable, storage tank and/or pressure vessel contents shall be included with the unit/identification
number, located beneath this number. This information is provided primarily, for safety purposes for both
operations and emergency services. Location and design of this label shall reflect this.
SUPPLIER shall review his equipment layout upon installation and specify, on a case by case basis, how
and where each item of equipment will be labeled. In all cases, equipment label locations shall be convenient
for recognition by Operations and Emergency services and this may take precedence over a prescribed
location.
Requirements for COMPANY logos and signage shall also be considered. This will be developed and
detailed by the COMPANY.

Specification For Protective Paint and Coatings: Minimum Works Obligations

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Specification For Protective Paint and Coatings: Minimum Works Obligations

Uploaded by

Copyright:

Available Formats

RUM AIL A PROJECT

Specification for Protective Paint and

WorleyParsons Europe Limited

© Copyright 2011 WorleyParsons

RUMAILA PROJECT 405000-00098 - DOCUMENT TEMPLATE

A Issued for Squad 13-May-2011 N/A N/A

B Issued for Customer 16-June-2011

0 Issued for Use 22.July-2011

1 Issued for Use 14-Dec-2011

001 02W-C-GO-GOOO-ML-SPC-0007 Page 2 of 46

REVISION DESCRIPTION SHEET

Rev. Para. Reason for Revision

0 3.2 Added - Group Defined Practices and Order of Precedence

1 Client comments incorporated (ref: 00102-CAN-0020)

1.1 Scope ................................................................................................................................. 7

1.2 Definitions .......................................................................................................................... 7

1.3 Abbreviations - ................................................................................................................... 8

2. REFERENCED DOCUMENTS .......................................................................................... 9

2.1 Group Defined Practices and Order of Precedence ........................................................ 11

3.1 Generic versus named products ...................................................................................... 12

3.2 Abrasives ......................................................................................................................... 12

3.3 Compressed Air ............................................................................................................... 12

3.4 Paint Materials ................................................................................................................. 13

4. GENERAL REQUIREMENTS .......................................................................................... 14

4.1 Extent of Painting ............................................................................................................. 14

4.2 Surfaces Not Be Painted .................................................................................................. 14

4.3 Fasteners ......................................................................................................................... 15

4.4 Protection of Stainless Steel Surfaces ............................................................................. 16

4.5 Safety Requirements........................................................................................................ 16

5. SURFACE PREPARATION ............................................................................................. 17

5.1 Items to be Protected ....................................................................................................... 17

5.2 Basic Cleaning ................................................................................................................. 17

5.3 Weld Preparation ............................................................................................................. 18

5.4 Abrasive Blasting of Carbon Steel ................................................................................... 18

5.5 Cleaning of Galvanized and Inorganic Zinc Surfaces ...................................................... 19

5.6 Cleaning and Blasting of Stainless Steel Surfaces .......................................................... 19

6. APPLICATION PROCEDURES ....................................................................................... 20

6.1 Preparation for Painting ................................................................................................... 20

6.2 Environmental Conditions ................................................................................................ 20

6.3 Paint Application .............................................................................................................. 21

6.3.1 General ................................................................................................................ 21

6.3.2 Spray Application ................................................................................................ 22

6.3.3 Brush Application ................................................................................................ 22

6.3.4 Roller Application ................................................................................................ 22

7.1 General Requirements ..................................................................................................... 23

7.2 Coating Damage Not Exposing Substrate Surface .......................................................... 23

7.3 Coating Damage Exposing Substrate Surface ................................................................ 23

7.4 Repair of Zinc Silicate Primer .......................................................................................... 24

7.5 Repair of Fully Cured Epoxy Coating............................................................................... 24

8.1 Shop Versus Field Painting Policy ................................................................................... 25

8.2 Responsibilities of the VENDOR ...................................................................................... 25

8.3 Responsibilities of the Paint Manufacturer....................................................................... 25

8.4 Site Painting ..................................................................................................................... 25

9. INSPECTION AND TESTING .......................................................................................... 27

9.2 Inspection Instruments ..................................................................................................... 27

9.3 Before Surface Preparation ............................................................................................. 28

9.4 Before And During Paint Application ................................................................................ 28

9.5 After Painting .................................................................................................................... 28

10. INSPECTION RECORDS AND REPORTS ..................................................................... 29

11. SHIPMENT AND PACKING ............................................................................................. 30

11.1 Handling of Coated Items ............................................................................................ 30

11.2 Coating Materials ......................................................................................................... 30