Construction QA/QC

Painting

Rev. No. Rev. Date Description of Revision Revised by Approval

00 21/April/2016 New KIA

PROPRIETARY & CONFIDENTIAL

This document and the information contained herein is E2C proprietary know-how. This document or any part
therefore should not be reproduced stored in a retrieval system or transmitted by any means, electronic or
otherwise, or divulged without permission of E2C.

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TABLE OF CONTENTS

1. Scope ......................................................................................................................3
2. Applicable Codes & Standards...............................................................................3
2.1 Codes & Standards .............................................................................................3
3. Witness Inspection Items ........................................................................................3
4. Test & Inspection Agenda ..................................................................................... 3
4.1 Receiving Inspection and Storage. .....................................................................3
4.2 Workmanship .................................................................................................... 4
4.3 Inspection of Surface Preparation ......................................................................5
4.4 Inspection of paint film ......................................................................................6
4.5 Inspection of painting appearance ......................................................................7
4.6 Corrective action for unacceptable defects.........................................................7
5. Lettering and Marking ............................................................................................8
5.2 Inspection of lettering and marking. .................................................................. 8
6. Document to be Issued ...........................................................................................8

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1. Scope
1.1 This procedure covers the requirements & procedure for test & inspections of surface
preparation, painting for structural steel work, field erected tanks and piping and other
equipment at the Client construction site.

1.2 This procedure shall be applied to the inspection items, method and criteria for field
construction work performed by the Construction Contractor under control of Construction
Management Contractor (CMC) and Client.

2. Applicable Codes & Standards

2.1 Codes & Standards
2.1.1 Steel Structures Painting Council (SSPC)
2.1.2 SIS 05 5900Pictorial Surface Preparation Standards Painting Steel Surface
2.1.3 ASTM D 33 63 Standards Test Method for Film Hardness by Pencil Test.

3. Witness Inspection Items

3.1 All surface preparations & painting works shall be subject to test & inspection under
witness by CC/CMC and /or Owner’s inspector at any reasonable time, before, during and
after completion.

3.2 Witness test and inspection items shall be in accordance with approved Inspection and Test
Plan (ITP).

4. Test & Inspection Agenda

4.1 Receiving Inspection and Storage.
4.1.1 Any paint in containers that are not plainly marked with the name, formula,
specification, batch number, color, and date of manufacture, or expiration date shall be
rejected.

Where expiration date is not included as part of the manufacturer’s labeling, the Construction
Contractor shall be responsible for review of manufacture date and manufacturer’s product
data and for marking each container with the expiration date. Containers not marked should
not be used.

4.1.2 Each lot of paint provided for site use shall be covered by a certificate from the
manufacturer which warrants compliance with, and testing to ensure the manufacturer’s
product specifications and those certificates shall be reviewed by Construction Contractor for
compliance with painting types as specified in specification. Those certificates shall also be
included in the QC Dossier (see section 6).
4.1.3 All paints and thinners shall be stored in a well. Ventilated place, free from excessive
heat, or direct rays of the sun. Open air storage shall be avoided particularly for heavy paints,
such as primers and undercoats, and or special paints which are supplied as two or more
components in separate containers. Follow storage recommendation by manufacturer.

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4.1.4 All paint shall be thoroughly mixed before application. For quantities over 5 liters, a
power stirrer shall be used. If a sludge has formed in the bottom of the paint can, mixing shall
be continued until the paint is homogenous. If the sludge can not be dispersed, the paint shall
not be used.

4.2 Workmanship
4.2.1 Surface preparation and painting shall not be carried out under the following conditions:

4.2.1.1 Surface Preparation

a. When the relative humidity is 85% or higher.

b. In case of rain or bad weather.
c. When substrate or metal temperature is less than 30C above the dew point, unless
specified by the paint manufacturer.
4.2.1.2 Painting

a. When the relative humidity is 85% or higher,

b. When the surfaces are moist or likely to become moist due to rain, snow, dew or frost.
c. When the surrounding atmospheric and metal temperature is below 5° C or above
40° C, and beyond the limits specified by the paint manufacturer.
d. When substrate or metal temperature is less than 3 °C above the dew point, unless
specified by the paint manufacturer.
e. During Sandstorm.
4.2.1.3 The Construction Contractor shall measure and report humidity, atmospheric
temperature and metal temperature before start of surface preparation or painting and at 4
hours (minimum) intervals.

4.2.2 The surface of the equipment shipped from overseas and stored long term shall be
cleaned by cloth rag or water prior to application of subsequent paint coats.

4.2.3 Construction Contractor shall observe for pot life and mixing ratio per manufacturer
recommendation, and expiration date of paints and report with certificates prior to use.

4.2.4 Weld joints shall not be painted prior to hydrotesting. Cover shall be provided after
visual inspection.

4.2.5 Raised Face or Gasket Area of flanges, and threaded areas shall not be blasted and
painted.

4.2.6 Equipment and other adjacent properties not intended for painting shall be protected
against damage.

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4.3 Inspection of Surface Preparation

4.3.1 Inspection of pre-blast operation

4.3.1.1 The inspector shall decide if the substrate requires solvent or detergent cleaning before
abrasive blasting.

4.3.1.2 Abrasive blasting shall be carried out only when the steel surface is at least 3° C above
the dew point.

4.3.1.3 Rough welds and cut-offs shall be ground to a radius, weld spatter shall be removed by
chipping and/or grinding. This should be done prior to blasting operation.

4.3.2 Inspection of Equipment

4.3.2.1 The compressed air supply shall be free of oil, moisture and contamination. As a
minimum, the inspector shall check and approve the air quality at the start and mid-point of
each 8 hour period. This shall be determined as follows:-

Attach a piece of blotter or absorbent paper to a clip board, then hold it approximately 450-650
mm in front of the blast nozzle during air flow only with a nozzle pressure of approximately
50 psig for one minute. Satisfactory results shall be no water or oil contamination on the
blotter. The blast system shall be operated for at least 5 minutes under actual field conditions
at the specified pressures prior to making the blotter test.

4.3.2.2 An operational deadman remote control valve shall be attached to the nozzle.

4.3.2.3 High intensity flood or spot lights shall be installed in vessels or tanks for visibility.

4.3.2.4 All personnel entering tanks or vessels after abrasive blasting shall wear rubber-soled
shoes with clean disposable covers, sweet bands and dirt-free gloves.

4.3.2.5 Blasting pressure shall be checked at the nozzle, not at the compressor.
4.3.3 Inspection of surface preparation for tanks and equipment.

4.3.3.1 Inspection items of the surface preparation shall be as follows:

INSPECTION ITEM INSPECTION FREQUENCY INSPECTION IMPLEMENT
Once in each area where surface
Cleaning of Rust etc. SIS photograph Magnifying class.
preparation is completed.
One location in 5-10 m2 where Standard specimen with Magnifying
Anchor Pattern
surface preparation is completed. Glass.

4.3.3.2 Inspection frequency for cleaning of rust etc. shall be once in each area where surface
preparation has been completed, regardless large or small, before primer coating. Anchor

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pattern shall be checked one location in 5-10 m2 where surface preparation has been
completed by blast cleaning.

4.3.3.3 The prepared surfaces shall be compared with the standard photographs of SIS or
SSPC for cleaning of rust, etc. and standard specimen for anchor profile. Where the prepared
surfaces are deemed to be equivalent to those indicated standard photographs and standard
specimen, they shall be acceptable.

4.3.3.4 All crevices, corners, and edges of shape steel, joint of steel plates, especially around
bolt head, weld beads, etc. shall be inspected with special care.

4.4 Inspection of paint film

4.4.1 Paint film thickness. Film thickness shall be measured for the following items:

INSPECTION ITEM INSPECTION FREQUENCY INSPECTION IMPLEMENT

Wet Film Thickness One Point / 5-10 m2 (Min. 10 points / Wet Film thickness gauge.
day)
Dry Film Thickness One Point/3-5 m2 (one point / 10m2 Dry Film Thickness Gauge (e.g.
for tank & equipment larger than 10m electrometer, microtest,).
dia.
Corners, snipes 100% Inspection Mirror/Dentist Mirror.

4.4.2 Measurement of wet film thickness have to be done only for reference and may not
require recording.

4.4.3 Measurement shall be carried out at least three times at each measuring point. The
average of three measurements shall be recorded as the measured value for the item
concerned.

4.4.4 Thickness gauges to be used for measurement of paint films shall be calibrated with test
specimens once in the morning and afternoon or whenever measurement starts.

4.4.5 Rating of measured value. When the measured values satisfy the following requirements,
they shall be acceptable:

4.4.5.1. Average of three points measured film thickness. Designated minimum film thickness
and up to maximum dry film thickness as recommended by paint manufacturer or approved by
Client.
4.4.5.2 If the measurement of Wet or Dry film thickness reveal shortage of specified thickness,
a touch-up-paint shall be applied to the area in accordance with manufacturer’s
instructions/specifications for touch-up coating/approved by Client.

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4.5 Inspection of painting appearance

4.5.1 Visual inspection shall be made on the following items once all surfaces:

4.5.1.1 The application of each coat for uniformity of color, thickness and coverage.

4.5.1.2 Check of between-coats drying requirements.

4.5.1.3 Observation of painted surface for paint runs, drips, wrinkles, blistering, peeling,
cracking, crawling, discoloring, stains, pinholes and spray dust.

4.5.1.4 Check of difficult-to-reach places such as edges, corners, crevices, welds, bolts,
obtaining treatment and coverage less equivalent than that of adjacent painting.

4.5.1.5 Where there are not marked defects in appearance, the paint film shall be deemed
acceptable. Any out of condition rejected by CMC/Owner shall be remedied/repaired.

4.5.2 Internal painting/coating of Tank shall be inspected for the surface continuity, degree of
cure by using inspection instruments, such as low voltage wet sponge holiday detector and
solvent whip test or film hardness test.

Unacceptable conditions and defects as per 4.5.1.3 shall be noted on the inspection report and
the condition corrected per paragraph 4.6, below, and correction confirmed by re-inspection
prior to acceptance/turnover. Areas of incomplete curing shall be monitored and if curing is
not completed within twice the paint manufacturer’s specified maximum curing time for the
product/conditions, the uncured area shall be rejected for removal of the paint and repainting
in accordance with paragraph 4.6 (1) below.

4.5.3 Underground piping installation coated with epoxy or tape wrapped shall be tested and
accepted prior to back filling.

4.6 Corrective action for unacceptable defects.

In case of unacceptable defects during or after painting, they shall be handled as follows:

4.6.1 Surface Preparation. The method of re-cleaning or re-preparation shall be in accordance

with repair procedure provided prior to start of painting.

4.6.2 Re-application of painting

4.6.3 Inspect for Wet film thickness and dry film thickness.

4.6.4 Check for the time to dry between coats

4.6.5 Re-inspect area visually.

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5. Lettering and Marking

5.1 Lettering and marking for tower, vessel, heat exchanger, reactor, tank, fired heater, rotary
machine, piping, electrical equipment, instrument, fire fighting equipment etc., shall be in
accordance with Client spec.

5.2 Inspection of lettering and marking.

5.2.1 Inspection shall be:

5.2.1.1 Position of lettering, marking at the stage of draft.

5.2.1.2 Size, space between letters, style, arrow direction at the stage of draft.

5.2.1.3 Surface preparation before painting (if required, sand papering, or SSPC-SP1)

5.2.1.4 Color of the letter after painting.

5.2.1.5 Background color coat after painting.

5.2.2 Color coating shall be as per Client Specification.

5.2.3 Any out of standard lettering/marking, rejected by CMC/Owner shall be remedied.

6. Document to be Issued
6.1 After completing the final inspection, all the test records and check sheets for the
performed inspection and tests as specified in Table I shall be issued in the form of QC
Dossier.

6.2 The QC Dossier shall be submitted in accordance with Client requirements.

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