GF LPU4 J SP 003 Spec For Painting and Coating

PROVISION OF LEASED
POWER UNIT FOR TRAIN 3, 4 & Doc No.:

5 AND GAS TREATMENT UNIT GF-LPU4-J-SP-003
(GTU) INCLUDING
OPERATIONS AND MAINTANCE Date:
16 September, 2021
(PACKAGE 4) FOR PETRONAS
CARIGALI IRAQ HOLDING
Specification for Painting and Coating Rev: A
Revision Revision Description Date of Issue

No.
A Issued for BID 16 September, 2021
Prepared by Reviewed by Approved by

Revision
No. Initial Date Initial Date Initials Date
A ZHAOKAI 16-SEP-21 CUIWEI 16-SEP-21

WEI
Approved by TA Signature Date

Specification for Painting and Coating
TABLE OF CONTENTS
1.0 INTRODUCTION .............................................................................................................5
2.0 ABBREVIATIONS ...........................................................................................................5
3.0 CODES & STANDARDS .................................................................................................6
4.0 ORDER OF PRECEDENCE ............................................................................................8
5.0 REFERENCE DOCUMENTS...........................................................................................8
6.0 EXECUTION ...................................................................................................................9
6.1 Shop Versus Field Painting Policy ............................................................................... 9
6.2 Responsibilities of the Contractor ............................................................................... 9
7.0 MATERIALS .................................................................................................................11
7.1 Abrasives ..................................................................................................................... 11
7.2 Compressed air ........................................................................................................... 11
7.3 Paint Materials ............................................................................................................. 12
8.0 SURFACE PREPARATION ..........................................................................................12
8.1 General ......................................................................................................................... 12
8.2 Pre-cleaning of surface and solvent cleaning ........................................................... 13
8.3 Blast cleaning .............................................................................................................. 14
8.4 Surface preparation by hand and power tool cleaning ............................................. 17
8.5 Surface preparation and cleaning by water jetting ................................................... 17
9.0 PAINT APPLICATION ..................................................................................................18
9.1 Pre-Application Procedures........................................................................................ 18
9.2 Scheduling ................................................................................................................... 19
9.3 Application Methods ................................................................................................... 20
9.4 Repairs and touch-up painting ................................................................................... 22

10.0 PAINTING AND COATING SYSTEMS .........................................................................24
10.1 Coating system selections ......................................................................................... 24
10.2 Painting and coating system schedules for external application ............................ 25
10.3 Painting and coating system schedules for internal application ............................. 30
10.4 Paint materials storage, shelf-life and handling ........................................................ 38
10.5 Coating system product approval requirement......................................................... 39
11.0 QUALITY CONTROL (QC) ...........................................................................................41
11.1 Inspection .................................................................................................................... 41
11.2 Project production testing .......................................................................................... 41
12.0 HEALTH, SAFETY AND ENVIRONMENT (HSE) ..........................................................42
12.1 Safety and health regulations ..................................................................................... 42
12.2 Environmental regulations ......................................................................................... 43
13.0 COLOUR SCHEMES ....................................................................................................44
13.1 Colour scheme for onshore installation .................................................................... 44
13.2 Colour identification for storage tank ........................................................................ 45
13.3 Identification piping system ....................................................................................... 45
13.4 Safety colours .............................................................................................................. 45
14.0 APPENDICES ...............................................................................................................45
APPENDIX A STORAGE TANK IDENTIFICATION SYSTEM
APPENDIX B PIPING IDENTIFICATION SYSTEM
APPENDIX C PIPING COLOUR IDENTIFICATION LEGEND
APPENDIX D COLOUR SCHEME FOR ONSHORE INSTALLATION & EQUIPMENT
APPENDIX E SPECIFICATION FOR INTUMESCENT COATINGS

1.0 INTRODUCTION
This document covers the requirements for painting, recommendations for the preparation
for exterior surfaces of aboveground piping, equipment & aboveground pipelines, storage
tanks, and structural steel made out of carbon steels and low alloys, galvanized steels,
stainless steels, copper and its alloys.
The painting works to be performed shall include all necessary steps like surface
preparation, protection of the other works, application of first coat, intermediate and top
(finish) coats, cleaning of the working area as well as intermediate and final inspection.
2.0 ABBREVIATIONS
The following abbreviations are applicable for this specification:
ASTM American Society for Testing and Materials
BS British Standards
cm Centimeters
CP Cathodic Protection
CS Carbon Steel
DFT Dry Film Thickness
HSE Health Safety and Environment
ISO The International Organization for Standardization
m2 Meter Square
mm Millimetres
NACE National Association of Corrosion Engineers
OSHA Occupational Safety and Health Administration
psi Pound per square inch
QA/QC Quality Assurance/Quality Control
RH Relative Humidity
SSPC Steel Structures Painting Council
USD United States Dollar
VOC Volatile Organic Compounds
WFT Wet Film Thickness
°C Degree Celsius
3.0 CODES & STANDARDS
The following Codes and Standards, to the extent specified herein, form a part of this
specification. When an edition date is not indicated for a code or standard, the latest edition
in force at the time of CONTRACTOR’s proposal submitted shall apply. The following code
& standards are applicable for this specification:
SSPC-SP1 Steel Structures Painting Council Manual – Solvent Cleaning
SSPC-SP3 Steel Structures Painting Council Manual – Power Tool Cleaning
SSPC-SP10 Steel Structures Painting Council Manual – Near White Blast

Cleaning
SSPC-SP11 Power Tool Cleaning to Bare Metal
SSPC-SP12 Surface Preparation and Cleaning of Steel and Other Hard Materials
by High- and Ultrahigh-Pressure Water Jetting Prior to Recoating
SSPC-AB1 Abrasive Specification No. 1; Mineral and Slag Abrasives
SSPC-PA2 Measurement of Dry Paint Thickness with Magnetic Gauges
SSPC-PS Guide 8 Guide to Top coating Zinc-Rich primers
SSPC-QP1/2 Procedure for Qualification and Conformance Testing of Blasting

Abrasives
ISO 11124 Specifications for Metallic Blast-Cleaning Abrasives
ISO 11125 Methods for Testing Metallic Blast-Cleaning Abrasives
ISO 11126 Specifications for Non-Metallic Blast-Cleaning Abrasives; Copper

Refinery Slag
ISO 11127 Methods for Testing Non-Metallic Blast-Cleaning Abrasives
ISO 2808 Paints and Varnishes - Determination of film thickness
ISO 4624 Paints and Varnishes - Pull-off test for adhesion
ISO 4628-2 Paints and Varnishes-Evaluation of degradation of paint coatings

Designation of intensity, quantity and size of common types of
defect. -Part 2: Designation of degree of blistering
ISO 4628-3 Paints and Varnishes - Evaluation of degradation of paint coatings

defect - Part 3: Designation of degree of rusting

defect Part 4: Designation of degree of cracking

defect - Part 5: Designation of degree of flaking
ISO 8502-1 Preparation of steel substrates before application of paints and

related products – Tests for the assessment of surface cleanliness
– Part1: Field test for soluble iron corrosion products

related products - Tests for the assessment of surface Laboratory
determination of chloride on cleaned surface

related products - Tests for the assessment of surface cleanliness -
Part 3: Assessment of dust on steel surfaces prepared for painting
(pressure-sensitive tape method)

related products - Tests for the assessment of surface cleanliness -
Part 4: Guidance on the estimation of the probability of condensation
prior to paint application

related products - Surface roughness characteristics of blast
cleaned steel substrates - Part 2: Method for the grading of surface
profile of abrasive blast-cleaned steel -Comparator procedure
ISO 8501-1 Preparation of Steel Substrates before Application of Paints And

Related Products – Visual Assessment of Surface Cleanliness
ISO 8502-3/4 Preparation of Steel Substrates Before Application of Paints and

Related Products
ISO 8504-2/3 Methods for Surface Preparation
ASTM B 117 Standard Practice for Salt Spray (Fog) Apparatus
ASTM D 869 Standard Test Method for Evaluating Degree of Settling of Paint
ASTM D 3276 Standard Guide for Painting Inspectors (Metal Substrates)
ASTM D 3359 Standard Test Method for Measuring Adhesion by Tape Test
ASTM D 4060 Standard Test Method for Abrasion Resistance of Organic Coatings
by the Taber Abraser
ASTM D 4285 Standard Test Method for Indicating Oil or Water in Compressed Air
ASTM D 4414 Standard Practice for Measurement of Wet Film Thickness by Notch
Gauges
ASTM D 4541 Standard Test Method for Pull-Off Strength of Coatings Using
Portable
ASTM D 4752 Standard Test Method for Measuring MEK Resistance of Ehtyl
Silicate
ASTM D 5064 Standard Guide for Conducting a Patch Test to Assess Coating
ASTM D 5162 Standard Practice for Discontinuity (Holiday) Testing of Non-

Conductive
ASTM E 337 Standard Test Method For Measuring Humidity With a

Psychrometer
BS 3900 Pt. E6 Methods of Tests for Paint Cross-Cut Tests
NACE 6A192 Dehumidification Equipment in Lining Application
NACE RP0181 Liquid-Applied Internal Protective Coatings for Oil Field
RAL 840 HR Standard Colors
BS 4800:2011 Schedule of Paint Colors for Building Purposes
PTS 30.48.00.31 Protective Coatings and Linings
4.0 ORDER OF PRECEDENCE
In case of conflict between the regulations, codes and standards, CONTRACTOR shall
refer to the Design Basis Memorandum (General) (FDP-COM-52-PRJ-SP-GE-002) of the
ITB for the Order of Precedence.
5.0 REFERENCE DOCUMENTS
The following documents reference are applicable to this specification:
FDP-COM-52-PRJ-SP-GE-002 Design Basis Memorandum (General)

6.0 EXECUTION
6.1 Shop Versus Field Painting Policy
Prefabrication primer (zinc rich primer) for temporary protection is allowed but these primers
shall be removed by blasting and the surface shall be blasted to the initial specified surface
profile. Shop and field painting shall be based on the following policy. Shop application of
the complete coating system is preferred. Where complete paint system before transport to
the site is not possible, first coat application in the shop followed by inter-coat and final
touch-up topcoat application on site after erection is preferred over complete site application.
CONTRACTOR shall submit a Work Plan / Method Statement delineating painting work
execution between shop and field painting and obtain PCIHBV'S approval.
6.2 Responsibilities of the Contractor
The responsibilities defined below for Vendors, Manufacturers, Applicators and Sub-
Applicators are to have better control over them by CONTRACTOR to comply with
PCIHBV’s requirements;
 Vendor shall complete painting till top coat. Otherwise, Vendor at their facility
shall perform surface preparation, priming and application of at least first coat to
the following items and painting punch list shall be submitted as part of release note
prior to shipment;
Exchangers Heaters Piping

Stacks Structural Steel Tanks
Vessels Other Misc. Items
The Vendor shall perform surface preparation, priming, and finish painting of the
following items including all attachments thereto in accordance with the painting
systems of this Specification or their standard paint specification provided the total
paint system has a minimum corrosion resistance of 3000 hours when tested in
accordance with ASTM B117;
Compressors Control Equipment Fans
Motors Electrical Equipment Pumps
Shelf Items Specialty Equipment Itemized Valves
Any painting procedures submitted by the Vendor and approved by the

CONTRACTOR shall be considered additional to the requirements of this
Specification but shall not be considered in lieu of or substitution for the procedures
and requirements stated in this Specification.
The Manufacturer shall transmit to the PCIHBV/CONTRACTOR, copies of the

technical correspondence addressed to the Applicator.
 The Paint Applicator shall be responsible for the;
 Supply and application of all paint materials, labor, 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;
 Removal of identification marks on bare or unfinished equipment, piping and

structural steel and re-application of the identification marks on the finished
surfaces. The paint Applicator shall consult with the PCIHBV/ CONTRACTOR
on the size of the markings;
 Full protection from abrasives and paints to items which shall not be painted;
 Cleaning and application of painting systems on welded and damaged surfaces;
 Collection and disposal of all toxic waste materials from the work site as
directed by the PCIHBV/CONTRACTOR;
 Appropriate arrangements for technical services of the Manufacturer before

and during planning and application of the paint systems. Paint Applicator’s
purchase order for paint materials shall include a provision stating that the
Manufacturer's technical representative shall directly report to the
PCIHBV/CONTRACTOR regarding the acceptability and workmanship of the
paint application. A copy of purchase order for the materials showing this
provision shall be transmitted to the PCIHBV/CONTRACTOR;
 Preparation of appropriate work planning and taking all precautions to avoid

interference with the execution of work of other Contractors;
 Obtaining the PCIHBV's releases that the equipment is certified safe and
available and that all appropriate tests are completed before starting any
painting work;
 The earthing of abrasive blast cleaning and painting equipment and paint
containers;
 Obtaining latest Application Data and maintaining the same for use by all the
parties;
 Application of the paint systems to the extent stated in the procurement

documents in accordance with this Specification and all other relevant
documents such as site regulations, safety rules, referenced standards and
codes, etc.
 Providing qualified painting inspectors and testing 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 any damage caused by third parties responsible to the
CONTRACTOR;
 Enforcing all Purchase Order and Specification requirements on his Sub-

Applicators;
 Obtaining and transmitting all relevant Sub-Applicators drawings and

engineering data to the PCIHBV/ CONTRACTOR;
 Obtaining and transmitting all Sub-Applicators warranties to the PCIHBV/

CONTRACTOR, in addition to the system warranty.
7.0 MATERIALS
The PCIHBV reserves the right to instruct the CONTRACTOR to use approved materials
from paint Manufacturers. Pre-qualification of Manufacturer’s products is subject to
compliance with PCIHBV's procedures and requirements.
Painting and furnishing products for all work shall be the best grade produced for each
particular kind of material.
Materials for primer and succeeding coats shall be the products of the same manufacturer
compatibility of primer and succeeding coats shall be checked before execution of work.
7.1 Abrasives
For site application, abrasives shall be super garnet with 30/60 or 20/40 (size to suit surface
preparation). Otherwise, garnet with 30/60 or 20/40 shall be considered. Spent / used garnet
shall not be used under any circumstances. Copper-slag shall not be used due to health
concern and affect to people. Abrasive test should be conducted at site in order to check
the characteristic and composition i.e. chloride content etc.
7.2 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. Compressed air pressure shall not be less than
6.2bar tested for oil and moisture by a blotting paper test regularly Oil traps and moisture
traps shall be cleaned when required.
7.3 Paint Materials
Coatings containing cadmium or lead or any toxic material to environment / personnel shall
not be used.
Paints for use over stainless steels or nickel alloys shall contain free chlorides or other
halides and zinc. Chlorides or other halides tied up within the cured resin's molecule may
be acceptable, unless they are subject to release through aging within the temperature
range specified.
All coatings and related materials shall be as identified in Section 10.0.
First coats, inter-coats, and finishes shall be factory tinted, sealed, and labeled. Thinners
and solvents shall be as identified in the coating Manufacturer’s data sheets.
All paint materials shall be used on a first-in, first-out basis.
Polyurethane finishes shall have excellent color retention and high gloss.
First coat colors shall be Manufacturer's standard colors. Finish colors, except for silicone
aluminum, shall be as noted in the color schedule of Appendix 3 and 4. For services above
93°C, if heat stable colors matching specified colors are not commercially available from the
Manufacturer's standard stock, heat stable colors shall be selected regardless of color
match subject to PCIHBV's choice of standard stock color.
The VOC (Volatile Organic Compound) level of the coating materials shall not exceed 20
mg/Nm3 in accordance with Iraqi Air Quality Standard’s maximum allowable emission limits.
CONTRACTOR shall be completely responsible for determining the compatibility of coating

materials being applied to the same item that are the products of different Manufacturers.
Material shall be stored in Manufacturer's containers and shall be used and applied in
accordance to Manufacturer’s recommendations.
8.0 SURFACE PREPARATION
8.1 General
For optimum paint coating performance, surfaces to be painted or coated shall be

completely dry and free from burrs, weld spatter, flux, rust, loose scale, dirt, grease, oil and
other foreign matter before any paint is applied.
If the surface has been exposed to a polluted, e.g. salt-laden atmosphere, it shall be tested
for presence of contaminants in accordance with procedures described in ISO 8502-1 and
the contaminants removed in accordance with procedures described in NACE Publication
6G186 prior to blasting or power tool cleaning.
After preparation of the substrate surface, any grit, dust etc. shall be removed and a layer
of primer applied before any corrosion or recontamination occurs, normally within 4 hours
after blasting.
Surface preparation shall be carried out by dry blast-cleaning wherever possible. The
surface preparation grades shall be as specified for the various painting and coating
systems described in section 10.2 and 10.3. The nearest equivalents of the main surface
preparation specifications are given below:
Nearest Equivalents of The Main Surface Preparation Specifications
Abrasive Blast Cleaning SSPC ISO 8501-1 NACE
Extremely thorough
SP 5 Sa 3 No 1
White metal blast
Very thorough near
SP 10 Sa 2.5 No 2
White metal blast
Thorough commercial blast SP 6 Sa 2 No 3
Light. Brush-off blast SP 7 Sa 1 No 4
Tool Cleaning SSPC ISO 8501-1 NACE
Extremely thorough power

SP 11 - -
Tool cleaning
Very thorough power tool

SP 3 St 3 -
Cleaning
-
Thorough hand tool cleaning SP 2 St 2
Solvent Cleaning SSPC ISO NACE
Solvent cleaning SP 1 -
Surface preparation shall be subjected to inspection before the prime coat is applied to
ensure all traces of dust and foreign matter have been removed by brushing, blowing with
dry clean compressed air, or vacuum cleaning.
8.2 Pre-cleaning of surface and solvent cleaning
Prior to the actual cleaning operation, surface contaminants such as oil, grease,
hydrocarbon, etc. shall be removed preferably by degreasing with suitable degreaser or
solvent cleaning according to SSPC-SP1. The degreased surface shall be further washed
with fresh water to remove all traces of the degreaser chemicals. The surface shall be
allowed to dry thoroughly before proceeding with any further coating work. This procedure
also applies to all metal surfaces to be coated that do not require blast cleaning or power
tool cleaning.
Excessive rust scale shall be removed by impact cleaning tools or high pressure water
jetting. Before abrasive blast cleaning, all equipment which could be damaged by blast,
dust or particulate matter shall be suitably protected by masking, wrapping, tapping, or other
means to prevent damage. Where required, the degree of contamination shall be assessed
in accordance with procedures described in ISO 8502-3. This equipment shall include, but
not necessarily be limited to, the following:
• Bearings;
• Control panels;
• Control valves;
• Conduit;
• Instrument dials;
• Expansion joint bellows;
• Machined surfaces;
• Shafts;
• Push buttons;
• Tags;
• Screws;
• Exposed moving parts.
All edges shall be ground to a minimum radius of 2 mm; flame cut areas shall be ground
flush. If this is not the case, PCIHBV shall be informed, and corrective action shall be taken
prior to final surface preparation.
8.3 Blast cleaning
8.3.1 Blast cleaning equipment
The compressed air supply used for blast cleaning shall be free from water and oil. A test in
accordance with ASTM D 4285 shall be conducted to determine the presence of oil or water
in compressed air used.
The compressed air supply used for blast cleaning shall be free from water and oil. Adequate
separators and traps shall be provided, installed in the coolest part of the system. They shall
be emptied regularly to prevent carryover of water and oil. Accumulation of oil and moisture
shall be removed from the air receiver by regular purging.
Air compressors shall not be allowed to deliver air at a temperature above 110 °C.
Abrasive blast cleaning equipment shall be an intrinsically safe construction and equipped
with a remote shut-off 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 head gear shall be ventilated
by clean, cool air served through a regulator filter, to prevent blast cleaning residues from
being inhaled.
8.3.2 Blasting abrasives
Blasting abrasives for use in blast cleaning carbon steels and low alloy steels are specified
in ISO 8504-2. Recommended blasting abrasives are as follows, but not limited to:
• Chilled Iron Grit or Shot;
• Steel and Malleable Iron Grit or Shot;
• Natural Mineral Abrasives;
• Non-metallic abrasives.
All blasting abrasives shall meet the requirements of SSPC-AB 1: Abrasive Specification
No. 1; Mineral and Slag Abrasives. Any blasting abrasives qualification shall be performed
in accordance with the procedure described in QP-AB 1: Procedure for Qualification and
Conformance Testing of Blasting Abrasives.
Where abrasives which are classified as a Scheduled Waste are used, the waste shall be
collected and disposed of at prescribed premises as per the local regulations.
Sand or other materials producing silica dust shall not be used.
All metallic blast-cleaning abrasives shall meet the requirements of ISO 11124 and tested
in accordance with test methods specified in ISO 11125 (Parts 1-7).
All non-metallic blast-cleaning abrasives shall meet the requirements of ISO 11126 and
tested in accordance with test methods specified in ISO 11127 (Parts 1-7).
Any blast-cleaning abrasives qualification shall be performed in accordance with the

procedure described in QP-AB 1: Procedure for Qualification and Conformance Testing of
Blast-Cleaning Abrasives (to be amended to reflect ISO 11124, 11125. 11126 and 11127
requirements).
The blast profile and angular anchor pattern shall be that recommended by the paint
manufacturer to suit the minimum requirement of their respective primers; and the minimum
peak-to-valley height shall be 25 microns, Roughness or anchor pattern measurement shall
be carried out by the painting contractor using instruments approved by PCIHBVs and in
accordance with the procedures described in ASTM D 4417. Where anchor patterns are not
specified in the paint manufacturer's technical data, table below shall be used and NACE
RP0181 shall be referred as a guide for determining the anchor pattern.
Relationship Between Coating Thickness and Anchor

Pattern
Dry Film Thickness. Anchor Pattern
125 - 200 m (5 - 8 mils) 25 - 50 m (1 - 2 mils)
200 - 500 m (9 - 20 mils) 50 - 75 m (2 - 3 mils)
500 m or more (over 20 mils) >75 m (3 - 5 mils)
8.3.3 Techniques and restrictions
As a guide, blast cleaning shall not be carried out when the temperature of the surfaces to
be blasted is less than 3°C above dew point and when the relative humidity of the air is
greater than 85%. For dew point determination refer to the procedure described in ASTM E
337.
In enclosed areas such as in Tanks and Vessels; where some adverse conditions (i.e.
environmental conditions outside the range of the specifications or short turnaround time
allotted) may prevail, dehumidification is recommended to prevent flash rusting. In the event
that dehumidification is employed the Relative Humidity (RH) within such an enclosure shall
be maintained at a maximum of 50% RH except for Inorganic Zinc Silicate. NACE
Publication 6A192 may be referred to determine the types of dehumidification equipment
suitable for the work.
Abrasive blasting shall not be done in open areas close to painting operations or wet coated
surfaces to prevent dust and grit contamination. Normally grit blasting shall be permitted
only during daylight hours except that rough abrasive blasting will be allowed during the
night provided that the surface is subsequently blasted to the specified standard under good
light conditions. The illumination of the surface during final blasting shall be at least 500 Lux
and all environmental restrictions shall be observed.
Maximum speed and most effective cleaning are obtained by systematic even blasting.
Work should be blocked out in 30 cm squares and each square blasted evenly until
complete.
All welded areas and appurtenances shall be given special attention for removal of welding
flux in crevices. Welding spatter, slivers, laminations and underlying mill scale removed
during fabrication and exposed before and during blast cleaning operations shall be
removed by the best mechanical means and the edges smoothed or rendered flush.
Where rectification is necessary on abrasive blast cleaned surfaces, the dressed areas shall
be re-blasted to remove all rust and grits, and to provide an adequate anchor pattern.
Blasting shall continue a minimum of 25 mm into any adjacent coated areas, and the edges
shall be feathered.
After dry blast cleaning, no acid washes, cleaning solutions, solvents or other chemical
treatments shall be used on metal surfaces. This restriction includes inhibitive washes to
prevent rusting.
Any blast cleaned steelworks on which rust develops shall be re-blasted prior to being
painted.
Used garnet shall not be used in any circumstances.
8.4 Surface preparation by hand and power tool cleaning
The most technically effective surface preparation method is blast-cleaning mentioned in

Section 8.3. Manual preparation shall only be used when blast-cleaning is either not feasible
or not strictly required, e.g. galvanized steel, stainless steel.
Manual cleaning shall be performed using hand wire brushes or mechanically operated tools
(grinders, chippers or wire brushes) in accordance with ISO 8504-3. The surface shall be
left roughly abraded to meet the requirement of SSPC-SP11 and a burnished surface shall
be avoided.
Where welds occur within these areas or when these areas cannot accommodate a power
disc, power impact tools shall be applied (vibratory and rotary hammers, needle guns,
chisels) followed by brush cleaning.
If the surface being prepared lies adjacent to a coated surface which is not to be refurbished,
the power tool cleaning shall overlap the coated surface by at least 25 mm. The minimum
requirement for successful coating application is St 3 at the time of coating.
Care shall be taken to ensure that the substrate surface does not become polished during
power tool cleaning.
8.5 Surface preparation and cleaning by water jetting
Where dry blast cleaning is not feasible or desirable because the resultant flying abrasive
particles and drifting dust may damage highly sensitive rotary equipment and fillers, cause
contamination of nearby mechanical equipment and structures, cause contamination of the
environment, or explosion risk; an alternative method NACE No. 5/SSPC SP 12 may be
considered for removing existing coatings and for surface cleaning.
Water jetting is effective in removing:
 deleterious amounts of water-soluble surface contaminants that may not otherwise be

removed by dry abrasive blasting alone, specifically in the bottom of pits and craters of
severely corroded metallic substrates;
 rust;
 shot-creting spatter;
 existing coatings and linings.
Because water jetting does not provide the primary anchor pattern known to the coatings
industry, this specification recommends its use primarily for recoating projects where there
is an adequate pre-existing profile.
The cleaned surfaces shall be dry before any paint is applied. Consultation with paint
manufacturer is required for the selection of a suitable primer.
9.0 PAINT APPLICATION
9.1 Pre-Application Procedures
9.1.1 Materials handling and use
Storing, thinning, mixing and handling of paint materials shall be in accordance with the
Manufacturer's recommendation. All paint materials and solvents shall be stored in the
closed original container bearing the manufacturer's label until required for use. Each
container must have full identification information including Manufacturer's name, product
identification, batch number, expiry date and colour.
Hazardous chemicals shall be classified, packaged and labelled appropriately in compliance

with the relevant local regulations and international standards and disposed-off accordingly.
All aspects of safety relating to the use of paints and associated thinners shall comply with
the Manufacturer's requirement.
The Manufacturer's pot-life requirements shall be followed. Mixing of different brands or

generic types of paint material is not permitted.
Surface shall be painted with Coating system specified in the Painting and Coating System
Schedules in section 10.2 and 10.3 and using paint material in accordance with application
data.
Paint shall be applied to dry, clean, prepared surface under conditions recommended in the
manufacturer's product data.
9.1.2 Mixing and thinning
All coating material shall be mixed by solvent proof mechanical stirrer for a sufficient time in
order for proper mixing of one or two packs paint and bring the material to a uniform
consistency. Sticks shall not be used.
Continuous agitation type spray pots shall be used when applying, heavily metal-pigmented
paint such as zinc or aluminium loaded paint.
Thinner shall not be added to primer or paints unless necessary for proper application
according to the Manufacturer's recommendation. The type of thinner used must comply
with the manufacturer's recommendation.
9.1.3 Surface treatments
Hydrostatic or other testing of welds shall be completed prior to painting weldments.
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. It shall be the
CONTRACTOR's responsibility to ensure that all masking material is thoroughly removed
from the equipment and any damage to the primed/painted surface is repaired prior to
shipment.
9.1.4 Other miscellaneous requirements
In a multicoated system, a mist coat shall be applied over inorganic zinc primer to avoid
surface defects. The CONTRACTOR shall exercise necessary care to ensure a smooth and
uniform coating is applied over inorganic zinc primer.
Extra coats of paint shall be applied on areas where shape and/or plane of application
results in thinly applied coating; e.g., at edges, welds behind angles, corners, etc. and areas
not fully accessible by spray in order to obtain the specified coverage and thickness. A stripe
coat of paint shall be brush applied before applying the subsequent coat. The sequence of
stripe coating shall be decided during the pre-job meeting.
9.2 Scheduling
Unless otherwise recommended by the Manufacturer and accepted by the PCIHBV, paints
shall not be applied when:
• The surface temperature is less than 3 °C above dew point;
• The surface temperature is below 5 °C as it could adversely affect the curing of

paints;
• The relative humidity is more than 85%, except for Inorganic Zinc Silicate up to 90%;
• The metal surface temperature is higher than that recommended by the

Manufacturer for application;
• Surface preparation has not been completed or oil, grease and dust are present on
the substrate to be painted;
• Poor weather conditions for painting exist or are expected within two hours of
application such as blowing sand or rain;
• When there is a deposition of moisture in the form of rain, condensation etc. on the
surface. Probability of condensation may be determined in accordance with
procedures described in ISO 8502-4;
• Where the available light is less than 500 lux.
9.3 Application Methods
9.3.1 General
Coatings shall be uniformly applied without runs, sags, solvent blisters, 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 if spray will not completely cover all surfaces.
Edges of existing coating shall be feathered towards the substrate prior to overcoating.
Surface that will be inaccessible after assembly, including the surface of lap joint flanges,
nozzle necks, lap joint stub ends, lap rings, bolt holds and some welded joints, shall receive
the complete painting system before being assembled. Contact surface of bolted
connections are to be primed only.
On structural steel areas subject to be assembled by high tension bolts, contact surface
shall be primed only with Inorganic zinc silicate. Intermediate and final coat shall not be
applied.
Primers should not be overcoated with the second coat paint until the specified minimum
overcoating time is achieved.
Intercoat contamination shall be minimised by maintaining proper cleanliness and by

applying the intermediate and finish coats within the overcoating time recommended by the
manufacturer. If contaminants are present, they shall be removed before applying
succeeding coats.
Contrasting colour shall be used for each coat of paint.

Flanges, nozzles, clips, access ways saddles and other attachments which protrude through
insulation shall be considered uninsulated and shall be painted in accordance with the
coating system for external surface for the respective system.
Each coat shall be applied with acceptance limits of Dry Film Thickness (DFT) as specified
in section 10.2 and 10.3. It must be ensured that solvent retention in any of the coats, caused
by the application of excessive coating thickness is avoided. Contractor shall ensure the
maximum DFT applied does not exceed as per Manufacture datasheet.
The minimum DFT of the specified coating systems shall always be complied with, even if
this means application of more coats of paint.
Coatings intended to be exposed to continuous immersion in fresh water, salt water and
brine internally and externally coated shall be inspected for holidays in accordance with the
methods recommended in ASTM D 5162.
9.3.2 Spray application
Paints shall be applied by Air Spray or Airless Spray.
Hose and containers shall be thoroughly cleaned before addition of new materials. The
spray gun shall be held no closer than 200 mm or more than 600 mm from the surface to be
coated. During application the spray gun shall always be held at a right angle to the
substrate. Each pass shall overlap the previous one by 50 percent. In order to achieve a
uniform application, when large surface areas are being coated, spray application shall be
made in two directions so that the passes are at right angles to each other i.e. cross spray
at 50% over lapping. Pressures and spray fan shall be adjusted so that the optimum spray
pattern is utilised for the surface being coated.
Opened paint container shall be properly covered when not in use Opened paint container
shall be properly covered when not in use
9.3.3 Brush application
Application with brush is acceptable under the following conditions subject to PCIHBV
approval:
• When areas cannot be properly coated by spray for any reason;
• When spray application is difficult due to location of work accessibility;
• Above ground level when it is considered that loss of paint under prevailing
conditions is excessive e.g. windy and progress of work has to be maintained and
personnel in or near the work site or equipment property, may be affected by spray
particles;
• For touch-up or repair of localized damaged paint or to areas of incorrectly applied

paint;
• For painting of stripe coat e.g. when applying the initial coat of paint to corners,
edges, crevices, holes welds or other irregular surface prior to spray application;
• When the substrate material to be applied are suitable for brush application;
• The number of coats shall be adjusted to the dry film thickness to match.
Paint brushes used shall be of a style and quality that will permit appropriate application of
the material being applied.
Material applied by brush shall be smooth, uniform in thickness, without any apparent
surface defects such as brush marks, runs, sags, or curtains.
9.3.4 Roller application
Roller application shall only be used with written approval from the PCIHBV. Roller
application may be used only when:
• Pumps;
• Spraying is not feasible;
• Primer coat is applied by brush;
• Paint application by roller method is acceptable to paint manufacturer and is in

accordance with the application data.
9.4 Repairs and touch-up painting
9.4.1 General
CONTRACTOR shall submit, for approval by the PCIHBV, a procedure for the repair and/or
touch up painting of each generic coating system.
Before application of any further coat of material, all damages to previous coats shall be
repaired. All loose paint shall be removed to a firm edge. All surface irregularities and
contaminants shall be removed. Hard, glossy surfaces may require abrading to obtain a
suitable surface for painting.
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 25mm. 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 with 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.
9.4.2 Coating damage not exposing substrate surface
Surface to be overcoated which become contaminated or damaged shall be cleaned by

solvent cleaning and/or lightly brush blasted to ensure that the surface is free of all
contaminants. Contaminants shall be removed by dry compressed air and wipe by hand
with clean, dry rags. The coating around the damaged area shall be chamfered by sanding
to ensure continuity of the patch coating. The full coating system shall then be reapplied
strictly in accordance with this specification.
9.4.3 Coating damage exposing substrate surface
The damaged area shall be re-clean to the original or maintenance painting system specified
for that item and the full coating system reapplied in accordance with the application data.
The re-cleaning shall carry over onto tightly adhering surrounding coating for not less than
25 mm all around and the edges shall be chamfered by sanding to ensure continuity of the
patch coating.
9.4.4 Repair of zinc silicate primer
Damaged surfaces of zinc primer shall be cleaned to remove all loose materials and blast
cleaned with a portable vacuum blast cleaning unit. The surface shall be coated with one
coat of the primer which is the same as the damaged primer.
If blast cleaning is not practical, power tool cleaning may be used subject to PCIHBV’s
agreement. In such cases, subject to operating temperature limitations, one or two packs
re-coatable zinc primer may be used in lieu of zinc silicate primer subject to PCIHBV’s
agreement.
9.4.5 Repair of fully cured epoxy coating
In case of repairing damage to fully cured epoxy coatings and/or painting of a fully cured
and aged epoxy coating, the coating work shall only be carried out after the surface of the
fully cured epoxy to be coated has been suitably abraded to provide an adequate anchor for
the coating to be applied. The repair coating shall be compatible with the existing coating.
A test for compatibility is described in ASTM D 5064.
9.4.6 Inadequate coating thickness
Areas with inadequate coating thickness shall be thoroughly cleaned and if necessary
abraded and additional coats applied shall blend in with the final coating on adjoining areas.
9.4.7 Handling and shipping of coated items
Coated items shall be carefully handled to avoid damage to coated surface. No handling
shall be performed before the coating system is cured to an acceptable level. Packing,
handling and storage facilities shall be of non-metallic type.
10.0 PAINTING AND COATING SYSTEMS
10.1 Coating system selections
10.1.1 General
The coating systems generally acceptable for the intended service are listed in Section 10.2
for external application and Section 10.3 for internal application. Selection and acceptance
of coating systems and products for a specific and specialized application which are not
listed herein shall be the prerogative of PCIHBV in consultation with the respective Paint
Manufacturers.
The dry film thickness of the coating systems specified herein are minimum requirements to
achieve the desired system performance.
10.1.2 Organic and inorganic zing-filled coatings
The metallic zinc content in the zinc dust shall be minimum 94%.
Zinc content by percentage weight for inorganic zinc silicate and epoxy zinc should comply
with SSPC-Paint 20. (Zinc rich primer, Type I 'Inorganic ' and Type II 'Organic') requirement
or equivalent.
Any new formulation related to zinc coating shall be subjected to qualification testing stated
in this standard.
If shop primer (for temporary protection) is applied, then it must be 100% full blasted to the
requirement stated in section 8.0 prior to the application of the full coating system.
For secondary surface preparation for primed surface:
All zinc salt formation shall be sweep blasted. All other possible contaminants shall be
sanded down and solvent cleaned before top coating. For damages, welding joints and rusty
area, spot blast to Sa 2.5 followed by one coat of epoxy zinc rich or power tool cleaned to
St3 and followed by Surface Tolerant epoxy - subject to PCIHBV approval.
10.1.3 Selection and application of top coats
For areas to be applied with polyester glass flake, all shop primer shall be removed
completely, i.e. Sa 2.5.
Prior to top coating zinc rich primers, SSPC-PS Guide 8 shall be consulted to select
compatible topcoats. The selection process requires identification of the generic type of
primer, compatibility considerations, and selection of compatible topcoats.
The minimum volume solids for high solid epoxy shall be 75%. As an alternative, a surface
tolerant high solid epoxy paint can be applied.
When top coating inorganic zinc silicate primed surface a mist coat (wet to wet technique)
is required to eliminate pin holing
10.2 Painting and coating system schedules for external application
10.2.1 Carbon steel design temp. <110°C non insulated in atmospheric zone
(a) COATING SYSTEM NO. 1A: INITIAL PAINTING
Surface preparation : Blast Cleaning to ISO 8501-1: 1988, Sa 2.5
Coating system DFT

1st coat Inorganic Zinc Silicate / Epoxy Zinc Rich 75 µ
nd
2 coat High Solid epoxy 150 µ
rd
3 coat Aliphatic polyurethane 50 µ
Total 275 µ
(b) COATING SYSTEM NO 1B: MAINTENANCE PAINTING FOR BLAST CLEANED

SURFACE
Surface preparation : Blast Cleaning to ISO 8501-1: 1988, Sa 2.5
Coating system DFT

1st coat Epoxy Zinc Rich 75 µ
nd
2 coat High Solid Epoxy 150 µ
rd
3 coat Aliphatic Polyurethane 50 µ
Total 275 µ
(c) COATING SYSTEM NO 1C: MAINTENANCE PAINTING FOR POWER TOOL

CLEANED SURFACE
Surface preparation: Blast Cleaning to ISO 8501-1: 1988, St 3
Coating system DFT

1st coat Surface Tolerant HIGH SOLID Epoxy 125 µ
2nd coat Surface Tolerant HIGH SOLID Epoxy 125 µ
rd
Total 300 µ
10.2.2 Carbon steel design temp < 110°C insulated in atmospheric zone
Surface preparation: Blast cleaning to ISO 8501-1: 1988, Sa 2.5
Coating system DFT

1st coat Inorganic Zinc Silicate / Epoxy Zinc Rich 75 µ
nd
Total 225 µ
(b) COATING SYSTEM NO. 2B: MAINTENANCE PAINTING FOR BLAST CLEANED
SURFACE
Coating system DFT

1st coat Epoxy Zinc Rich 75 µ
nd
Total 225 µ
(c) COATING SYSTEM NO. 2C: MAINTENANCE PAINTING FOR POWER TOOL
CLEANED SURFACE
Surface preparation: Power tool cleaning to ISO 8501-1: 1988, St 3
Coating system DFT

1st coat Surface Tolerant High Solid Epoxy 125 µ
nd
2 coat Surface Tolerant High Solid Epoxy 125 µ
Total 250 µ
10.2.3 Carbon steel design temp >110°C (insulated and non-insulated) in the atmospheric zone
(a) COATING SYSTEM NO. 5A: INITIAL PAINTING AND MAINTENANCE PAINTING
i) Coating System No. 5A (1):Facilities with surface temperature 110 – 250°C Surface
preparation: Blast cleaning to ISO 8501-1: 1988, Sa 2.5
Coating system DFT

1st coat Inorganic Zinc Silicate 75 µ
nd
2 coat Modified Silicone Acrylics 30 µ
3rd coat Modified Silicone Acrylics 30 µ
Total 135 µ
ii) Coating System No. 5A (2): Facilities with surface temperature 250 - 450°C Surface
preparation: Blast cleaning to ISO 8501-1: 1988, Sa 2.5
Coating system DFT

1st coat Inorganic Zinc Silicate 75 µ
nd
2 coat Silicone Aluminium 25 µ
rd
Total 125 µ
Note
(1) Modified Silicone Acrylics and Silicone Aluminium shall be air-drying type.
(2) If the operating temperature is in different range/class than the design temperature,
then the selection of the coating system shall be considered on a case by case
basis.
(b) COATING SYSTEM NO. 5B: MAINTENANCE PAINTING POWER TOOL

CLEANED SURFACE
i) Coating System No. 5B (1): Facilities with surface temperature 110 - 250°C
Surface preparation: Power tool cleaning to ISO 8501-1: 1988, St 3.
Coating system DFT

1st coat Zinc Graphite 40 µ
2nd coat Modified Silicone Acrylics 30 µ
rd
3 coat Modified Silicone Acrylics 30 µ
Total 100 µ
ii) Coating System No. 5B (2): Facilities with surface temperature 250 - 450°C
Surface preparation: Power tool cleaning to ISO 8501-1: 1988, St 3
Coating system DFT

1st coat Zinc graphite 40 µ
nd
2 coat Silicone aluminium 25 µ
rd
3 coat Silicone aluminium 25 µ
Total 90 µ
NOTE
(1) For isolated / spot touch up maintenance painting only.
(2) Modified Silicone Acrylics and Silicone Aluminium shall be air-drying type.
10.2.4 Galvanised steel
Surface preparation: Degrease as SSPC-SP1 and wash with fresh clean water, light
abrade or sweep blast surface to provide anchor pattern of 25µ.
Coating system DFT

st
1 coat Surface Tolerant High Solid Epoxy 125 µ
nd
Total 175 µ
NOTE
(1) Hot dip galvanizing shall be carried out in accordance with the requirements of BS
729: "Hot dipped galvanized coatings on iron and steel articles". A minimum of 610
gm/m2 (DFT 86 m) of zinc shall be applied. Maintenance of galvanized steel shall
be treated as carbon steel as per this section 10.2.
10.2.5 Stainless steel
(a) COATING SYSTEM NO. 7A: INITIAL PAINTING AND MAINTENANCE PAINTING
(i) Coating System No. 7A (1) (Non-insulated facilities operating < 110°C)
Surface preparation: Sweep blast with dry, non-iron containing grit or roughen surface with
emery paper to provide an anchor profile.
Coating system DFT

1st coat High Solid Epoxy (Refer to Note 1 below) 125 µ
nd
Total 175 µ
(ii) Coating System No. 7A (2) Insulated facilities operating < 110°C
Surface preparation: Sweep blast with dry, non-iron containing grit /roughen surface with
emery paper to provide an anchor profile.
Coating system DFT

1st coat High Solid Epoxy (Refer to Note 1 below) 125 µ
Total 125 µ
(iii) Coating System No. 7A (3) Insulated and non-insulated facilities operating 110 - 600°C
Surface preparation: Sweep blast with dry, non-iron containing grit to create an anchor
profile.
Coating system DFT

1st coat Silicone Aluminium 25 µ
nd
Total 50 µ
NOTE
(1)
High solid epoxy should be non-inhibitive and non-metallic pigmented
(b) PAINTING GUIDE FOR STAINLESS STEEL
Table below can be used as a guideline to select painting system for Stainless Steels.
Temp Range Martensitic/Ferritic Austenitic Duplex/Super Remarks

Duplex
110°C up to Coating System Coating System Coating System Insulated &
600°C # 7A(3) # 7A(3) # 7A (3) non insulated
Coating System Coating System Coating System Insulated
Up to 110°C # 7A (2) # 7A (2) # 7A (2)
Coating System Coating System No Painting Non-insulated
# 7A (1) # 7A (1)
10.2.6 Carbon Steel Storage Tank
Selection of initial painting systems for carbon steel storage tanks shall be made based on
specific requirements of the relevant sections 10.2.1 through to 10.2.5.
(b) COATING SYSTEM NO. 8B: INITIAL AND MAINTENANCE PAINTING FOR
UNDERSIDE OF BOTTOM PLATE (ONLY IF PAINTING IS REQUIRED FOR
CORROSION PROTECTION TO SUPPLEMENT CATHODIC PROTECTION)
Coating system DFT

1st coat Epoxy Zinc 75 µ
nd
2 coat Coal Tar Epoxy 300 µ
Total 375 µ
(c) COATING SYSTEM NO. 8C: SHELL & ROOF PLATE, STAIRWAYS, STAIR TREADS,
GANGWAYS AND OTHERS EXTERNAL PARTS INCLUDE THE PIPING (NON
GALVANIZED)
The maintenance painting scheme shall follow that for carbon steel design temperature at
< 110 °C.
The recommended Tank identification system is given in Appendix 1.

10.2.7 LPG Bullet Tank
(a) COATING SYSTEM NO. 9A : INITIAL PAINTING
Surface preparation: Blast cleaning to ISO 8501-1: 1988, Sa2.5
Coating system DFT

1st coat Glass Fibre Reinforced Bitumen 3000 µ
2nd coat Glass Fibre Reinforced Bitumen 3000 µ
Total 6000 µ
(b) COATING SYSTEM NO. 9B : INITIAL PAINTING
Surface preparation: Blast cleaning to ISO 8501-1: 1988, Sa2.5
Coating system DFT

1st coat Epoxy or Urethane 400 µ
nd
2 coat Epoxy or Urethane 400 µ
Total 800 µ
10.2.8 Coating system no.10 markings
Surface preparation: Degrease and wash with clean fresh water. Abrade surface to provide
another pattern.
Coating system DFT

Marking : Aliphatic polyurethane 50 µ
Total 50 µ
The recommended piping identification system and legend are given in Appendix 2 and 3,
respectively.
10.2.9 Coating System No 12: Fire Barriers / Passive Fire Protection (PFP) System
Fire Barriers / Passive Fire Protection (PFP) System shall be as per Appendix 5.
10.3 Painting and coating system schedules for internal application
10.3.1 Fuel Gas (Sweet & Sour)
(a) COATING SYSTEM NO.13A: INITIAL PAINTING, MAINTENANCE

PAINTING FOR BLAST CLEANED SURFACE AND POWER TOOL CLEANED
SURFACE.
Surface preparation: Blast cleaning to ISO 8501-1: 1988, Sa 2.5, Power cleaning to ISO
8501-1: 1988, St 3 for minor painting.
Surface to be painted: All over
Service Temperature: Up to 60°C
Coating system DFT

1st coat Amine Adduct Epoxy 125 µ
2nd coat Amine Adduct Epoxy 125 µ
Total 250 µ
10.3.2 Crude/Condensate (Sweet & Sour), Emulsion/Slop
(a) COATING SYSTEM NO. 14A: INITIAL PAINTING, MAINTENANCE PAINTING

FOR BLAST CLEANED SURFACE AND POWER TOOL CLEANED SURFACE
(i) Coating System No. 14a (1): Roof and Shell plate
Surface preparation: Blast cleaning to ISO 8501-1: 1988, Sa 2.5, Power tool cleaning to
ISO 8501-1: 1988, St 3 for minor touch-up painting
Coating system DFT

Total 250 µ
NOTE
1. Floating roof tank shell plates which are subjected to excessive abrasion and wear
shall be uncoated. However, if the PCIHBV considers otherwise, suitable coating
systems may be specified.
(ii) Coating System No. 14A (2): Bottom plate and Vessels
Surface preparation: Blast cleaning to ISO 8501-1: 1988, Sa 2.5, Power tool cleaning to
ISO 8501-1: 1988, St 3 for minor touch-up painting
Service Temperature : Up to 60°C
Coating system DFT

3rd coat Amine Adduct Epoxy 100 µ
Total 300 µ
(iii) Coating System No. 14A (3): Alternative system for Bottom Plate

Surface to be painted: Bottom plate
Coating system DFT

1st coat Epoxy Primer 50 µ
2nd coat Epoxy Glassflake 200 µ
3rd coat Epoxy Glassflake 200 µ
Total 450 µ
10.3.3 Light Naphtha, Heavy Naphtha, Treated Naphtha, Reformate, Jet A-1 Fuel, Lube Oil, Fuel
Oil, Gasoline (Unleaded), Gasoline (Leaded)

Surface preparation: Blast cleaning to ISO 8501-1: 1988, Sa 2.5, or Power tool cleaning
to ISO 8501-1: 1988, St 3 for minor painting.
Surface to be painted : All over
Coating system DFT

Total 250 µ
10.3.4 Diesel

Surface preparation: Blast cleaning to ISO 8501-1: 1988, Sa 2.5, or Power tool cleaning to
ISO 8501-1: 1988, St 3 for minor painting.
Surface to be painted : Roof and Shell plate
Coating system DFT

Total 250 µ
NOTE
(1)
Floating roof tank shell plates which are subjected to excessive abrasion and
wear shall be uncoated. However, if the PCIHBV considers otherwise, suitable
coating systems may be specified.
(b) COATING SYSTEM NO. 16B: INITIAL PAINTING, MAINTENANCE PAINTING

ISO 8501-1: 1988, St 3 for minor painting
Surface to be painted: Bottom plate and Vessels
Coating system DFT

rd
3 coat Epoxy Glassflake 200 µ
Total 450 µ
(c) COATING SYSTEM NO. 16C: ALTERNATIVE SYSTEM FOR BOTTOM PLATE
Surface preparation: Blast cleaning to ISO 8501-1: 1988, Sa 2.5,
Surface to be painted: Bottom plate and Vessels
Service Temperature: Up to 60 °C
Coating system DFT

3rd coat Epoxy Glassflake 200 µ
Total 450 µ
10.3.5 Potable (Drinking / Aerated / Non-Aerated) Water, Sea Water (Aerated / Non-Aerated),
Produced Water, Brackish, Demineralised Water, Brine

ISO 8501-1: 1988, St 3, or Sweep blast with dry, non-iron containing grit to create an anchor
profile.
Surface to be painted: All over and applicable for stainless steel tank

Coating system DFT
Total 250 µ
NOTE:
(1)
Coating system applied for potable water system shall be accompanied with a
Health certificate.
10.3.6 Steam (Condensate), Boiler Feed

Coating system DFT

1st coat Phenolic Epoxy 150 µ
2nd coat Phenolic Epoxy 150 µ
Total 300 µ
10.3.7 Utility Air
(a) COATING SYSTEM NO. 19A: INITIAL PAINTING, MAINTENANCE PAINTING FOR
BLAST CLEANED SURFACE AND POWER TOOL CLEANED SURFACE
Surface preparation: Blast cleaning to ISO 8501-1: 1988, Sa 2.5, or power tool cleaning to
(b) COATING SYSTEM NO. 19B: ALTERNATIVE SYSTEM

Coating system DFT

1st coat Polyester Glassflake 400 µ
or
Epoxy Glassflake 400 µ
Total 400 µ
(c) COATING SYSTEM NO. 19C: INITIAL PAINTING, MAINTENANCE PAINTING

Service Temperature: More than 60°C
Coating system DFT

1st coat Phenolic Epoxy 125 µ
2nd coat Phenolic Epoxy 125 µ
Total 250 µ
(d) COATING SYSTEM NO. 19D: ALTERNATIVE SYSTEM
Surface preparation: Blast cleaning to ISO 8501-1:1988, Sa 2.5
Coating system DFT

1st coat Vinyl Ester Glassflake 125 µ
Total 250 µ
10.3.8 Common inhibitors, Demulsifier, oxygen scavenger

Surface preparation: Blast cleaning to ISO 8501-1:1988, Sa 2.5, or Power too cleaning to
ISO 8501-1:1988, St 3 for minor painting

Coating system DFT

1st coat Vinyl Ester Glassflake 800-1500 µ
2nd coat Vinyl Ester Glassflake 800-1500 µ
Total 1600-3000 µ
10.3.9 10.3.9 Methanol & Percroethalyne

Coating system DFT

1st coat Epoxy Phenolic 125 µ
2nd coat Epoxy Phenolic 125 µ
Total 250 µ
Surface to be painted : All over
pH: 6-9
Coating system DFT

1st coat Inorganic Zinc Silicate 75-100 µ
Total 75-100 µ
10.3.10 Triethylene Glycol / Methylethylene Glycol

ISO 8501-1: 1988, St 3 for minor touch-up painting.

Coating system DFT

Total 250 µ
ISO 8501-1: 1988, St 3 for minor painting
Coating system DFT

Total 800-1000 µ
(c) COATING SYSTEM NO. 22C: INITIAL PAINTING, MAINTENANCE PAINTING

FOR BLAST CLEANED SURFACE AND POWER TOOLCLEANED SURFACE
Service Temperature: Up to 60 °C
Coating system DFT

Total 800-1000 µ
10.3.11 Chemicals (others)
(a) ACIDS & ALKALIS, AMMONIA, CAUSTIC SODA, BIOCIDE, CHLORINE,

DESCALERS
In the event that there are large variations in the description of chemical cargo; the
CONTRACTOR shall consult the Paint Manufacturers for the selection of the most
appropriate coating system to be applied. Typical information to be furnished by the
CONTRACTOR shall include:
 Chemical action (concentration, pH, impurities or contaminants, chemical

reactions, etc.);
 Temperature (maximum, minimum, and operating, cycle e.g. steam out

condition);
 Pressure (maximum, minimum, and operating, cycle);
 Environmental conditions (outside, inside, climate, accessibility);
 Possibility of different cargo.
The tank internals e.g. attachments, etc. shall be coated with the same respective coating
system.
10.4 Paint materials storage, shelf-life and handling
10.4.1 Storage
All containers containing paint materials shall be stored under cover giving protection from
direct sunlight and rain at a temperature below 35°C. The storage condition should also
allow for adequate ventilation to minimise paint container deterioration from humidity.
Materials should be systematically stored after delivery so that a First-In-First-Out (FIFO)
withdrawal procedure can be adopted.
10.4.2 Shelf-life
The shelf-life quoted on product data sheets is generally a conservative value which takes
into account the variable storage conditions encountered; and it is probable that paints can
be applied without any compromise on its performance after the shelf life period has
elapsed. However, if the quoted shelf-life period has been exceeded, it is recommended
that the usability of the product shall be checked by the Manufacturer and notified to
PCIHBV. The procedure described in ASTM D 869 shall be used to evaluate degree of
settling of paint.
Paint which has liveried, gelled, or otherwise deteriorated during storage shall not be used.
10.4.3 Handling
Many of the paints used in the oil and gas industry are heavy duty protective coatings
supplied in 5 to 20 litres containers. Because of the weight of the containers, care must be
taken in handling to avoid injury to the individual and damage to equipment. Palletised
materials with mechanical handling should be used whenever possible.
When handling, damage can occur to the container and in severe cases leaks or spills of
the paint may result. Damage to any container should be avoided to maximize storage and
shelf-life of the paint.
10.5 Coating system product approval requirement
New coating products, upgrading of existing product or formulation changes of approved

coating products shall be submitted for a full laboratory screening before the product can be
considered as an approved product.
Complete coating systems shall be tested and qualified in accordance with the procedures
described in QP-CS1: Procedure for Qualification and Testing of Coating Systems.
10.5.1 Test panels
One (1) set of test panels shall be prepared for each generic coating system as per the
various ASTM test requirements depending on the types of tests to be carried out.
The test panels shall be prepared in the field, for example in a coastal fabrication yard, to
simulate field application condition where adverse climatic conditions may prevail. Each test
panel shall be surface cleaned and coated to the' requirement as prescribed in this
specification.
All test panels should be kept indoors for a period of seven (7) days for curing before any
testing.
10.5.2 Product QA/QC report
Paint Manufacturers shall submit QA/QC reports on the coating systems that passed the
laboratory screening tests. The QA/QC reports must have the following information:
 Drying time;
 Hold up property;
 Glossiness;
 Specific gravity;
 Viscosity.
Paint Manufacturers shall maintain that the properties of their coating systems selected for
actual painting work will be the same as the ones that passed the laboratory screening tests.
In this regard and if deemed necessary, paint manufacturers in consultation with the
PCIHBV, may be required to send their paint batches to the approved third party testing
agency to verify conformance to the QA/QC report stated herein.
Whenever considered deemed necessary, PCIHBV may carry out a non-conformance audit
on the paint manufacturers.
10.5.3 Paint quality control batch certificate
Paint manufacturers shall furnish their Paint Quality Control Batch certificates to ensure that
the properties of the products supplied are consistent with the laboratory tested products.
As a minimum, the following information shall be provided:
 Manufacturer's name;
 Factory location;
 Date of manufacture;
 Batch number;
 Product name;
 Generic name;
 Key composition/components description :
 Resin;
 Pigments;
 Curing Agent (generic name);
 Solvent (generic name);
 QC Test Results including Test Standard, Pass Criteria, Actual Results;
 Colour;
 Viscosity;
 Density/S.G.;
 Fineness;
 Drying Time;
 Hiding Power;
 Gloss.
11.0 QUALITY CONTROL (QC)
11.1 Inspection
Compliance to this specification shall be controlled through inspection of each phase of a

painting programme. Inspection is required during all phases of surface preparation and
coating application.
11.2 Project production testing
The purpose of project production testing is to check and verify the CONTRACTOR’s
compliance and to demonstrate that the painting procedures, equipment and craftsmanship
satisfy this specification and meet paint manufacturer requirement.
The production testing shall be conducted after the CONTRACTOR have selected the
coating systems. The production testing shall not be used by the CONTRACTOR to qualify
coating systems.
All observations, data and test results of the production trial shall be documented in pre-
approved agreed format; which shall include information such as painting contractor, type
of cleaning and surface standards, generic coating materials, manufacturers and product
brand names, batch number, blasting/painting environmental conditions, test results, etc.
The following tests shall be conducted by CONTRACTOR and witnessed by PCIHBV's

representative and/or Paint Vendors:
 Visual Inspection shall be carried out on each individual coat and completed coating
system listing the appearance of the coating. The coating shall be free of run
pinholes, cracking, blistering, sagging, crater, dry spray and over spray;
 Surface profile height shall be spot checked and documented using an approved
surface profile gauge (e.g. Elcometer 123);
 Film thickness measurement for both WFT and DFT shall be conducted during all
coating application sequences (i.e. individual coats and specified total dry film
thickness). WFT and DFT measurement shall comply with ASTM D4414 and SSPC-
PA2, respectively;
 Adhesion Test shall be performed on a flat surface in accordance with ASTM D4541
Standard test method for pull-off strength of coating using hydraulic adhesion tester
for coating total DFT above 200 microns. Adhesion test on final coat or complete
coating system shall be conducted after curing for a minimum of seven (7) days.
Degree of curing for Inorganic Zinc coatings shall be determined using the method
described in ASTM D4752. The recommended minimum "pull-off' value for
glassflake coating system is 500 psi and all other coating systems, shall be minimum
300 psi;
 For coating DFT less than 200 microns (mainly reference to single pack coatings),
power tool cleaned surface (maintenance system) galvanized steel, aluminium &
stainless steel, the X-cut technique, and the use of pressure sensitive adhesive
tapes to the cut surface shall be used. The X-cut test shall be carried in accordance
to ASTM D3359 Method A Standard test method for measuring adhesion by tape
test.
All areas of coating that have been damaged due to the destructive test shall be repaired
immediately.
12.0 HEALTH, SAFETY AND ENVIRONMENT (HSE)
Everyone working in this project shall adhere to local and statutory regulations. Paint
manufacturers Safety Data Sheets will be available and instructions for handling and storage
will be followed. Fire extinguishers will be placed in accessible locations close to the storage,
application and mixing areas.
12.1 Safety and health regulations
PCIHBV shall have a stake in ensuring that contractors employed have the capability to
comply with health and safety regulations, and that hazardous operations in the protective
coatings industry are recognized such as:
 Materials
 Fire Hazards and Explosions

 Health Hazards
 Materials
 Paint Application;
 Surface Preparation;
 Access and Rigging;
 Ladders;
 Fall Hazards;
 Confined Spaces.
 Equipment Grounding
CONTRACTOR shall submit and has full responsibility for maintaining a proper and
sufficient safety loss and prevention programme covering the work and covering the
employees.
CONTRACTOR shall implement HSE Compliance Programme for securing the safety,
health and welfare of persons at work, for protecting others against risks to safety or health
in connection with the activities of persons at work.
The components of the HSE Compliance Programme shall include:
 Policy statement establishing goals and commitment of management and the means
for communicating these to all employees;
 Delegation of responsibilities for implementing the programme;
 Methods for identifying hazards and hazardous activities and for controlling tem;
 Commitment to ongoing training and education for all supervisors and employees on
all aspects of job safety and health;
 Proper reporting and record keeping, and investigation of all accidents, injuries and
illness;
 Methods and procedures for complying with specific local regulation and
international standards;
 Periodic review of the programme with revisions made as necessary.
12.2 Environmental regulations
Painting and coating activities have a significant effect on the environment. Some examples
of these activities and their specific effects are:
➢ Abrasive Blast Cleaning
Significant quantities of dust from the abrasive and the surface debris are made
airborne and can contribute to air pollution. This dust is recognized as a fugitive
emission that is often regulated. Control of dust generation shall be in compliance
with the local regulations.
➢ Paint Application
In the process of spraying, a substantial portion of the liquid coating does not reach
the substrate but is lost due to overspray. In addition, most coatings have appreciable
quantities of volatile organic compounds (VOC) that can contribute to smug
formation. VOC level shall not exceed the maximum allowable level accordance to
Iraqi Air Quality Standard maximum allowable emission limits
➢ Waste
Both coating removal and coating application generate waste products, which must
be properly disposed of. In many instances, the waste may be classified as
hazardous by the local regulations because of the heavy metal (e.g. lead) content of
the residue, or the solvents of unused paint or thinner.
The control of Scheduled Wastes shall be in compliance with local regulations.

➢ Product Storage
The storage of certain products which might have the potential ecological damage
that could result from a spill or leak from storage vessels shall be in compliance with
local regulations.
➢ Leaching of Coatings
Under certain circumstances, toxic or otherwise undesirable components of applied
coating films may leach into the environment.
The above activities collectively can affect almost all the major environmental
receptors i.e. air, soil, groundwater, surface water, potable water.
Contractors hired to remove hazardous paint shall be qualified in accordance with

the procedures described in SSPC-QP 2(1). The qualification process shall evaluate
four (4) functions:
 Management of Hazardous Paint Removal;
 Technical Capabilities;
 Qualification of Personnel; and
 Safety and Health.
13.0 COLOUR SCHEMES
13.1 Colour scheme for onshore installation
Colour scheme for Onshore Installation is as per Appendix 4.
Where applicable, colour schemes shall be in accordance with local statutory rules and
regulations and customs specific to the PCIHBV individual requirements.
If an intermediate coat has to be applied, it should be applied a shade lighter than the top
coat in order to increase the inspectability.
13.2 Colour identification for storage tank
Colour identification should be painted on a square (1m x 1m) 2 at the tank shell in position
which is easily visible. The colour scheme shall be specific to the PCIHBV's individual
requirements.
For easy reference, the product contents and the tank number should be worded above the
colour identification square box. The size of the lettering and the location is described in
Appendix 1.
13.3 Identification piping system
Identification may be accomplished by stenciling, the use of tape or markers. In any

situations, the detail dimensions, number and location of identification markers shall be
based on the particular piping system as specified in Appendix 2 and 3.
For other systems not described in Appendix 2 and 3, the PCIHBV shall determine them as
appropriate based on ANSI 13.1 - Scheme for identification of Piping System.
13.4 Safety colours
Where appropriate for safety reasons, the following colour scheme shall be adopted.
Items Colour Scheme BS 4800
Black and OSHA Yellow (in

Dangerous obstructions 00-E-53 / -
alternate bands)
Dangerous or exposed parts of
OSHA Orange -
machinery
Fire Equipment and services OSHA Red -
First Aid equipment OSHA Green -
14.0 APPENDICES
Appendix 1: Storage Tank Identification
Appendix 2: Piping Identification System
Appendix 3: Piping Colour Identification Legend
Appendix 4: Colour Scheme for Onshore Installation & Equipment.
Appendix 5: Specification for Intumescent Coatings

Specification for External Surface Preparation & Painting
APPENDIX A
STORAGE TANK IDENTIFICATION SYSTEM

APPENDIX A - STORAGE TANK IDENTIFICATION SYSTEM

APPENDIX B
PIPING IDENTIFICATION SYSTEM

APPENDIX B - PIPING IDENTIFICATION SYSTEM
IDENTIFICATION LEGEND FLOW DIRECTION

TYPE PIPE O.D. ARROW
A B C D E
1 0.75 - 1.25 0.5 0.75 8.00 0.75 4.00
2 1.50 - 2.00 0.75 1.00 8.00 1.00 5.00

3 2.50 - 6.00 1.25 2.25 12.00 2.25 8.00
4 8.00 - 2.25 4.00 24.00 4.00 12.00
10.00
5 Over 10.00 3.75 5.00 32.00 5.00 16.00
APPENDIX C
PIPING COLOUR IDENTIFICATION LEGEND

APPENDIX C - PIPING COLOUR IDENTIFICATION LEGEND
PIPING COLOUR IDENTIFICATION LEGEND
PROCESS LINE
Gas Gas Squirrel Gray / Tideway 18 B 21
Liquid Liquid Squirrel Gray / Tideway 18 B 21
Process Process Squirrel Gray / Tideway 18 B 21
DRAIN & RELIEF
Drain, Hot Oil Hot oil drain Squirrel Gray / Tideway 18 B 21
Drain, Pressurised Pressurised, drain Squirrel Gray / Tideway 18 B 21
Drain, Gravity Hazard, drain Squirrel Gray / Tideway 18 B 21
Condensate Drain Cond. Drain Squirrel Gray / Tideway 18 B 21
Flare, High Press. HP flare Squirrel Gray / Tideway 18 B 21
Flare, Low Press. LP flare Squirrel Gray / Tideway 18 B 21
Vent Vent Squirrel Gray / Tideway 18 B 21
Vent, Atmospheric Atmosphere vent Squirrel Gray / Tideway 18 B 21
Flare and other stacks Squirrel Gray / Tideway 18 B 21
STEAM & CONDENSATE
Condensate Condensate Squirrel Gray / Tideway 18 B 21
Steam Steam Squirrel Gray / Tideway 18 B 21
Boiler Feed Water Boiler H2O Squirrel Gray / Tideway 18 B 21
UTILITY WATER
Cooling Water Cooling H2O Squirrel Gray / Tideway 18 B 21
Firewater/ Fire Fire H2O Poppy / Carnival Red 04 E 53
Extinguishing
Potable Water/ Service Potable H2O Squirrel Gray / Tideway 18 B 21
Water
Ballast Water Sea Water Service H2O Squirrel Gray / Tideway 18 B 21
Washdown
Chilled Water Chilled H2O Squirrel Gray / Tideway 18 B 21
PIPING COLOUR IDENTIFICATION LEGEND (CONT.)
UTILITY& GENERAL
air, instrument inst. air Squirrel Gray / Tideway 18 B 21
air, utility utility air Squirrel Gray / Tideway 18 B 21
gas, instrument inst. gas Squirrel Gray / Tideway 18 B 21
gas, utility utility gas Squirrel Gray / Tideway 18 B 21
hydraulic hydraulic Squirrel Gray / Tideway 18 B 21
UTILITY GAS & FUEL
BLANKET gas blanket gas Squirrel Gray / Tideway 18 B 21
diesel fuel diesel fuel Squirrel Gray / Tideway 18 B 21
aviation fuel aviation fuel Squirrel Gray / Tideway 18 B 21
fuel gas fuel gas Squirrel Gray / Tideway 18 B 21
nitrogen nitrogen Squirrel Gray / Tideway 18 B 21
UTILITY OIL
lube oil lube oil Squirrel Gray / Tideway 18 B 21
seal oil seal oil Squirrel Gray / Tideway 18 B 21
hot oil hot oil Squirrel Gray / Tideway 18 B 21
CAUSTIC & CHEMICAL
chemical chemical Squirrel Gray / Tideway 18 B 21
glycol glycol Squirrel Gray / Tideway 18 B 21
caustic caustic Squirrel Gray / Tideway 18 B 21
chlorine chlorine Squirrel Gray / Tideway 18 B 21
GENERAL
treated water treated H2O Squirrel Gray / Tideway 18 B 21
black water black H2O Squirrel Gray / Tideway 18 B 21
grey water grey H2O Squirrel Gray / Tideway 18 B 21
hot water hot H2O Squirrel Gray / Tideway 18 B 21
OTHERS
to be determined by PCIHBV
APPENDIX D
COLOUR SCHEME FOR ONSHORE INSTALLATION & EQUIPMENT

APPENDIX D - COLOUR SCHEME FOR ONSHORE INSTALLATION & EQUIPMENT
No. ITEM COLOR BS 4800 CODE

Tanks (except U/G), Vessels,
1 Warm (light) Gray 18 B 21
Towers
Machine
2 Machinery manufacturer’s ---
Standard Paint
3 Structural, Skids Warm (light) Gray 18 B 21
Process Gas Piping (Including

4 inlet Sales, Multi-Phase Gas Warm (light) Gray 18 B 21
Streams)
5 Fuel and Instrument Gas Piping Warm (light) Gray 18 B 21
Process hydro-Carbon Liquid

6 Warm (light) Gray 18 B 21
Piping (
7 Instrument Air Warm (light) Gray 18 B 21
8 Drain, Flare, Relief Piping Warm (light) Gray 18 B 21
9 Fire and emergency Accent Red 04 E 53
10 Water (Except Firewater) Warm (light) Gray 18 B 21
Orange / White In 20-J-8 Color, But

11 Flare and Other Stacks
alternate 37 Series
APPENDIX E
SPECIFICATION FOR INTUMESCENT COATINGS

APPENDIX E - SPECIFICTION FOR INTUMESCENT COATING
1.0 MATERIAL SELECTION
1.1 General
Intumescent coatings are selected for fire proof applications. HC (Hydrocarbon) pool fire is
the only fire scenario expected on this project. The materials selection given in this appendix
covers passive fire protection in HC pool fire scenario.
Each type of fireproofing system uses a different combination of materials with various
physical and chemical properties. These properties shall be taken into consideration so that
the system selected is appropriate for its intended application. Where fireproofing coatings
are applied directly to steel, Vendor’s recommendations for primers, applications and
thickness shall be strictly followed.
1.2 Classify the Fire Types
In general, there are two types of fire scenarios:
a. HC Pool Fire Scenario
b. Jet Fire Scenario
1.3 HC Pool Fire Definitions
Hydrocarbon pool fires are defined as “a buoyant diffusion HC flame in which the fuel (HC)
is configured horizontally.” HC pools do not have a flame impingement effect, however, the
temperatures may eventually rise enough to cause failure of the material / structure.
1.4 Types of Fire Protection
There are mainly two types of fire protection:
1. Active Fire Protection; this covers protection via fire extinguishers, water deluge
systems, water sprinklers, etc.
2. Passive Fire Protection; the fireproofing system has no effect and remains passive
until a fire starts.
Passive fire protection can further be divided into two types:
 Passive-Passive Fire Protection
The fireproofing material remains passive before and after the fire starts and it does
not directly react to fire (no char production, etc.).
 Active-Passive Fire Protection
The fireproofing material remains passive until the fire starts. However, when there
is a fire scenario, the fireproofing material starts reacting, intumesces (increases in
volume in certain products) and may form a char further providing insulation.
1.5 Materials Selection Basis
The following factors shall be taken into consideration and form the basis of materials
selection for fireproofing systems:
▪ Specific Weight (density); the weight limitations imposed by the strength of the steel
supports for the assembly to be fireproofed. Design review shall ensure that the
assembly can support the additional weight of fireproofing at the temperature reached
during fire exposure, while the metal strength is reduced.
▪ The fire resistance rating (in hours) selected.
▪ Resistance to thermal diffusivity.
▪ Weatherability and chemical tolerance.
▪ Bonding strength; The material’s adhesion strength and durability. Specific surface
preparation and /or support structures are specified for rated systems. Manufacturer’s
specifications shall be followed exactly to assure the installed system is the equivalent
of the tested system.
▪ Protection from corrosion
▪ Hardness and impact resistance
▪ Vibration resistance and compressive, tensile and flexural strength
▪ Coefficient of expansion
▪ Vapour permeability and porosity
▪ Cost and maintenance
▪ Fireproofing materials shall not contain any Asbestos material.
1.6 Fireproof Materials Selection
1.6.1 Critical Core Temperature (CCT)
Critical Core Temperature (CCT) is defined as “the temperature at which steel loses half its
tensile-yield strength.”
Critical Core Temperature shall be detailed define for the Project. For general guidance (To
be confirmed by CONTRACTOR) the following are given:
i. Structural Steel (non-load bearing) 410⁰C.
ii. Structural Steel (load bearing) 370⁰C
iii. Pressurised Equipment 315⁰C
1.7 Recommended Fireproofing Products
The various major products that are recommended have been given in the table below. Any
product selected shall be thoroughly reviewed technically in-line with the passive fire
proofing requirements for the project and submitted for PCIHBV‟s approval. Other
equivalent materials may also be considered subject to PCIHBV approval.
Product Type of Fireproofing Material VENDOR

Pitt-Char XP Intumescent Epoxy PPG Industries
Chartek 1709 Intumescent Epoxy AkzoNobel / International
NanoChar Intumescent Epoxy IAG, USA
Table 1: Fireproofing Products
1.7.1 Intumescent Epoxy
Type and Dry Film Thickness of the primer shall be approved by PFP Manufacturer/Supplier.
The adhesion of the primer shall NOT in any case be less than 10 MPa measured with
hydraulic Pull-off Adhesion Tester (PAT) instrument in accordance with standard ISO 4624.
As a guide the primer systems to be used under Epoxy PFP products shall conform to the
list below:
Primer System Dry Film Thickness

Normal Areas Overlap Areas
Epoxy primer: 50 to 75 microns (2-3 mils) 100 microns (4 mils)
Carbon steel substrate
Epoxy primer: 35 to 50 microns (1.4-2 mils) 75 microns (3 mils)
Stainless steel substrate
Epoxy Zinc Primer 50 to 75 microns (2-3 mils) 100 microns (4 mils)
Epoxy Zinc Primer plus tie coat 75 to 110 microns (3-4.4 mils) 120 microns (5 mils)
Table 2: Epoxy Paint DFT
Epoxy tie coat (25 to 35 microns (1 to 1.4 mils) DFT) should be used with zinc primers if
Epoxy PFP is not applied immediately after the primer has cured or if the primer is exposed
to humid or outdoor conditions prior to application of the PFP system.
“Overlap areas” refers to internal angles of structural sections and other areas where
multiple spray passes are unavoidable. DFT‟s may be exceeded in stripe coat areas.
1.7.2 Primers
To prevent flash rusting or contamination of blasted surface, immediately after blasting the
surfaces shall be primed with the PFP Manufacturer / Supplier approved primer.
Where a zinc rich primer is used, a tie-coat shall be used to minimise the potential for zinc
salt formation. The Applicator (approved & certified by the Manufacturer / Supplier) must
follow the primer manufacturer’s written application instructions regarding ambient
conditions, storage, mixing, application method and overcoating times. The primer system
shall be fully cured prior to application of epoxy intumescent PFP system.
Over thickness application of the primer can seriously compromise the bond strength of the
system and cause failures that may not become apparent until tested under fire load
conditions. Over-thickness of primer will not be accepted by the project and areas shall be
re-blasted and correctly primed at the primer Applicator’s own expense. PFP system
Manufacturer’s / Supplier’s must specify maximum allowable primer dry film thicknesses
(DFT). PFP system Manufacturer’s / Supplier’s must specify primer type suitable for the
operating temperature range of the item to be coated. QA/QC documentation for the primer
system shall consist of primer manufacturer, product name, type, batch numbers,
certificates of conformity, and record of applied thickness for each element recorded on a
daily basis.
1.7.3 Mesh Reinforcements
In order to assure that the char formed during fire exposure remains in place to insulate the
substrate, carbon and glass fiber mesh reinforcement shall be installed during PFP
application.
As general rule mesh reinforcement shall be installed at mid-depth of PFP thickness. PFP
thickness shall be fully in accordance with the certified design class of surface to protect.
The average measured PFP thickness shall be within the following tolerance range of the
specified design thickness: -0mm/+2mm.
Coat back of the PFP system shall be applied to a minimum distance of 450mm on all
secondary members that exceed 3,000mm2 in area at the joint with a primary member.
Under all conditions, surface preparation, primers/substrates and topcoats are subject to
acceptance by the manufacturer of sprayed on PFP coating.
The PFP shall be applied in accordance with the recommendations and instructions given
in the application manual published by Manufacturer/Supplier and approved by PIL,
including but not limited to mixing, equipment, application method, curing and inspection,
method for measuring wet and dry thickness, repair.
The Applicator chosen shall be certified by the Manufacturer/Supplier of the Epoxy PFP.
After the PFP coating material has cured, and before application of topcoat, the thickness
of the coating shall be checked. Holes shall be drilled down to the substrate on a spot check
basis to measure that the thickness is correct. The holes shall be marked and filled with
fresh material immediately after the readings.
Ultrasonic techniques such as Elcometer probes may be used where feasible as an

alternative to verify the coating thickness. On horizontal surfaces and cavities, adequate
water drainage shall be ensured. Areas, which are difficult to access for spraying of passive
fire protective coating, shall to the extent possible, be boxed in before the passive fire
protective coating is applied. Adequate water shedding shall be arranged for.
1.7.4 Welding of Pins & Fixings
No welding of pins, or other fixings, for securing of mesh or support of PFP systems shall
be allowed on process equipment unless specifically authorized in writing beforehand by
PCIHBV.
The PFP system Applicator shall utilize systems and designs that avoid the need for welding
of pins or fixings.
1.7.5 Additional Requirements
PFP system shall be applied monolithically where practical. The designer shall consider
appropriate PFP block-outs for assembly and for expected attachments. Where welding of
fixtures to the surfaces after the application of the PFP is required, the materials and
procedures used shall be approved by PCIHBV.
The proprietary PFP design shall be in accordance to UL 1709.
A weatherproof topcoat is normally required for most proprietary systems, and may only be
omitted with approval of PCIHBV. This weatherproof topcoat must typically be maintained if
the performance is to be guaranteed or shall be selected from PU based coating.
The system shall be asbestos-free.
The system shall not cause corrosion of the steel work when exposed to the expected
ambient conditions (e.g. freeze/thaw or moisture).
The toxicity of off-gasses and excessive production of smoke from the fire exposed
proprietary PFP shall be assessed for applications where fireproofed equipment or
structures are located indoors.
A quality assurance program is established to verify the application complies with

specifications. This is particularly important for epoxy based PFP materials.
The surface preparation and any priming of the steel shall be per the Manufacturer's
requirements
Test panel shall be conducted especially on coating exposed to radiant heat for 1 hour.
1.8 Thickness Calculation
CONTRACTOR shall submit thickness calculations and results for the proprietary
fireproofing material selected as per options given in this document. Manufacturer’s
recommended minimum thickness shall be strictly followed. As a guideline, table 3 and 4
below may be referred:
Chartek 7
Design Reinforcement and thickness bulkheads (mm)
Lloyd’s Register Det Norske Veritas USA Bereau of Shipping
A60 Class 5.0
NC NC
(Insulated backface) HK-1 Mesh
H-0 Class (400°C) 5.0 5.0 6.5
HK-1 Mesh HK-1 Mesh HK-1 Mesh
H-30 Class 7.0
NC NC
HK-1 Mesh
H-60 Class 5.0 5.1
NC
(Insulated backface) HK-1 Mesh HK-1 Mesh
H-60 Class 10.0 9.0 10.0
H-120 Class
NC NC NC
(Insulated backface)
H-120 Class 13.0 13.0 14.0
Table 3: Bulkheads, (Chartek)
Chartek 7
Design Reinforcement and thickness decks (mm)
Lloyd’s Register Det Norske Veritas USA Bereau of Shipping
A60 Class 8.0 8.0
NC
(Insulated backface) HK-1 Mesh HK-1 Mesh
H-0 Class (400°C) 5.0 5.0 6.5

H-30 Class 7.0
NC NC
HK-1 Mesh
H-60 Class
NC NC NC
H-60 Class 10.0 9.0 10.0
H-120 Class
NC NC NC
15.0 15.0
H-120 Class NC
HK-1 Mesh HK-1 Mesh
Table 4: Decks (Charter)
1.9 Inspection, testing and maintenance
1.9.1 Testing for HC Pool Fires
Testing for HC Pool Fires shall be as per API 2218. CONTRACTOR shall submit relevant
international codes (DNV, Lloyds, ABS, etc.).
1.9.2 Inspection
To reduce the risk of structural failure from corrosion under insulation/fireproofing material
or the risk from fire because the fireproofing material loosens or gets damaged by underlying
corrosion, all fireproofed surfaces shall periodically be inspected & tested as per schedule
prepared by the owner based on local environmental conditions and criticality of the
equipment.
Periodic inspection and testing maximizes the useful life of the fireproofing system. The
manufacturer or applier may be invited to participate in the inspection. Inspection shall
include but not be limited to the following:
 Survey coatings for surface cracking, delamination, rust, staining, or bulging.

 Survey coatings for signs of weathering (colour change, powdering, thinning of coat).
 Selectively remove small sections of fireproofing to examine conditions at the face of
the substrate and the surface of the reinforcing wire. Repair the inspection area.
 Visually check for the loss of the fireproofing materials as a result of mechanical abuse.
 When the fireproofing material is applied, coat and set aside several pieces of structural
steel for periodic fire-testing over the expected life of the coating. (This is not necessary
with rigid box or flexible containing systems).
 Inspect to make sure that the fireproofing hasn’t been removed for maintenance and
not replaced.
1.9.3 Maintenance
Timely and consistent maintenance provides assurance that the fireproofing system has not
been compromised. Most epoxy based PFP systems are maintenance free and act as good
corrosion resistant materials as well (protection against corrosion under insulation). The
epoxy systems are also used in normal paint specifications and hence provide a good
protection mechanism.
Main problems that occur and may require maintenance are as follows:
Hairline Cracking
When more than hairline cracking appears, the opening shall be cleaned out and filled with
new material according to Manufacturer’s instructions.
Substrate Disbonding
Loss of bonding to the substrate may be determined by surface bulges or an abnormal
sound when the surface is tapped with a light hammer.
Bond Failure
In evident area of bond failure, fireproofing shall be removed and the substrate shall be
thoroughly cleaned and properly primed before new material is applied.
Surface Coating
If surface coating is required to prevent moisture from penetrating, it shall be renewed at
intervals recommended by the manufacturer. The previously listed inspections shall be
completed prior to renewal of coating to ensure that defects are not hidden by the coating.

GF LPU4 J SP 003 Spec For Painting and Coating

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PROVISION OF LEASED

POWER UNIT FOR TRAIN 3, 4 & Doc No.:

Specification for Painting and Coating Rev: A

Revision Revision Description Date of Issue

Prepared by Reviewed by Approved by

A ZHAOKAI 16-SEP-21 CUIWEI 16-SEP-21

Approved by TA Signature Date

1.0 INTRODUCTION .............................................................................................................5

2.0 ABBREVIATIONS ...........................................................................................................5

3.0 CODES & STANDARDS .................................................................................................6

4.0 ORDER OF PRECEDENCE ............................................................................................8

5.0 REFERENCE DOCUMENTS...........................................................................................8

6.0 EXECUTION ...................................................................................................................9

6.1 Shop Versus Field Painting Policy ............................................................................... 9

6.2 Responsibilities of the Contractor ............................................................................... 9

7.0 MATERIALS .................................................................................................................11

7.1 Abrasives ..................................................................................................................... 11

7.2 Compressed air ........................................................................................................... 11

7.3 Paint Materials ............................................................................................................. 12

8.0 SURFACE PREPARATION ..........................................................................................12

8.1 General ......................................................................................................................... 12

8.2 Pre-cleaning of surface and solvent cleaning ........................................................... 13

8.3 Blast cleaning .............................................................................................................. 14

8.4 Surface preparation by hand and power tool cleaning ............................................. 17

8.5 Surface preparation and cleaning by water jetting ................................................... 17

9.0 PAINT APPLICATION ..................................................................................................18

9.1 Pre-Application Procedures........................................................................................ 18

9.2 Scheduling ................................................................................................................... 19

9.3 Application Methods ................................................................................................... 20

9.4 Repairs and touch-up painting ................................................................................... 22

10.0 PAINTING AND COATING SYSTEMS .........................................................................24

10.1 Coating system selections ......................................................................................... 24

10.4 Paint materials storage, shelf-life and handling ........................................................ 38

10.5 Coating system product approval requirement......................................................... 39

11.0 QUALITY CONTROL (QC) ...........................................................................................41

11.1 Inspection .................................................................................................................... 41

11.2 Project production testing .......................................................................................... 41

12.0 HEALTH, SAFETY AND ENVIRONMENT (HSE) ..........................................................42

12.1 Safety and health regulations ..................................................................................... 42

12.2 Environmental regulations ......................................................................................... 43

13.0 COLOUR SCHEMES ....................................................................................................44

13.1 Colour scheme for onshore installation .................................................................... 44

13.2 Colour identification for storage tank ........................................................................ 45

13.3 Identification piping system ....................................................................................... 45

13.4 Safety colours .............................................................................................................. 45

14.0 APPENDICES ...............................................................................................................45

APPENDIX A STORAGE TANK IDENTIFICATION SYSTEM

APPENDIX B PIPING IDENTIFICATION SYSTEM

APPENDIX C PIPING COLOUR IDENTIFICATION LEGEND

APPENDIX D COLOUR SCHEME FOR ONSHORE INSTALLATION & EQUIPMENT

APPENDIX E SPECIFICATION FOR INTUMESCENT COATINGS

The following abbreviations are applicable for this specification:

ASTM American Society for Testing and Materials

DFT Dry Film Thickness

HSE Health Safety and Environment

ISO The International Organization for Standardization

NACE National Association of Corrosion Engineers

OSHA Occupational Safety and Health Administration

psi Pound per square inch

QA/QC Quality Assurance/Quality Control

SSPC Steel Structures Painting Council

USD United States Dollar

VOC Volatile Organic Compounds