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CONTENTS
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. SCOPE REFERENCE DOCUMENTS SURFACE NOT TO BE PREPARED SURFACE PREPARATION MATERIAL & EQUIPMENT STORAGE SELECTION OF PAINT SYSTEM APPLICATION INSPECTION FINISH COAT COLOUR & COLOUR CODING SAFETY

ATTACHMENT
PAINT PROCEDURE OF VENDOR VENDOR PAINT CATALOG

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1.0
1.1

SCOPE
This Procedure describes the requirements for shop and field painting including surface preparation, application, materials, touch-up painting, inspection of painting for Piping, Steel Structures, Tanks, Vessels, Machinery, ducts and other items being installed / constructed at MSQ (EPCC-1) Upgradation project site, IOCL Panipat by L&T. Changes and deviations required for any specific job due to clients requirements or otherwise shall be referred to Jacobs for deviation permit. E XTENT OF WORK

1.2 a)

b)

c)
d)

The following surface and materials shall require shop, pre-erection and field painting: All Uninsulated C.S & A.S equipment like columns, vessel, drums, storage tank, heat exchangers, pumps, compressors, electrical panels and motors etc and tanks, and equipment in ETP plant. All Uninsulated carbon and low alloy piping fittings and valves (including painting of identification marks), furnace, ducts, and stacks. All items contained in a package unit as necessary. All structural steel work, pipe , structural steel supports, walkways, handrails, ladders, platforms, etc. MS chimney without refractory lining & flair lines. Identification colour bands on all piping as required including insulated aluminium clad, galvanized, SS and nonferrous piping. Identification lettering / numbering on all painted surfaces of equipment / piping insulated aluminium clad, galvanized, SS and non-ferrous piping. Marking / identification signs on painted surfaces of equipment /piping hazardous service. Supply of all primers, paints and all other materials required for painting other than Owners supply. Over insulation surface of equipments and pipes wherever required. Painting under insulation for carbon steel and stainless steel as specified. Repair work of damage / pre- erection / fabrication shop primer and weld joints at field. Internal surfaces of RCC tanks and structures in Effluent treatment plant. REFERENCE DOCUMENTS
COLOUR CODING IS-101 ASTM ASA A 13.1-1981 Colour coding inspection manual for piping issued by M&I Refineries Division of IOCL in May 2004 Methods of test for ready mixed paints and enamels American standard test methods for paints and coatings Scheme for identification of piping systems:

e)
f) g) h) i) j) k) l) m)

2.0
2.1 2.2 2.3 2.4

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American National Standards Institution 2.5 2.6 2.7 2.8 2.9 SIS-05 5900-1967 SSPC-SP BS-4232 U.S.A (NACE) 18-3177-000-V.02-201/A4 Swedish Standard (Surface preparation standards for painting steel surfaces) Steel Structures Painting Council, U.S.A (Surface Preparation Specifications) British Standards (Surface Finish of Blast-cleaned for painting) National Association of Corrosion Engineers General Specification of Shop & Field Painting.

3.0
3.1 3.2 3.3

SURFACE NOT TO BE PREPARED

Uninsulated austenite Stainless Steel Plastic and / or plastic coated materials Non ferrous materials like aluminium, galvanized piping, gratings and Handrails etc. except G.I. Tower. (However if there are any specific requirement by the Owner, the same shall be painted as per the relevant specifications)

4.0 4.1

SURFACE PREPARATION
In order to achieve the maximum durability, blast cleaning is considered the most desirable method to achieve required profile however one or more of following methods of surface preparation shall be followed, depending on conditions of steel surface and as instructed by Jacobs. Adhesion of the paint film to surface depends largely on the degree of cleanliness and surface profile of the metal surface. Proper surface preparation contributes more to the success of the paint protective system. a) Manual or hand tool cleaning b) Mechanical or power tool cleaning. c) Blast cleaning.. Mill scale, rust scale and foreign matter shall be removed fully to ensure that a clean and dry surface is obtained. The minimum acceptable standards in case of manual or hand tool cleaning shall be St.2 or equivalent. In case of mechanical or power tool cleaning it shall be ST. 3 or equivalent. In case of blast cleaning it shall be Sa 2-1/2 or equivalent as per Swedish Standard SIS-055900-1967 or equivalent. Where highly corrosive conditions exist, then cleaning shall be Sa 3 as per Swedish Standard. Remove all other contaminants; oil, grease etc. shall be removed by use of an aromatic solvent Blast cleaning shall not be performed where dust can contaminate surfaces undergoing such cleaning or during

4.2

4.2.1

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4.2.2 4.2.3

humid weather conditions having humidity exceed 85%. However, at times of unfavourable weather conditions, Jacobs shall have the liberty to control the time period, at his sole discretion and / or to insist on re-cleaning, as may be required, before primer application is taken up. The external surface of RCC chimney to be painted shall be dry and clean. Any loose particle of sand, cement, aggregate etc., shall be removed by scrubbing with soft wire brush if necessary acid etching with 10% -15% HCL solutions for about 15 minutes shall be carried and surface must be thoroughly washed with water to remove acid & loose particles then dry completely before application of paint

4.3

Air Blast Cleaning / Grit blasting

The surfaces shall be blast cleaned using one of the abrasives Al 2O3 particles chilled cast iron or malleable iron and steel at pressure of 7 kg/cm2 at appropriate distance and angle depending of nozzle size maintaining constant velocity and pressure. Chilled cast iron, malleable iron and steel shall be in the form of shot or grit of size not greater than 0.055 maximum in case of steel and malleable iron 0.04 maximum in case of chilled iron.. Compressed air shall be free from moisture and oil. The blasting nozzle should be venturi style with tungsten carbide or boron carbide as the materials for liners. Nozzle orifice may vary from 3/16 to . On completion of blasting operation, the blasted surface shall be clean and free from any scale or rust and must show a grey white metallic luster. Primer or first coat of the paint shall be applied within 4 hours of surface preparation. Blast cleaning shall not be done outdoors in bad weather without adequate protection or when there is dew on the metal, which is to be cleaned. Surface profile shall be uniform to provide good key to paint adhesion, i.e., 35 to 50 microns. If possible vacuum collector shall be installed for collecting the abrasives and recycling.

4.4

Mechanical or Power Tool Cleaning

Power tool cleaning shall be done by mechanical striking tools, chipping hammers, grinding wheels or rotating steel wire brushes. Excessive burnish of surface shall be avoided as it can be reduce paint adhesion. On completion of cleaning, the detached rust mill scale etc. shall be removed by clean rags and / or washed by water or steam thoroughly dried with compressed air jet before application of paint.

4.5

Manual or hand tool cleaning

Manual or hand tool cleaning is used only where safety problems limit the application of other surface preparation procedure and there is approach problem in certain areas and hence does not appear in the tables of paint systems. Hand tool cleaning normally consists of the following : a. Hand descaling and / or hammering b. Hand scraping c. Hand wire brushing Rust, mill scale spatters, old coatings and foreign matter, shall be removed by hammering, scrapping tool, emery paper cleaning, wire brushing or combination of the above methods. On completion of cleaning, loose material shall be removed from the surface by clean rags and the surface shall be bushed, swept, dusted and blow off with compressed air / steam to remove all loose matter. Finally the surface may be washed with water and dried for

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effective cleaning. . The surface preparation shall be done as per following standard:-

SR. NO.
1.

DESCRIPTION

VARIOUS INTERNATIONAL STANDARDS Swexish BRITISH SSPCStandard NACE STANDA SP SIS-05USA RD USA 5900 BS-4232
SSPCSP-2

REMARKS

Manual or Hand tool cleaning Removal of loose rust, loose mill scale and loose paint, chipping, scrapping, standing and wire brushing. Surface should have a faint metallic sheen. Mechanical or power tool cleaning Removal of loose rust, loose mill scale and loose paint to degree specified by power tool chipping, descaling, standing wire brushing, and grinding, after removal of dust, surface should have a pronounced metallic sheen. Blast cleaning (air & water) there are four common grades of blast cleaning White metal Blast cleaning to white metal cleanliness. Removal of all visible rust. Mill sale, paint & foreign matter 100% cleanliness desired surface profile.

ST.2

This method is applied when the surface is exposed to normal atmospheric conditions when other method can not be adopted and also for spot cleaning during maintenance painting.

ST.3

SSPCSP-3

3 3.1

Where extremely clean surface can be expected for prolong life of paint system.

SA.3

SSPCSP-5

NACE#1

First Quality

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SR. NO.
3.2

DESCRIPTION

VARIOUS INTERNATIONAL STANDARDS Swexish BRITISH SSPCStandard NACE STANDA SP SIS-05USA RD USA 5900 BS-4232

REMARKS

Near White metal

SA 21/2

SSPCSP-10

NACE#2

Second Quality

3.3

Commercial Blast Blast cleaning until at least twothird of each element of surface are is free of all visible reduces with desired surface profile Brush-off Blast Blast cleaning to white metal cleanliness, removal of all visible rust, mill scale, paint & foreign matter. Surface profile is not so important.

SA 2

SSPCSP-6

No.3

Third Quality

The minimum requirement for chemically resistant paint systems such as epoxy, vinyl, polyurethane based and inorganic zinc silicate paints, also for conventional paint systems used under fairly corrosive conditions to obtain desired life of paint system. For steel required to be painted with conventional paints for exposure to mild corrosive atmosphere for longer life of the paint system.

3.4

SA 1

SSPCSP-7

No.4

5.0
5.1

MATERIAL & EQUIPMENT

All tools, brushes, rollers, spray guns, blast material, hand power tools for cleaning, inspection instruments, e.g surface profile gauges, holiday detectors, pin hole detectors, dry film thickness gauge etc. and all equipments, scaffolding materials, shot blasting equipments, scaffolding materials, shot blasting equipments & air compressor etc. required to be used shall be suitable for the work and all in good order and shall be arranged by L&T at site and in sufficient quantity.

6.0
6.1

STORAGE
All painting shall be stored only in rooms to be arranged by L&T and approved Engineer-In-Charge for the purpose. All necessary precaution shall be taken to prevent fire. The storage building shall preferably be separate from adjacent building. A sign board bearing the word PAINT STORAGE- NO NAKED LIGHT HIGHLY INFLAMMABLE shall be clearly displayed outside.

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7.0
7.1 7.2

SELECTION OF PAINT SYSTEM

Selection of the paint system shall vary with type of environment envisaged in and around the plant. For PRE-ERECTION / PRE- FABRICATION & SHOP PRIMING FOR CARBON STEEL, LOW TEMPERATURE CARBON STEEL & LOW ALLOY STEEL, STEEL UNINSULATED AND INSULATED STRUCTURE, PIPING & EQUIPMENT ETC. Sr.No. Design Temperature In Surface Preparation Paint System Total DFT In Remarks o C Microns (min) 7.2.1 7.2.2 -90 to 400 401 to 500 SSPC-SP-10 SSPC-SP-10 1coat of F-9 1coat of F-12 65-75 40-50 No over coating is to be done Finish coat at site

7.3

For PRE-ERECTION / PRE- FABRICATION & SHOP PRIMING FOR CARBON STEEL, LOW TEMPERATURE CARBON STEEL & LOW ALLOY STEEL, STEEL UNINSULATED AND INSULATED ITEMS IN ALL ENVIRONMENTS. Sr.No. Design Surface Preparation Paint System Total DFT Remarks Temperature In In o C Microns (min) 7.3.1 -90 to 400 SSPC-SP-3 1 coat of F-9 65-75 (for repair only) SSPC-SP-10 7.3.2 401-500 SSPC-SP-3 (for repair only) SSPC-SP-10 2 coats of F-12 40-50 For operating temperature less than 80oC irrespective of design temperature F-8 shall be used.

7.4

For REPAIR OF ALL WELD JOINTS AND DAMAGES OF GALVANIZED STEEL, CARBON STEEL AND ALLOY STEEL STRUCTURES, PIPING AND EQUIPMENT AFTER ERECTION ON ABOVE GROUND OVERHEAD AREAS AT SITE

Sr.No. 7.4.1 7.4.2

7.5 7.5.1

Design Surface Temperature In Preparation o C -14 to 80 SSPC-SP-3 81 to 500 SSPC-SP-3

Paint System 1 coat of F-8 1 coat of F-12

Total DFT In Remarks Microns 100 20

PAINT SYSTEM FOR SHOP AND FIELD PAINTING For all un-insulated areas above ground carbon steel, low temperature carbon steel and low alloy steel, external

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surface of columns, vessels, heat exchangers, blowers, piping , pumps, towers, compressors, flare lines, stack, chimney, furnace, flue gas, ducts, structural steel, ladders, handrails, platforms, fire water lines and above ground product pipe line. Sr. No. Operating Surface Preparation Paint System Total DFT Remarks Temperature In Field Primer Finish Paint In oC Microns (min.) 7.5.1.1 -14 to 80 SSPC-SP-10 Repair of 1 coat of F-2 @ 145 (for repair of pre prefabrication 40 DFT/ coat fabrication of primer 1 coat of F-9 primer F-9) @ 65 -75 DFT / coat as per the clause 7.3.1 in table 7.3 + Field Primer : 1 coat of P-6 @ 40 microns DFT/coat=105 7.5.1.2 81 to 250 SSPC-SP-10 Repair of 2 coats of F-11 105 Test certificates for heat (for repair of pre prefabrication resistance of F-11 @ 20 DFT / fabrication of primer 1 coat of F-9 COAT from paint primer F-9) (for @ 65 -75 DFT / 2 x 20=40 manufacturer should repair of pre coat as per the enclosed fabrication of clause 7.3.1 in primer F-9) table 7.3 7.5.1.3 251 to 400 SSPC-SP-10 (for repair of pre fabrication of primer F-9) (for repair of pre fabrication of primer F-9) SSPC-SP-10 Repair of prefabrication primer 1 coat of F-9 @ 65 -75 DFT / coat as per the clause 7.3.1 in table 7.3 Repair of prefabrication primer 1 coat of F-12 @ 20 DFT / coat as per 7.3.2 in table 7.3 2 coats of F-11 @ 20 DFT / COAT 2 x 20=40 (OR) 1 coat of engineered siloxane coating @ 50 DFT/coat 2 coats of F-11 @ 20 DFT / COAT 2 x 20=40 (OR) 1 coat of engineered siloxane coating @ 50 DFT/coat 105 Test certificates for heat resistance of F-12 from paint manufacturer should be enclosed. F12 requires heat curing as per manufacturers recommendations. Test certificates for heat resistance of F-12 from paint manufacturer should be enclosed.

7.5.1.4

401 to 500

60

7.5.2

All un-insulated storage tank external shell, roof tops and structures of petroleum products (excluding floating roof

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decks), D.M. water, fire water, raw water & portable water, sour water, slop tank and clean water tank and VBU /HCU feed tanks excluding the items covered below: Sr. No. Operating Temperature In oC Total DFT Remarks In Microns (min.) Fire water piping near hydrants (1 meter on the both the sides of hydrants) stair tread and platform. External painting of steel equipment, piping structural etc. with impingement of water at ambient temperature (e.g. equipment in the vicinity of cooling towers) Field Primer -14 to 80 Repair of 2 coats of F-6B @ prefabrication 100 DFT / primer 1 coat of COAT + 1 coat of F-9 @ 65 -75 F-2 @ 40 DFT / coat as DFT / coat =240 per the clause 7.3.1 in table 7.3 -14 to 80 SSPC-SP-10 Repair of 2 coats of F-6A @ prefabrication 100 primer 1 coat of DFT/ coat F-9 @ 65 -75 2X100=200 DFT / coat as per the clause 7.3.1 in table 7.3 External side un-insulated storage vessel for petroleum products Repair of 2 coats of F-11 @ Ambient to SSPC-SP-10 prefabrication 20 250 primer F-9 as per DFT/coat the clause 7.3.1 2X20=40 in table 7.3 External side un-insulated storage vessel not covered in the heading of table 7.5.2 251 to 400 SSPC-SP-10 Repair of pre 2 coats of F-12 @ fabrication primer 20 DFT / coat = F-9 as per 7.3.1 2X20=40 or one coat of in table 7.3 engineered siloxane coating @ 50 DFT / coat SSPC-SP-10 305 F-9, F-6B, F-2 can be applied at ambient temperature Surface Preparation Paint System Finish Paint

7.5.2.1

7.5.2.2

265

F-9, F-6A, F-2 can be applied at ambient temperature

7.5.2.3

105-115

Test certificate for heat resistance of F-11 from paint manufacturer should be enclosed.

7.5.2.4

105 or115

F-12 shall be applied in the field before taking the system into service as it needs hot curing at high temperature.

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Sr. No.

7.5.2.5

7.5.2.6

7.5.2.7

7.5.2.8.1

7.5.2.8.2

Total Remarks DFT In Microns (min.) External side of un-insulated storage vessels not covered in the heading of table 7.5.2 401 to 500 SSPC-SP-10 Repair of pre2 coats of F-12 @ 105or 115 F-12 shall be applied in fabrication primer 20 DFT / coat = the field before taking the system into service F-9 as per 7.3.2 2X20 =40 or 1 coat of as it needs hot curing at in table 7.3 engineered high temperature. siloxane coating @ 50 DFT / coat Un-insulated floating roof deck top side of carbon steel or alloy steel of storage tanks for Naphtha, HSD, H 2 , Unit feed, DHT feed, crude including all new and modified existing tanks in LBT area and MS -14 to 80 SSPC-SP-10 Repair of pre- 2 coats of F-6A @ 240 F-6A & F-9 can be fabrication primer 100 applied at ambient F-9 as per 7.3.1 DFT/coat temperature in table 7.3 =2X100=200 External tank shell portion for high humid areas (1.25 M above the annular plate.) -14 to 80 SSPC-SP-10 Repair of pre- 1 coat of F-6B @ 205 F-9, F-6B & F-2 can be fabrication primer 100 DFT/coat + applied at ambient temperature F-9 as per 7.3.1 1 coat of F-2 @ in table 7.3 40 DFT /coat Bottom side surface of bottom plate (soil side) for all storage tank -14 to 80 SSPC-SP-10 Repair of 2 coat of F-7 @ 315 F-7 should be suitable prefabrication for using under 125 DFT/coat = primer 1 coat of 2X125=250 corrosive soil over coating of F-9 should F-9 @ 65 -75 be avoided as it would DFT / coat as lead to mud cracking. per the clause 7.3.1 in table 7.3 Tank shell lower portion exterior (1.25m above the annular plate on foundation) -14 to 80 SSPC-SP-10 Repair of 2 coats of F-7 @ 265 F-7 should be suitable prefabrication for using under 100 primer by 1 coat DFT/coat corrosive soil over of F-9 @ 65 -75 =2X100=200 coating of F-9 should DFT / coat as be avoided as it would per the clause lead to mud cracking. 7.3.1 in table 7.3

Operating Temperature In oC

Surface Preparation

Paint System Field Primer Finish Paint

(CONTINUED IN NEXT PAGE)

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Sr. No.

7.5.2.9 7.5.2.9.1

7.5.2.9.2

7.5.2.10 7.5.2.10.1

7.5.2.10.2

7.5.2.10.3

Total DFT Remarks In Microns (min.) Bottom surface of bottom plate (soll side) for storage tanks like clear water tanks, shop oil tanks, fuel oil tanks VGO, CGO / VR and similar high temperature services 81 to 150 SSPC-SP-10 Repair of 2 coats of (F-14) 315 Application of paint prefabrication specially shall be done before primer by 1 coat formulated coal tar placing the plates on epoxy coating foundation and before F-9 @ 65-75 @125 DFT / welding. DFT / coat as per clauses coat=2X125=250 7.3.1 in table 7.3 OR OR 1coat of F-15 2 coats of F-15 240 epoxy phenolic epoxy phyenolic primer coating coating system @ 80 DFT / @ 80 DFT coat /coat=2X80=160 151 to 400 SSPC-SP-10 Repair of 2 coats of (F-14) 315 prefabrication specially primer by 1 coat formulated coal tar epoxy slioxane F-9 @ 65-75 coating @125 DFT / coat as per clauses DFT / 7.3.1 in table coat=2X125=250 7.3 Carbon steel stack, chimney, furnace & flue gas duc Upto 80oC SSPC-SP-3 1 coat of F-8 (A1 100 operating grade) @ 100 temp. DFT / coat Irrespective of design temp. 81 to 250 SSPC-SP-10 Repair of 2 coats of F-11 105 prefabrication @20 DFT / primerF-9 as per coat 7.3.1 of table 7.3 2X20=40 251 to 400 SSPC-SP-10 Repair of 2 coats of F-12 105 prefabrication @20 DFT / primerF-9 as per coat 7.3.1 of table 7.3 2X20=40 Field Primer Operating Temperature Surface Preparation Paint System Field Primer Finish Paint Total DFT In Remarks

Operating Temperature In oC

Surface Preparation

Paint System Finish Paint

Sr. No.

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Microns (min.) 165

In oC 7.5.2.10.4 401 to 500 SSPC-SP-10 Repair of prefabrication primerF-9 as per 7.3.1 of table 7.3 1 coat of F-16 A/ Epoxy-Slioxane coating @ 100 DFT / coat 2 coats of F-7 @ 100 DFT/coat 2X100=200

7.5.2.10.5

All gratings Upto 80oC operating temp.

SSPC-SP-2

7.5.3 PAINTING UNDER INSULATION FOR INSULATED (HOT, COLD & SAFETY) CARBON STEEL, LOW ALLOY STEEL, LOW TEMPERATURE CARBON
Sr. No. Operating Temperature In oC Surface Preparation Field Primer Paint System Finish Paint Total DFT In Microns (min.) 315 Remarks

7.5.3.1 7.5.3.1.1

7.5.3.1.2

7.5.3.2

Insulated carbon steel, low alloy steel and LTCS piping and equipment and tanks -45 to 125 oC SSPC-SP-10 Repair of 2 coats of F-14 @ operating prmierF-9 @ 65 125 DFT/ coat= temp. But -75 DFT. 2 x 125=250 or 3 design temp. coats of F-15= up to 150 oC 3 x 80 = 240 Operating SSPC-SP-10 Repair of 2 coats of F-12 @ temperature prmierF-9 @ 65 20 DFT/ coat= -45 to 125 oC -75 DFT. 3 x 20=60 But design temperature 151 -400 oC Insulated stainless steel including alloy -20 piping

For other temperature ranges no painting is required under insulation

105-115

Sr. No.

Operating Temperature In oC

Surface Preparation

Paint System Field Primer Finish Paint

Total DFT In Microns (min.)

Remarks

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If the piping & equipments are already erected then surface shall be prepared by cleaning with emery paper and wash / flush with chloride free DM water followed by wiping with organic solvent. All the coating materials for SS shall be free from leachable chlorides.

7.5.3.2.1 7.5.3.2.2

Below 0 oC to all minus temperature 0 to 120

Aluminium sheeting with aluminium foil and Chloride free mineral sealant coating barium chromate shall be applied. SSPC-SP-10 (1525 surface profile) None 250 240 or

7.5.3.2.3

7.5.3.2.4

7.5.3.3

2 coats of F-14 @ 125 DFT/ coat= 2 x 125= 250 or 3 coats of F-15= 3 x 80=240 121 to 400 SSPC-SP-10 None 3 coats of F-12 @ 20 DFT/ coat= 3 x 20 =60 or 1 coat of poly slioxane or coating ( F-16 A/B ) @ 75 DFT/ coat 401 to 600 SSPC-SP-10 None 2 coats of heat resistant silicone aluminium paint @ 20 DFT/ coat= 2 x 20 = 40 No painting required for insulated monel, incoloy and nickel lines.

60

40

TABLE 7.5.4 INTERNAL PROTECTION OF CARBON STEEL WATER BOXES AND TUBE SHEETS OF COOLERS / CONDENSERS Water boxes, channels, partition plates, end covers and tube sheets etc. Sr. No. Operating Temperature In oC Up to 80 Up to ferrous brass sheets Non and tube Surface Preparation Field Primer SSPC-SP-10 SSPC-SP-3 Paint System Finish Paint 2 coats of F-7 @ 125 DFT/ coat= 2 x 125= 250 2 coats of F-7 @ 125 DFT/ coat= 2 x 125= 250 Total DFT In Microns (min.) 290 300 Remarks

7.5.4.1 7.5.4.2

1 coat of P-6 @ 40 DFT/ coat 1 coat of P-4 @ 8-10 DFT/ coat 1 coat of P-6 @ 40 DFT/ coat

For C.S. For non surfaces ferrous

FIELD PAINTING SYSTEM FOR NON-FERROUS TUBE SHEET Sr. No. Operating Temperature Surface Preparation Field Primer Paint System Finish Paint Total DFT In Remarks

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Microns (min.) 300

In oC 7.5.4.3 UP TO 80 Non SSPC-SP-10 1 coat of p-6 @ 8 2 coats of F-7 @ ferrous and DFT/ coat 125 DFT/ coat= brass tube 2 x 125= 250 sheets 7.5.5 SHOP & FIELD PAINTING SYSTEM FOR EFFLUENT TREATMENT PLANT Sr. No. Operating Surface Paint System Temperature Preparation Field Primer Finish Paint In oC -14 to 80 (for C.S/ M.S.Item): Screens, Walk way bridges, Baffles, Dual media filters(external ), Vertical pumps, piping in treated effluent sump and pump house, external side lining of slop oil MS tank -14 to 80 (CS / MS item) for vertical pump and piping in, Bio-sludge sump and pump, Filter feed sump and pump, process sump, sanitary sump, Transfer sump, MS Slop oil tank Operating Temperature In oC SSPC SP -10 1 Coat of F-9 @ 65-75 DFT / coat 3 coats of F-6A @100 DFT / coat 3x100=300

7.5.5.1

Total DFT In Microns (min.) 365

Remarks

7.5.5.2

SSPS SP -10

1 Coat of F-9 @ 65-75 DFT / coat

2 coats of F-6A @100 DFT / coat

265

Sr. No.

Surface Preparation

Paint System Field Primer Finish Paint

Total DFT In Microns

Remarks

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(min.)

7.5.5.3

7.5.5.4

internal, scrapping mechanism in Clarifier, Screw Pump -14 to 80(All RCC surfaces such as tanks, structures, drains, etc) in Process Sump, TPI separator (Process and oil ), Aeration tank, transfer sump, etc. Up to 60 deg. C C.S/MS dual media filters (Internal),Che mical dosing tanks internal such as DAP, Urea

Blast cleaning to SSPC-SP guide lines and Acid etching with 1015% HCI acid followed by through water washing.

As per SMMSEIL specification for Epoxy screed lining no. 6-06209(Latest revision)

As per SMMS-EIL specification for Epoxy screed lining no. 6-06209(Latest revision)

3 mm

Epoxy screed lining shall be used as per specific instructions from Engineer-incharge at site

SSPC SP -10

Rubber lining as per SMMS-EIL spec. 6-06-204 (Latest revision)

4.5 mm

7.5.6 COATING SYSTEM FOR EXTERNAL SIDE OF UNDERGROUND CARBON STEEL PLANT PIPING AND TANKS Sr. No. Operating Temperature In oC Surface Preparation Paint System Field Primer Finish Paint Total DFT In Microns (min.) Remarks

7.5.6.1 7.5.6.1.1 7.5.6.1.1.1

Carbon steel plant piping ( Underground ) Yard Coating 25 to 60 SSPC SP -10 1 coat of synthetic fast drying primer type-B as per AWWA-C203(1991) Operating Temperature In oC Surface Preparation Field Primer

4 mm thick coaltar coating wrapping as per AWWA-C203 in 2 layers of each 2 mm thickness Paint System Finish Paint

4 mm

CTE coating shall conform to 120 / 5 as per BS : 4164

Sr. No.

Total DFT In Microns

Remarks

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(min.)

7.5.6.1.2 7.5.6.1.2.1

Over the Ditch Weld Joint coating 25 to 60 SSPS - SP -10

1 coat of synthetic fast drying primer type-B as per AWWA-C203(1991)

Same as 12.1.1.1 (OR) heat shrinkable PE Sleeves conforming to DIN 30672 stress class C 3coats of F-7@100 DFT / coat 3x100=300

4 mm

7.5.6.2 7.5.6.2.1

Carbon steel plant piping ( Underground ) 61 to 90 SSPC SP -10 1 Coat of F-9 @ 65-75 DFT / coat

365

91 to 150

SSPC SP -10

1 Coat of F-9 @ 65-75 DFT / coat

151 to 400

SSPC SP -10

1 Coat of F-9 @ 65-75 DFT / coat

3coats of F-14 @ 100 DFT/Coat (OR) 3 coats of F-15 @ 75 DFT/coat 3x75 = 225 2 coats of F-16 A/B @ 75 DFT/coat = 2x75= 150 3coats of F-7@100 DFT / coat 3x100=300

365 (OR) 225 for the F-15 system 215

7.5.6.3 7.5.6.3.1

External side un-insulated underground storage tank -40 to 80 SSPC SP -10 1 Coat of F-9 @ 65-75 DFT / coat

365

-90 to 41 81 to 400 deg. C

SSPC SP -10

1 Coat of F-9 @ 65-75 DFT / coat

2 coats of F-16 A/B @ 75 DFT/coat = 2x75= 150

215-225

7.5.7 Sr. No.

FIELD PAINT SYSTEM FOR CARBON STEEL AND ALLOY STEEL STORAGE TANKS (INTERNAL) Operating Surface Preparation Paint System Total DFT Remarks

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Finish Paint

Temperature In oC 7.5.7.1 7.5.7.1.1

In Microns (min.) Internal surfaces of underside of floating roof, internal surface of cone roof, bottom plate, roof structures, structural steel, ladders, supports for storing crude oil, LDO and HSD (Excluding white oil products) -14 to 80 SSPC SP -10 1 Coat of F-9 @ 3coats of F-7@100 365 F-7 should be suitable 65-75 DFT / DFT / coat for immersion service 3x100=300 of the products given. coat Field Primer

7.5.7.2 7.5.7.2.1

7.5.7.3 7.5.7.3.1

Bare shall inside floating roof tanks and cone roof tanks for products mentioned in 13.1 -14 to 80 SSPC SP -10 Phosphate 2 coats @ 10 20 treatment with 2 x 10 =20 phosphating chemicals (2 coats) Floating cone roof tanks for petroleum products such as ATF, gasoline, naphtha, kerosene. Motor spirit, inside of bottom plate, underside of floating roof; shell above maximum liquid level structural steel, ladders, etc. and inside of complete shell for ATF storage tanks. -14 to 80 SSPC SP -10 1 Coat of F-9 @ 3coats of F-7@100 365 F-6 should suitable for immersion service of 65-75 DFT / DFT / coat 3x100=300 petroleum product like coat ATF, kerosene, petrol, etc. Bare shell of inside of floating cum cone roof tanks for products gasoline, naphtha, kerosene, motor spirit -14 to 80 SSPC-SP-10 1 coat of F-9 @ none 65-75 No covering is allowed. 65-75 DFT / Same as per preerection primer, if any coat Internal protection of fixed roof type storage tanks for portable water: inside of shell, under side of roof and roof structure inside surface, bottom plate and structural steel works, ladders, walkways, platforms, etc. -14 to 80 SSPC-SP-10 2 coats of P-6 @ 2 coat of F-6 @ 280 F-6 shall be suitable for immersion service 40 DFT / coat 100 DFT / coat 2 x 40 = 80 2 x 100 = 200 D.M. ( Demineralised water) and hydrochloric acid (HCL): internal shell, bottom plate & all accessories -14 to 60 SSPC-SP-10 Natural rubber lining as per SMMS specifications 606-204 Operating Temperature In oC Surface Preparation Field Primer Paint System Finish Paint Total DFT In Microns (min.) Remarks

7.5.7.4 7.5.7.4.1 7.5.7.5 7.5.7.5.1 7.5.7.6 7.5.7.6.1

Sr. No.

7.5.7.7

EG tanks ( Internal shell, bottom plate roof and all accessories)

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225

7.5.7.7.1 7.5.7.8 7.5.7.8.1 7.5.7.9 7.5.7.9.1

all

3 coats vinyl chloride co-polymer amercoat 23 @ 75 / coat Inside pontoon and inside of double deck of all floating roofs -14 to 80 SSPC-SP-10 1 coat of F-8 @ 100 DFT / coat Internal surface of amine & sour water storage tanks -14 to 80 SSPC-SP-10 1 coat of F-9 @ 3 coats of F-15 @ 215 - 225 65-75 DFT / 75 DFT / coat coat 2 x 75 = 150

SSPC-SP-10

200

215-2

PRIMERS & FINISH COATS PRIMERS

P-2 P-4 P-6 : : : Chlorinated rubber zinc phosphate primer Etch primer / wash primer Epoxy zinc phosphate primer

FINISH COATS / PAINTS

F-1 F-2 F-3 F-6A F-6B F-7 F-8 F-9 F-11 F-12 F-14 : : : : : : : : : : : First quality corrosion resistant synthetic enamel Acrylic- Polyurethane finish paint Chlorinated rubber finish paint High build epoxy finish coating cured with polyamine hardner High Build epoxy finish coating cured with polyimide hardner High Build coal tar epoxy coating Self priming surface tolerant high build epoxy coating Inorganic Zinc silicate coating Heat resistant synthetic medium based aluminium paint Heat resistant silicone aluminium paint Specially formulated polyamine cured coal for epoxy coating suitable

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upto 150 deg C F-15 F-16A F-16 B : : : Epoxy Phenolic Coating Epoxy slioxane coating: Amercoat 738 Epoxy slioxane coating: Berger 938

8.0
8.1 8.1.1

APPLICATION
COATING PROCEDURE AND APPLICATION Surface shall not be coated in rain , wind or in environment where injuries airbome elements exists, when the steel surface temperature is less than 5F above dew point when the relative humidity is greater than 85% or when the temperature is below 40F. Blast cleaned surface shall be coated with one complete application of primer as soon as practicable but in no case later than 4 hrs. the same day. To the maximum extent practicable, each coat of material shall be applied as a continuous film uniform thickness free of probes. Any spots or areas missed in application shall be recoated and permitted to dry before the next coat is applied. Applied paint should have the desired wet film thickness. Each coat shall be in proper state of cure or dryness before the application of succeeding coat. Material shall be considered dry for recoating when an additional coat can be applied without the development of any detrimental film irregularities, such as lifting or loss of adhesion of the under coat. Manufacturer instruction shall be followed for inter coat interval. When the successive coat of the same colour have been specified, alternate coat shall be tinted, when practical, sufficiently to produce enough contrast to indicate complete coverage of the surface. The tinting material shall be compatible with the material and not detrimental to its service life. AIR FOLLOWING: SPRAY APPLICATION SHALL BE IN ACCORDANCE WITH THE

8.1.2 8.1.3

8.1.4

8.1.5

8.2 8.2.1

The equipment used shall be suitable for the intended purpose, shall be capable of properly atomizing the paint to be applied and shall be equipped with suitable pressure regulators and gauges. The air caps, nozzles and needles shall be those recommended by the manufacture of the equipment for the material being sprayed. The equipment shall be kept in satisfactory condition to permit proper paint application. Traps or separators shall be provided to remove oil and condensed water from the air. These traps or separators must be of adequate size and must be drained periodically during operations. The air from the spray gun impinging against the surface shall show no condensed water or oil.

8.2.2

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8.2.3 8.2.4

Ingredients shall be kept properly mixed in the spray pots or containers during application by continuous mechanical agitation. The pressure on the material in the pot and of the air at the gun shall be adjusted for optimum spraying effectiveness. The pressure on the material in the pot shall be adjusted when necessary for changes in elevation of the gun above the pot. The atomizing air pressure at the gun shall be high enough to properly atomize the paint but not so high as to cause excessive fogging of paint, excessive evaporation of solvent, or less by over spray. Spray equipment shall be kept sufficiently clean so that dirt, dried plant and other foreign material are not deposited in the paint film. Any solvents left in the equipment shall be completely removed before applying paint to the surface being painted. Paint shall be applied in a uniform layer with overlapping at the edge of the spray pattern. The spray patterns shall be adjusted so that the paint is deposited uniformly. During application, the gun shall be held perpendicular to the surface and at a distance which will ensure that a wet layer of paint is deposited on the surface. The trigger of the gun should be release at the end of the stroke. All runs and sags shall be brushed out immediately or the paint shall be removed and the surface repainted. Areas inaccessible to the spray gun shall be painted by brush; if not accessible by brash, daubers or sheepskins shall be used. All name plates, manufacturers, identification, tags, machined surfaces, instrument glass, finished flange faces, control valve items and similar items shall be masked to prohibit coating deposition. If these surfaces are coated the component shall be cleaned and restored to the original condition. Edges of structural shapes and irregular coated surfaces shall be coated first and an extra pass made later. If a spray gun shows choking immediately de-choking procedure shall be followed.

8.2.5

8.2.6

8.2.7 8.2.8 8.2.9

8.2.10 8.2.11

8.3

AIRLESS SPRAY APPLICATION

Airless spray application shall be accordance with the following procedure; as per steel structure, paint manual VolI and Vol-II by SSPC , USA. Airless spray release on hydraulic pressure rather than air atomization to produce the desire pray and air compressor or electric motor is used to operate a pump to produce pressure 1000 to 6000 PSI, paint is delivered to the spray gun at this pressure through a single hose within the gun, a single paint stream is divided into separate streams, which are forced through a small orifice resulting atomization of paint without the use of air. These results in more rapid coverage with less over spray. Airless spray usually is faster, cleaner, more economical and easier to use than conventional air spray. Airless spray equipment is mounted on wheels and paint is aspirated in a hose that sucks paint from any container, including drunks. The unit shall have inbuilt agitator that keep the paint uniformly mixed during the spraying. The unit shall consist of inbuilt strainer, usually very small quantities of thinning is required before spray in case of build epoxy (two pack) 30:1 pump ratio and 0.020-0.023 inch tip size will provide a good spray pattern. Ideally fluid hoses should not be less than 3/8 inch ID and not longer than 50ft. to obtain optimum result.

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In case gun choking, de-choking shall be followed immediately.

8.4 8.4.1 8.4.2 8.4.3 8.4.4 8.4.5 8.4.6 8.5

BRUSH APPLICATION OF PAINT SHALL BE IN ACCORDANCE WITH THE FOLLOWING Brushes shall be of a style and quality that will enable proper application of paint Round or oval brushes are most suitable for rivets, bolts, irregular surface and rough or pitted steel. Wide flat brushes are suitable for large flat areas, but they shall not have width over five inches. Paint shall be applied into all corners. Any runs or sags shall be brushed out. There shall be a minimum of brush marks left in the applied paint. Surface not accessible to brushes shall be painted by spray, daubers or sheepskin. MANUAL APPLICATION BY SLING A canvas strip (alternatively a tinplate strip) about 450 mm wide and 1.5m long is held under the pipe by two men holding this sling move it up and down and walk slowly while fresh coating is poured on the pipe and they manipulate the sling so that an even coating is coating is obtained all round the bottom. This work shall be done very carefully and by experienced personnel. There shall not be any formation of whiskers and holes in the coating. The coating film shall be inspected by mirror.

8.6

DRYING OF COATED SURFACE No coat shall be applied until the preceding coat has dried. The material shall be considered dry for re-coating when another coat can be applied without development of any film irregularities such as lifting or loss of adhesion of undercoats. Drying time of the applied coat should not exceed maximum specified for it as a first coat; if it exceeds the paint material has possibly deteriorated or mixing is faulty. No paint shall be force dried under conditions which will cause checking, wrinkle, blistering formation of pores, or detrimentally affect the conditions of the paint. No drier shall be added to paint on the job unless specifically called for in the manufacturers specification for the paint. Paint shall be protected from rain, condensation, snow and freezing until dry to the fullest extent practicable.

8.7 8.7.1

REPAIR OF DAMAGED PAINT SURFACE Quickly remove the primer from damaged area by mechanical scrapping and emery paper to expose the white metal.

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Blast clean the if possible. Feather the primer over the intact adjacent surface surrounding the damaged area by emery paper. 8.7.2 Repair of damaged pre-erection and shop priming in the design temperature of -90oC to 400oC 8.7.3 8.7.4 8.7.5 8.7.6 8.8 8.8.1 8.8.2 8.8.3 8.8.4 8.8.5 8.8.6 8.8.7 8.9 Surface preparation shall be done as per procedure One coal of F-9 shall be applied wherever damage was observed on pre-erection / pre fabrication / shop primer of inorganic zinc silicate coating (F-9)

Paint application Shop priming / Pre-erection priming with F9 or F12 shall be done only on blasted surface Shop priming / Pre erection priming with F-9 shall be done only with airless spray. For large flat surface field painting shall be done by airless spray otherwise brush can be used. DOCUMENTATION A written quality plan with procedure qualification trials and for the actual work Daily progress report with details of weather conditions, particular applications, no. of coats and type of materials applied, anomalies, progress of work versus programme Result of measurement of temperatures relative humidity, surface profile, film thickness, holiday detection, adhesion tests with signature of appropriate authority Particulars of surface preparation and paint application during trials and during the work. Details of non- compliance, rejects and repairs Type of testing equipments and calibration Code and batch numbers of paint materials used PRIMER APPLICATION After surface preparation, the primer should be applied to cover the crevices, comers, sharp edges, etc., in the presence of inspector nominated by Jacobs.

8.9.1 8.9.2

The shades of successive coats should be slightly different in colour in order to ensure application of individual cost, the thickness of each coat and complete coverage should be checked as per provision of this specification. This should be approved by Jacobs before application of successive coats. L&T shall provide standard thickness measurement instrument with appropriate range(s) for measuring. Dry film thickness of each coat, surface profile gauge for checking of surface profile. Holiday detectors and pinhole detector and protector whenever required for checking in case of immersion conditions. All the inspections instruments shall be provided by L&T.

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8.9.3

8.9.4

8.9.5 8.9.6

Prior to application of paints on surface of chimneys, the thickness of the individual coat shall be checked by application of each coat of same paint on M.S test panel. The thickness of paint on test panels shall be determined by using gauge such as Elkometer. The thickness of each coat shall be checked as per provision of this specification. This shall be approved by Jacobs before application of paints on surface of chimney. At the discretion of Jacobs the paint manufacturer must provide the expert technical service at site as and when required. This service should be free of cost and without any obligation to the owner, as it would be in the interest of the manufacturer to ensure that both surface preparation and application are carried out as per their recommendations. Final inspection shall include measurement of paint dry film thickness. Adhesion, holiday detection check of finish and workmanship. The thickness should be measured at as many points/ locations as decided by Jacobs and shall be within +10% of the dry film thickness, specified in the specifications. L&T shall arrange for spot checking of paint materials for sp. Gr. Glow time (ford cup) and spreading rate.

9.0

INSPECTION AND TESTING

9.1 All painting materials including primers and thinners brought to site by L&T for application shall be produced directly from manufactures as per specifications and shall be accompanied by manufacture's test certificates. Paint formulations with out certificates are not accepted. 9.2 Jacobs at his discretion may call for paint formulations. L&T shall arrange to have such tests performed including batch wise test of wet paints for physical & chemical analysis. All costs shall be bone by L&T. 9.3 The painting work shall be subject to inspection by Jacobs at all times. In particular following stage-wise inspection will be performed and L&T shall offer the work for inspection and approval at every stage before proceeding with the next stage. The record of inspection shall be maintained in the registers. Stages of inspection are as follows: a) Surface preparation b) Primer application c) Each coat of paint In addition to above, record should include type of shop primer already applied on equipment e.g. Red Oxide zinc chromate or Red lead primer etc. Any defect noticed during the various stages of inspection shall be rectified by L&T to the entire satisfaction of Jacobs before proceeding further. Irrespective of the inspection ,repair an approval at intermediate stages of work, L&T shall be responsible for making good any defects found during final inspection / guarantee period/defect liability period as defined in general condition of contract. Dry film thickness (D.F.T) shall be checked and record after application of each coat and extra coat of paint should be applied to make-up the DFT specified without any extra cost to owner, the extra cost should have prior approval of Jacobs.

10.0

FINISH COAT COLOUR & COLOUR CODING

Finish coat and colour coding shall be applicable as per approved document L&T/MSQ/COLOUR

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CODE//001 Rev 00 and approved format L&T/MSQ/COLOUR CODE 001 Rev 00.

11.0

SAFETY Safety Precautions shall be followed as per HSE manual.

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