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Specification for Painting and Coating of Oil and Gas Production Facilities Part - 4 Version 2

Table 1 Inspection and Testing Summary Work Stage


Safety Procedures PDO HSE rules Working practices Equipment condition Ventilation Protection Sensitive equipment Adjacent structures/ vehicles Raw Materials Paint Abrasives Conformance to specification Conformance to specification, cleanliness, particle size. ISO-8504-2 Monitor climatic conditions Measurement Visual, documentation, viscosity check to ISO 2431 Documentation, physical/chemical analysis, particle size distribution to ISO 11125-2 Observe and measure variables Monitor air temperature Monitor surface temperature Monitor humidity to ISO 8502-4 Measure directly or calculate Measure Conformance to HSE regulations Monitor all variables as above Size of enclosure. Capacity of air moving equipment. Observe and confirm conformance Observe and confirm conformance As above Monitor dust levels. Measure air part flow As above Digital Thermometer Contact Thermometer Whirling/Sling or Psycro-Dyne Hygrometer Direct reading digital Dewmeter, >500 lux Check operators have proper protective clothing. Ref. Section 8 Check equipment electrical earthing, safety valve dead mans handle operation. Ref. Section 8 Stop work when conditions are outside acceptable limits Stop work if dust levels become excessive . Air 6x per hour Read relative humidity from Hydrometric Tables Confirm by charts or conversion calculator Flow cup type B No. 4 Standard Wire Sieves Packaging, labelling, shelf life, etc. Ref. Section 3.1.3 Make available to PDO record, of paint consumption Reject if wetted by salt water, rain or condensation or moisture content too high. Reject any work blasted with wet abrasive1 Ref. Sections 5.1 and 6.1 Allow time for temperature to stabilise Observation Visual Ensure all protection in place Ensure all protection in place. Isolate work area. Remove vehicles to safe area Observation Visual, documentation, Method Statement Visual, documentation, Method Statement Equipment safety checks Check VOC and air flow rate Ref. Section 7.1 Check requirements for working on live stations and operating equipment Replace faulty equipment

Assessment

Assessment Method

Test Equipment

Notes

Climatic Conditions Weather Air temperature Surface temperature Humidity Dew point Lighting Surface Preparation Personnel protection Equipment Climatic conditions Ventilation for enclosed spaces

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Specification for Painting and Coating of Oil and Gas Production Facilities Part - 4 Version 2.0

Work Stage
Surface cleanliness Surface cleanliness (cont.) Soluble salts

Assessment
Observation

Assessment Method
Visually examine and compare with relevant parts of ISO 8502 Contaminant Pick-up Bresle Method to ISO 8502-6 Test papers Visually examine, compare with standards to ISO 8503 Measure record values to ASTM D 4417 Surface replica to ASTM D4417 As above

Test Equipment
Inspection Mirrors. Illuminated Magnifier. Pictorial Standards Sellotape test ISO-8502-3 Bessle Sampler, Quantab Indicator Papers Surface Comparator, KeaneTator, Rugotest Digital /Mechanical Profile Gauges Textex Tape and Micrometer As above Measure profile height

Notes
Reject surface having large embedded particles that cannot be removed. Tightly adherent fine particles are acceptable. Removing particle by wire brushing is not acceptable.(2) Confirm cleaning has been adequate3 Qualitative checks for Cl, Fe and S etc.

Observation Chemical analysis

Surface profile Anchor pattern Surface roughness Coating Application Climatic conditions

Observation, comparison Observation, measurement Replication Monitor all variables as above

Provides permanent record of surface profile Stop work when conditions are outside acceptable limits Application temperature range as specified by Manufacturer Recoat intervals will depend on ambient temperature Control vapour to 10% of LEL. For some paints having mixed solvents, it is difficult to ventilate to below the TLV. Applicators working in tanks and vessel must wear breathing apparatus4 Ref. Section 8.3 Details to be included in ITP and in daily record

Ventilation for enclosed spaces

Size of enclosure. Capacity of air moving equipment.

Check LEL, TLV or MAC values. Monitor vapour concentrations. Measure air part flow Inspector to check conformance with datasheets

Product documentation. Explosimeter Personal Air Sampling.

Application of Coatings

Visual

SP-1246

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Specification for Painting and Coating of Oil and Gas Production Facilities Part - 4 Version 2.0

Work Stage Inspection


Wet Film Thickness Dry Film Thickness

Assessment
Measurement Measurement

Assessment Method
Use gauges in accordance with ISO 2808 Method 7 A/B Use gauges in accordance with ISO 2808 Method 6 Destructive test using special inspection instruments

Test Equipment
Wet Film Comb. Wet Film Wheel Magnetic and Electromagnetic and Eddy Current Gauges PIG Paint Inspection Gauge Optical magnifier Appropriate solvent Mechanical and Hydraulic Adhesion Testers

Notes
Spot check during application to ensure specified film thickness is being maintained Calibrate instruments at least twice daily using standard foils. Use statistical methods for determining acceptability5 Destructive test on any substrate to confirm DFTs (Not for production painting) Reject if appearance and condition are unacceptable6 Rubbing for 1 min. should not soften coating to fingernail scratch Acceptance: Pull-off force as specified in performance testing. Typically 3-10 N/mm2 . Tests to be done on cuopons

General appearance Degree of cure Adhesion

Observation Observation Pull Off Measurement for New Coating Systems

Visual inspection Solvent swabbing Pull-off tests to ISO 4624

45 oCross cut test

Cross-cut and peel tests to ASTM-3359

45 oCross cut test

For checking internal surfaces and local repairs. For repairs test adhesion between first coat and substrate and between coats. Acceptance: Classification 5A or 4A See note 7 for details Calibration: High voltage - 5-6V per 1 coating thickness9

Film integrity/ porosity

Conductivity

Holiday Testing to NACE RP0188-99

High Voltage Spark Tester

SP-1246

April 2010

Specification for Painting and Coating of Oil and Gas Production Facilities Part - 4 Version 2

Notes to Table 1
1. Blasting Abrasive Quality Abrasive must come from a recognised supplier and be certified in respect of cleanliness and particle size distribution. If there is any doubt about the quality of the blasting grit, the Contractor shall provide a specification covering sieve grading, chemical analyses and physical properties. If such a specification is not available, the Contractor shall take two samples, of minimum 1 kg each, from each of abrasive and arrange for analysis by an independent third party. Specification and/or analysis results shall be submitted to PDO for comparison with accepted values. 2. Surface Cleanliness The Contractor shall visually examine the surface to ensure that dust or dirt has been removed. The Inspector shall not accept a blasted surface contaminated by large embedded abrasive particles that can not be brushed off using a stiff brush. If such contamination is detected, no further blasting shall be performed, using the same batch of abrasive. Tightly adherent embedded fine particles, however, need not be a cause for rejection. Work may be allowed to continue using a different batch, make or type of abrasive approved by PDO. When using copper slag abrasive under high ambient temperature condition, as in Oman, the visual standard Sa 2 may not be obtained due to embedded fine particles causing a different shade. If there is any doubt on the acceptability of the prepared surface, the Contractor shall provide a dedicated visual standard for Sa 2 using copper slag under these conditions. 3. Soluble Salts Soluble salts on a steel surface are taken up in distilled water using a Bressle Sampler. The Bressle titration method shall be used to measure the chloride content. From titration measurements, the recommended maximum salt contamination for immersed surfaces or for tank and vessel coatings is 20-40mg/m2 chloride. Note the value for maintenance work is higher at 60-80mg/m2 4. Ventilation Before and during blasting and coating work in enclosed spaces, adequate ventilation shall be established. During coating operations the vapour concentration shall be monitored at regular intervals using approved equipment and should never exceed 10% of Lower Explosion Limit. This is considered adequate for personnel health protection, avoidance of explosion hazards and to ensure adequate evaporation of solvent from the paint. The TLV (Threshold Limit Value) or MAC (Maximum Allowable Concentration) of the paint used must be known. Ventilation shall be such as to maintain, wherever practical, a safe atmosphere below the TLV. 5. Materials Safety and Handling Data Sheets Vendors are required to supply SHOC cards for each generic paint product in the total coating system. 6. Dry Film Thickness (DFT) After the film is sufficiently dry or cured, the Contractor shall measure the coating thickness and submit the results to PDO. Guidelines for the number of DFT measurements for external coatings to be made after each coat may be usefully based on the 80-20 Rule. This rule suggests that: the measured thickness must not be less than 80% of the specified DFT and a maximum of 20% of the total area painted may be below the specified DFT

The following statistical measurement procedure for the Rule is suggested: 1. Select a number of randomly chosen and continuous 10m2 areas in such a way that 5% of the entire control area is covered. 2. In each area, select a minimum of five 50cm2 sized test fields.

Take three DFT readings in each field and calculate the mean value to be as one single measurement SP-1246 4 April 2010

Specification for Painting and Coating of Oil and Gas Production Facilities Part - 4 Version 2.0

Acceptance criteria: No more than 20% of the total of single measurements to be less than the minimum specified DFT The lowest single measurement should be at least 80% of the minimum specified DFT

The DFT of different layers of a paint system may be measured using a paint inspection gauge using calibrated cutters and microscope. This however is a destructive test and not suitable for production painting. For internal coating systems use a 90:10 rule and apply the same procedure as above. 7.0 Adhesion Testing Pull off adhesion testing in accordance with ISO-4624 and cross cut testing in accordance with ASTM D3359 shall be carried out on test panels to ensure the coating system meets the performance requirements. The panels will then be used as a check to compare the cross testing results done on the actual structure. Cross cut testing shall be carried out at the following frequencies. For external coatings and repair work 1 per 100m2 with a minimum of 2 per structure. For internal coatings and repairs the frequency shall be 1 per 10m2 with a minimum of 2 per structure. For repairs only cross cut testing shall be used and this will be carried out on the structure. Adhesion testing is not applicable to GRE lining or pipeline repairs. 8. Visual Inspection Each coating applied shall be inspected visually. The paint system applied should have the correct shade, degree of gloss and evenness and be free from tackiness after drying/curing and free from cracks, holidays, runs, sags, wrinkles, brush or roller marks or other defects that may deleterious to the quality of the coating. Finishing coats shall be even in colour and gloss. 9. Integrity Testing For internal coating systems 100% of the surface shall be tested using a metallic brush type holiday detector in accordance with NACE RP 0188-99. Special attention shall be paid to welds, edges and irregular surfaces. For external surfaces, random inspection, which shall be representative of the entire surface shall be conducted. A high voltage spark detector shall be used for all heavy-duty systems including glassflake, GRE, high DFT epoxies and pipeline coating repairs. Testing shall be in accordance with NACE RP 0188 and RP0274 (for pipeline coatings). The type of brush shall be suitable for the surface being inspected. The voltage setting shall be according to the Manufacturers recommendations or as given in the coating system specification. Generally the detector voltage is set at 5-6V for every micron of coating thickness.

1.1

Reporting
The Inspector or Contractor shall record and report daily all inspection results as stated in the Method Statement. If work is carried out within the Sultanate of Oman, standard Daily Report Sheets as shown in appendix-B shall be used for reporting. Such a report shall contain the following minimum information: 1. General - Date, project and job identification, Contractor and Inspector names - Inspection location and times - Safety Aspects Ambient Conditions - Air and substrate temperatures, relative humidity, dew point - Presence of wind or dust, sunlight or shade - Access and illumination conditions

2.

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