Xstrata Technology Pty LTD: Surface Preparation & Protective Coating - General Requirements

Xstrata Technology Pty Ltd
ABN 65 118 727 870

Level 4, 307 Queen Street, Brisbane, Queensland 4000
Telephone: +61 7 3833 8500. Facsimile: +61 7 3833 8555 www.xstratatech.com

XSTRATA TECHNOLOGY PTY LTD

TECHNICAL SPECIFICATION PMA-XT-SP0012

SURFACE PREPARATION & PROTECTIVE COATING -
GENERAL REQUIREMENTS

Signatures Revision Date
Revised
Description/Comment
Originator Checked Approved
0 25-Jan-10 Approved for Use C. Hanna B. Boucher H. Joubert

TECHNICAL SPECIFICATION
SURFACE PREPARATION & PROTECTIVE COATING - GENERAL
REQUIREMENTS
Document No.:
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Rev No.
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ABN 65 118 727 870
REQUIREMENTS
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TABLE OF CONTENTS
1 SCOPE AND CONTENT OF GUIDELINES................................................................................................. 3
2 STANDARDS........................................................................................................................................... 3
3 DEFINITIONS........................................................................................................................................... 4
4 ABBREVIATIONS .................................................................................................................................... 5
5 CONTRACTORS RESPONSIBILITIES ........................................................................................................ 6
6 SAFETY REQUIREMENTS........................................................................................................................ 6
7 PLANNING REQUIREMENTS................................................................................................................... 7
8 QUALITY ASSURANCE ........................................................................................................................... 7
9 GENERAL SURFACE PREPARATION....................................................................................................... 9
10 SURFACE PREPARATION CASES ...................................................................................................... 12
11 SURFACE PREPARARTION OF CONCRETE AND MASONRY SURFACES.......................................... 13
12 CLEANING, PROCESSING, SURFACE TREATMENT, TESTING, AND HANDLING OF PIPEWORK USED
FOR CONVEYING OXYGEN ENRICHED COMBUSTION AIR OR HIGH PURITY OXYGEN............................. 14
13 CLEANING OF HYDRAULIC AND FUEL PIPE-WORK AFTER FABRICATION...................................... 17
14 PROTECTIVE COATING APPLICATION.............................................................................................. 18
15 REPAIRS TO NEW COATINGS........................................................................................................... 21
16 GALVANISED COATING FOR STEEL................................................................................................. 22
17 IDENTIFICATION............................................................................................................................... 24
18 HANDLING, PACKING AND TRANSPORT OF FINISHED COATED ITEMS......................................... 25

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1 SCOPE AND CONTENT OF GUIDELINES
1.1 This specification defines the requirements for industrial protective coatings systems for
substrates on equipment, structures and civil works for use in Xstrata Technology (XT) Projects.
This specification does not include information on the following coating and lining systems:
Metal spraying
Rubber lining
Anodising
Colorbond or Pre-coated Metal Sheeting
Manufacturers standard coatings systems applicable to propriety equipment such as
electrical motors, valves, actuators and instrumentation.
2 STANDARDS
2.1 All coating materials, surface preparation and application activities shall comply with the
current issue of the relevant standards including the following.

AS 1318 SAA Industrial Safety Colour Code
AS 1319 Safety Signs for the Occupational Environment
AS 1345 Identification of the Contents of Pipes, Conduits and Ducts
AS 1580 Paints and Related Materials Method of Test
AS 1627 Metal finishing Preparation and Pre-treatment of Surfaces, Parts 0 to 9
AS 1940 Storage and Handling of Flammable and Combustible Liquids
AS 2105 Inorganic Zinc Silicate Paint
AS 2310 Glossary of Paint and Paint Terms
AS 2312 Guide to the Protection of Iron and Steel Against Exterior Atmospheric
Corrosion
AS 2700 Colour Standards for General Purposes
AS 3750 Paints for Steel structures
AS 3894 Site testing of Protective Coatings
AS 3990 Mechanical Equipment (Steelwork)
AS 4100 Steel Structures (Appendix C)
AS/NZS
ISO 9002
Quality Systems Model for Quality Assurance in Production, Installation
and Servicing
SIS
055900
Pictorial Surface Preparation Standards for Painting Steel Surfaces (Swedish
Standard)
NACE NACE International Joint surface Preparation Standard NACE No 5/SSPC-SP
12 Surface Preparation and Cleaning of Steel and Other Hard Materials by
High and Ultra High Water Jetting Prior to Recoating
International Protective Coatings Hydroblasting Standards.
International Protective Coatings Slurry Blasting standard.
International Protective Coatings Abrasive sweep Blasting.

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3 DEFINITIONS
XT: Xstrata Technology Pty Ltd

Client: Person or company to whom XT reports to. (Also known as the
Principal)

Engineer: Person or company appointed by XT to oversee the Contract between
the Contractor and XT. (Also known as Superintendent for the Contract)

XT Inspector: Person or company appointed by XT to inspect the work carried our by
the Contractor and or Painting Contractor

Contractor: Person or company that reports to XT. In certain circumstances the
Painting Contractor and the Contractor may be one and the same.

Painting Contractor: Person or company responsible for carrying out surface treatment work.
The Painting Contractor usually reports to the Contractor, however, in
certain circumstances the Painting Contractor and the Contractor may
be one and the same.

Approved: Approval, in writing, by a statutory authority, XT, the Engineer or a
recognised governing body (i.e. NATA, Standards Australia). In the
event of conflict, that conflict shall be resolved by giving precedence in
the order as stated.

Method Statement: A detailed account of methods and procedures used in surface
preparation and protective coatings application.

Pre-blast: Preliminary blasting operations carried out to remove old, contaminated
coatings prior to profile blasting.

Profile blast: Blasting operations carried out to achieve a desired profile, usually the
final blast prior to coating, or surface treatment.

Spot blast: Blasting operations carried out to remove localised corrosion, or
damage, to otherwise sound coatings.

Stripe coat: Brush applied coating, usually to edges, welds and other areas
susceptible to coating breakdown.

Substrate: Base material over which a protective coating is applied.

Whip blast: Light blasting carried out to abrade a surface, with minimal removal of
the substrate.

Site: A site other than the Painting Contractors works

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4 ABBREVIATIONS
ACA: Australasian Corrosion Association
AS: Australian Standard
BS: British Standard
DFT: Dry Film Thickness
EPA: Environment Protection Authority
ITP: Inspection and Test Plan
kPa: kilo Pascals
MSDS: Material Safety Data Sheets
NACE: National Association of Corrosion Engineers, Houston Texas
ppm: Parts per million
QA: Quality Assurance
QC: Quality Control
RH: Relative Humidity
TDS: Total Dissolved Solids
m: Microns (0.001 mm)

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5 CONTRACTORS RESPONSIBILITIES
5.1.1 The Contractor shall supply all tools, equipment, scaffolding, weather protection, abrasives,
coating materials and thinners, labour, supervision, and all other things necessary to apply
the nominated coatings to structures and/or equipment as specified.
5.1.2 All surface preparation work and application of coatings shall be performed by personnel
with a minimum of three years' experience with heavy-duty industrial coating application,
particularly using solvent free epoxy systems.
5.1.3 The Painting Contractor shall be accredited under lS0 9002 or equivalent.
5.1.4 All work may be subject to inspection by XT. The Contractor shall conduct their inspections
and quality control responsibilities in accordance with their approved Quality Plan including
their Inspection and Testing Plan (ITP).
5.1.5 Inspection by the XT shall not imply acceptance for any defective work subsequently found.
5.1.6 The Contractor shall employ a coating inspector certified by ACA, NACE, ICQRR, or an
approved equivalent body to verify that coatings are applied in accordance with this
specification and with the coating manufacturer's recommendations.
5.1.7 The identity and qualifications of the appointed inspector shall be nominated to the XT
Engineer prior to the commencement of work.
5.1.8 Inspection of the work shall be in accordance but not limited to the requirements of Section
8 of this specification.
5.1.9 The Contractor shall ensure that all surface preparation and coating work is performed in
accordance with the coating manufacturer's recommendations and the provisions of this
specification.
5.1.10 If the work does not comply with these instructions, it may be deemed to be defective. Such
defective work shall be made good by re-preparation and/or re-coating, in accordance with
the applicable specifications, at no additional cost to XT.
5.1.11 The Contractor shall maintain detailed records and prepare documentation in accordance
with Section 8 of this specification, as well as the Quality Assurance Requirement
Specification, and shall submit such documentation to the XT Engineer as required in the
Contract.
6 SAFETY REQUIREMENTS
6.1.1 All appropriate SH&E procedures and requirements shall be complied with.
6.1.2 Coating materials thinners etc are classified as hazardous materials. The use and storage
shall comply with AS 1940, Coating Manufacturers Recommendations and the Dangerous
goods act.
6.1.3 Health and safety instructions as described on the Manufacturers Safety Data Sheets (MSDS)
and warning labels on containers relating to the use of coatings, thinners and cleaning
operations such as fume exposure, confined ventilation storage issues etc. shall be fully
understood by the workers before commencement of protective coating activities.

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7 PLANNING REQUIREMENTS
7.1.1 All surface preparations and coatings shall be shop applied wherever possible
7.1.2 Unless otherwise specified, no steel components shall be installed without all of their surfaces
having at least been prepared and a primer coat applied. This is of special importance where
subsequent blast cleaning would be harmful to installed equipment or other coated surfaces.
7.1.3 It is essential that the environmental conditions applicable at the time and place of the
intended work, including ambient temperature, relative humidity, substrate temperature and
wind conditions, are within the manufacturer's limits for the nominated preparation process
or coating application. The limits of these environmental conditions are given in section 13 of
this specification. Under no circumstances, shall coatings be applied if environmental
conditions are outside of those listed.
7.1.4 The Contractor shall ensure that adequate allowance is made in the schedule for poor
coating conditions or that other provisions are made to ensure that the specified application
conditions are attained.
8 QUALITY ASSURANCE
o Full quality assurance requirements are detailed in the Quality Assurance Requirement
Specification for Procured Items.
o The Contractor shall carry out the work in accordance with the requirements of this
Specification. All work shall conform to the relevant Australian Standards and to XTs
requirements. It is the responsibility of the Contractor to demonstrate at any stage of the
work his conformance to the requirements of this Specification to the satisfaction of the XT
Engineer.
o The contractor shall appoint a certified coating supervisor (ACA, NACE or approved
equivalent) for the inspection and testing of the coating system.
o The Contractor shall perform all necessary inspections to assure that the work is meeting all
requirements of this Specification.
o The Contractor shall provide at least three days notice to the Engineer prior to the
commencement of any protective coating work.
8.1 QUALITY ASSURANCE AND TRACEABILITY
8.1.1 Preference shall be given to the manufacturers and applicators of protective coatings, which
are certified to ISO 9002 or equivalent, or in the process of gaining certification or holding
approval from the Paint Contractors' Certification Program (Class 4).

8.2 INSPECTION AND TEST WORK PLANS (ITPs)
8.2.1 The Quality Plan shall contain an Inspection and Test Plan (ITP) nominating approved daily
inspection reports (to AS 3894.10) and Equipment Inspection reports (to 3894.11) reflecting
the required quality control points and activities over each phase of the protective coating
system, e.g. surface preparation, application, acceptance testing, transport, coatings repairs
etc. Approval from the XT Engineer must be gained before commencement of protective
coating preparation and application.

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8.3 PAINTING CONTRACTOR RECORDS
8.3.1 The Painting Contractor shall maintain written records of the work so that complete
traceability of all work and materials provided under this Specification is maintained. The
three Australian Standards 3894-10, -11, & -12 QA report forms shall be used as a minimum
record keeping format.
8.3.2 These reports shall be maintained on a daily basis and submitted to the XT Engineer when
requested, or if not specifically requested, at the completion of the Works.

8.4 FILM THICKNESS TESTING
8.4.1 The film thickness is the minimum dry film thickness, including primer coats specified in the
painting system. Final acceptance of each increment of work will not be made until the dry
film thickness meets or exceeds the specified thickness. Regardless of the number of coats
specified, such additional coats shall be applied as may be necessary to achieve the specified
thickness, at the Painting Contractor's expense.
8.4.2 The Painting Contractor shall provide and operate wet film and dry film thickness gauges of
an approved type to ensure the correct thickness of each coat and the full system is achieved.
8.4.3 Total dry film thickness on metallic substrates shall be determined by means of a properly
calibrated electronic thickness inspection gauge in accordance with AS 3894 & AS/NZ
1580.108.1. The results of these measurements shall recorded by the Contractor.
8.4.4 Each nominated coat shall not be less than the specified minimum DFT (as described in AS
3894.3). The average of any 5 readings on each 10m of surface area shall be equal to or
greater than the specified DFT and no single point reading shall be less than 80% of the
specified DFT. The DFT shall not exceed the maximum DFT nominated in the manufacturers
data sheet.
8.4.5 DFT readings shall be taken in a manner and location that is representative of the entire area.
8.4.6 Calibration of the DFT gauge shall be performed prior to each batch of measurements using
a series of known standards. Calibration methods are detailed in the Australian Standard
3894.
8.4.7 During application of the coating system the wet film thickness of each coat shall be regularly
checked with an appropriate gauge to ensure that the required wet film thicknesses are
being applied.

8.5 FILM CONTINUITY
8.5.1 Coated surfaces requiring film continuity inspection such as the coatings on the inside of
tanks and internal surfaces of launders shall be tested for holidays, pinholes, scratches and
other coating discontinuities by means of an approved pinhole or holiday detector (Spark
Tester).
8.5.2 Testing shall be conducted in accordance with AS 3894.
8.5.3 The final continuity tests shall be a hold point in the Contractors ITP and may be performed
and or witnessed by the Xstrata Technology Inspector.

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8.6 CORRECTION OF DEFECTS AND DEFICIENCIES
8.6.1 All deficiencies and defects revealed by the above inspection and test methods shall be
promptly repaired or corrected.

8.7 XSTRATA TECHNOLOGY INSPECTOR
8.7.1 A certified inspector of coatings, ACA (Australian), NACE (United States), Icorr (U.K), or
approved equivalent may be appointed by the / Engineer for the Contact for inspection and
testing of protective coating systems to be applied by the Painting Contractor.
8.7.2 All work may be subject to inspection by the Xstrata Technology Inspector. However, this
shall not relieve the Painting Contractor of his own Quality Assurance/Quality Control
responsibilities nor prevent the Contractor from appointing his own inspector.

8.8 INSPECTION & TESTING
8.8.1 Testing shall include but not limited to:
Surface contaminant test.
Surface profile measurement testing
Coating Dry Film Thickness Test (DFT) to AS 3894.3.
Adhesion test to BS 3990
Continuity Testing (holiday detection) to AS 3894.1
Testing for cure of coatings to AS 3894.4

9 GENERAL SURFACE PREPARATION
o The performance of any paint coating system is directly dependent upon the correct and
thorough preparation of the surface prior to coating. The most expensive and technological
advanced coating system will fail if the surface preparation is incorrect or incomplete.
o The importance of removing oil, grease, old coatings and surface contaminants such as mill
scale, corrosion product on steel, laitance on concrete and zinc salts on galvanised surfaces
cannot be over emphasised.
o The principal factors affecting performance are:
Soluble surface contamination including salts, sulphides, oils, grease, drilling and
cutting compounds,
Integral surface contamination including rust, mill scale and surface profiles
(roughness).

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9.1 SURFACE DECONTAMINATION
9.1.1 Surface decontamination is required prior to the application of protective coatings, when
preparing previously coated or uncoated steel that has been exposed to a corrosive
environment.
9.1.2 Before abrasive blasting is carried out, all soluble surface contaminants shall be removed in
accordance with AS 1627.1. This can be achieved by the use of:
Proprietary emulsions
Degreasing compounds
Steam cleaning
9.1.3 Solvent washing shall be followed by wiping with clean rags. The wiping clean is essential,
because if this is not carried out thoroughly the result of solvent washing will simply spread
the contaminants.
9.1.4 Once abrasive blasting has been completed, all surfaces shall be tested for the presence of
chlorides, soluble metal salts and alkaline/acidic contaminants with a SCAT Kit or similar
approved tests, such as:
Using ferrous ion (Eisen) indicator strips.
Titrations analysis e.g. Quantab Chloride Titrator No 1174 indicator test strips.
PH indicator strips
9.1.5 No steel may be coated until the contaminants are below the following maximum ranges for
contamination:
Soluble iron salts < 3mg/l.
Sodium Chloride less than 30 ppm
PH between 6 and 8
9.1.6 When these ranges are exceeded, use a high-pressure potable water spray (hydro blast) using
a minimum nozzle pressure of 25,000 kPa to remove any contaminants from the surface.
Hydro blasting shall only be used on steel, which has previously been abrasive blasted, UNO.
9.1.7 After each hydro blast, the surfaces shall be retested and if contamination values are still
found to exceed the maximum values, the surfaces must be hydro blasted again and
retested.
9.1.8 The frequency of testing shall not be less than once every 10m
2
.
9.1.9 Hydro blasting must be used until any contamination falls below the maximum range for
each contaminant. The testing shall be recorded on a suitable approved quality control
sheet.
9.1.10 Hydro blasting shall comply with NACE Standard 5/SSPC-SP12 Surface Preparation and
Cleaning of Steel and Other Hard materials by High and Ultra High Pressure Water Jetting
Prior to Recoating.

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9.2 SURFACE DEFECTS
9.2.1 Surface defects likely to be detrimental to the protective coating system shall be brought to
the attention of the XT Engineer for evaluation.
9.2.2 Defects deemed to be structurally deleterious shall be removed and/or repaired and the area
re-blasted in accordance with the relevant XT Coating System. Defects such as voids crevices
gaps etc. that are deemed not to be structurally deleterious shall be filled with an approved
solvent-less epoxy filler after prime coat and before top coat.
9.2.3 Flash rusting shall be re-blasted in accordance with AS 1627.4 and the specified XT coating
system.

9.3 ABRASIVE BLASTING
9.3.1 Abrasives shall comply with AS 1627.4 and shall be dry and free from contamination.
9.3.2 Abrasives shall be tested for chlorides or other contaminants before first time use. Chlorides
shall not exceed 30 ppm.
9.3.3 The abrasive medium shall be new and unused. Recycled abrasive shall only be used for pre-
blasting. The use of silica sand or other potentially harmful abrasive material shall not be
used.
9.3.4 Blast cleaned surfaces left uncoated for more than four (4) hours shall be re-blasted to the
specified class before priming.
9.3.5 Abrasive blasting shall not be carried out (except for pre-blasting) when:
The relative humidity is above 85%.
The metal temperature is less than 3
C above dew point.

9.4 WHIP BLASTING
9.4.1 Whip blasting is an abrasive blast of a previously blast cleaned surface, to restore a class of
surface preparation which has deteriorated with time.
9.4.2 Whip blasting shall be carried out when specified. It is typically used when:
Recoating old epoxy coatings
The re-coating interval for a two-pack system is exceeded.
Applying new coating over a glossy substrate.
Coating galvanised steel or Aluminium.
9.4.3 The following conditions must be met when whip blasting unless otherwise approved by the
XT Engineer:
Compressor air not exceeding 300 kPa.
Abrasive grades between 0.2 0.5mm.
Abrasive material is clean & dry.
Minimum nozzle size 10mm.
Blast nozzle held at about 45 to the substrate at a distance of approximately 400mm
from the surface.

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9.5 SWEEP BLASTING
9.5.1 Sweep blasting is a light abrasive blast cleaning to roughen a surface or remove light rust,
foreign particles and outer surface coatings. It shall be carried out in accordance with
Appendix D of AS1627.4.

9.6 WET ABRASIVE BLASTING
9.6.1 Wet abrasive blasting uses slurry consisting of water and abrasive. This process eliminates
hazardous dust that may be generated by abrasive blasting heavily contaminated steel.
Furthermore, when wet blasting old, extensively corroded steel many of the soluble corrosion
products and/or chlorides in the pits of the steel will be washed out. This greatly improves the
performance of the applied coating. However a disadvantage is that the wet steel will
corrode rapidly.
9.6.2 Wet Abrasive blasting and any measures required to prevent flash rusting shall be in
accordance with AS1627.4
9.6.3 Where wet blasting is used and shows signs of corrosion the surface must be dry abrasive
sweep blasted before the application of the protective coating.

10 SURFACE PREPARATION CASES

10.1 PREPARATION OF PRE-TREATED SURFACES
10.1.1 Galvanised steel surfaces shall be degreased by solvent cleaning or other approved method in
accordance to AS 1627.1. The surface shall then be whip blasted to remove the oxide film
and surface contamination with minimal reduction in the galvanised coating thickness. The
blasted surface shall exhibit a dull grey finish and a surface profile suitable for proper
adhesion of the specified protective coating.
10.1.2 Pre-painted surfaces shall be degreased in accordance with AS 1627.1, and then whip
blasted removing gloss, chalking, loose material and peeling, or laminated paint.

10.2 PREPARATION OF MAINTENANCE COATINGS
10.2.1 The pre-painted surfaces shall be degreased in accordance with AS 1627.1, and then whip
blasted to remove gloss, chalking, loose material and peeling, or laminated paint, prior to
maintenance coating.
10.2.2 The contractor shall ensure that old coatings are tested and deemed lead free before surface
preparation.
10.2.3 Repair and maintenance coating of existing coatings shall be determined according AS2312
section 10.2.
10.2.4 Compatibility between existing and new coatings systems shall be ensured using existing
records, use of test patches or analytical testing e.g. Infrared Spectroscopy, to identify the
original coating.

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10.3 SPOT CLEANING
10.3.1 The cleaning of localised corrosion or coating breakdown areas shall be carried out prior to
protective coating maintenance activities. This shall require the removal of decomposing
protective coating and/or corrosion product, by either abrasive blasting, power tool cleaning
or hand cleaning. The specified cleaning method must provide a suitable substrate for the
coating being applied. The perimeter of the sound existing coating to bare steel interface
shall be feathered for 50mm to provide a smooth finish surface. The sound coating shall be
dry abrasive sweep blasted to provide a suitable key for the protective coating.
10.3.2 Before application of a protective coating, the surface profile of the shall be measured in
accordance with AS 1627.4 and conformed as complying to the specified XT coating system.
10.3.3 Hand cleaning, where specified, shall be in accordance with AS 1627 Part 7.
10.3.4 Power tool cleaning, where specified, shall be in accordance with AS 1627, Part 2.

11 SURFACE PREPARARTION OF CONCRETE AND MASONRY SURFACES
11.1 EXISTING PAINTED SURFACE
11.1.1 The surface shall be clean, dry and free from grease (see clause 6.2 degreasing). Any
corrosion salts shall be removed by light abrading and water washing. The cleaned surface
shall then be abraded or very lightly blasted using low pressure and non-metallic abrasive and
primed with a coat of etch primer prior to painting. For lead-based existing coating,
thoroughly abrade surface and omit etch primer.
11.2 NEW CONCRETE
11.2.1 The surface should be clean, dry and free from oil, grease and other contaminants such as
forming lubricants and curing components, which would affect adhesion of a coating. The
moisture content of the concrete or masonry should be less than 6%, measured by a
Protimeter Survey Master or similar.
11.2.2 Laitance and loose surface powder formed on new concrete must be removed. The alkalinity
and porosity of the surface must be considered when painting concrete or masonry. The
preferred surface treatment is
Sweep blasting using recoverable abrasive blasting media.
Wire brushing.
A proprietary acid etch treatment followed by thorough water washing
11.2.3 Any cracks shall be filled with an approved epoxy sealant prior to painting.

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12 CLEANING, PROCESSING, SURFACE TREATMENT, TESTING, AND HANDLING OF
PIPEWORK USED FOR CONVEYING OXYGEN ENRICHED COMBUSTION AIR OR
HIGH PURITY OXYGEN
12.1 GENERAL
12.1.1 Very stringent handling, cleaning and testing procedures will apply to the internal surfaces of
all equipment and pipe-work associated with the conveyance and distribution of oxygen
and/or highly oxygen enriched air. The Supplier shall comply with the requirements set out in
the following sections relating to handling and execution of surface treatment, cleaning
procedures, inspection and approval of cleaned items, protective sealing against re-
contamination after completion of cleaning and clear marking for identification and
protection against installation of non-approved items.
12.1.2 Care shall be taken during cleaning operations to avoid personal injury from toxic vapours
generated from some cleaning chemicals. Special attention shall be given to the handling of
these products, and to the protective measures required for personnel using them including
suitable clothing or other special protective body cover and work area ventilation.
12.1.3 The cleaning areas shall be clean and completely protected from intrusion of contaminating
materials including dusts, grinding cuttings, etc.
12.1.4 Equipment and tools used in the cleaning areas shall be cleaned so as to be free of oil,
grease, hydrocarbons or any other prescribed contaminants, and dedicated to the work
described herein. Personnel engaged in the work shall not have oil, grease or other
contaminating substances on hands or clothing.
12.1.5 Equipment supplied free-issue to the supplier, such as valves, bellows and instrumentation
items, and designated as cleaned for oxygen service shall be stored and protected against
contamination and only removed from their sealed packaging immediately prior to
incorporation into an assembly with fully processed pipe spools or other components.
12.1.6 All blasting, chemical cleaning/washing and final assembly activities relating to oxygen
conveyance and distribution pipe work shall have client (Xstrata) hold points on the relevant
ITP.
12.1.7 CAUTION!! The dried residues of all degreasing solutions are flammable. These residues must
therefore be completely removed during processing by rinsing. For stainless steel equipment,
clean potable water can be used to rinse any residues away. If the equipment is
manufactured from plain carbon steel, a rust inhibitor must be added to the clean potable
water before it can be used for rinsing purposes.
12.2 SPECIAL EQUIPMENT
12.2.1 Applied Australia Pty Ltd Degreasing Agent No. 4480 (or XT approved equivalent)
12.2.2 Applied Australia Pty Ltd Rust Inhibiter Agent No. 4-320 (or XT approved equivalent)
12.2.3 Ultra-violet (UV or black-light) light source. The light source is required to emit a
wavelength of between 2500-3700 Angstrom units with a minimum power output of
800W/cm2.
12.2.4 Paper suitable to test for the presence of hydrocarbons. Cigarette paper (e.g. Tally-Ho,
Zigzag) or Xstrata approved equivalent.
12.2.5 Dry, oil-free compressed air to ISO 8573.1:2001 Class 2.2.1.

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12.3 INTERNAL CLEANING FOR OXYGEN ENRICHED AIR PIPING
12.3.1 Inspect all piping material prior to fabrication and degrease as necessary in order to prevent
any contamination of the piping material during fabrication.
12.3.2 Inspect piping immediately following fabrication. Any slag, or welding residues should be
removed.
12.3.3 Degrease, flush, and dry. (Refer to Section 12.5 for details regarding degreasing and use of
rust inhibitor agents).
12.3.4 Further inspection of the bore of the piping, using a ultra-violet light source, should be
carried out. Should the piping be found to contain any amounts of hydrocarbon materials, it
is recommended the piping be degreased, flushed, and dried. (Refer to Section 12.5 for
details regarding degreasing and use of rust inhibitor agents). This cleaning procedure may
help prevent the impregnating of unwanted material during the grit-blasting procedure.
12.3.5 Grit blast the entire inner surfaces of the plain, carbon steel fabricated pipe assemblies using
clean, new garnet grit medium and dry, oil-free compressed air. Clean to AS1627.4 Class
SA2
1
/
2
. Upon completion, remove unwanted dust and grit using dry, oil-free compressed air
or nitrogen.
12.3.6 Rinse using clean, high pressure potable water until all traces of grit medium has been
removed. If the piping is fabricated from plain carbon steel, a rust inhibitor must be added to
the potable water prior to it being used for rinsing. The degreasing, flushing and drying must
then immediately follow the rinsing process.
rust inhibitor agents). This procedure is to be performed immediately following the rinse
procedure.
12.3.8 Inspect piping using a ultra-violet light source. Areas that are inaccessible and cannot be
inspected with the UV light (Refer Section 12.2) are to be inspected using paper (Refer
Section 12.2). Acceptability of cleaning shall be determined by Xstrata Technology or its
nominated representative. Should unacceptable levels of trace hydrocarbons be found
during inspection, then, repeat the previous degreasing, flushing and drying step as
necessary.
12.3.9 Immediately following inspection and approval of the state of cleanliness by the XT Engineer,
or XT representative, all piping must be sealed. Prior to sealing, desiccants should be packed
in the piping to prevent any moisture from condensing in the pipe. The Contractor can then
securely seal all screwed ports with caps or plugs and install blank flanges with gaskets on all
flanged openings.
12.3.10 Apply the protective coatings to the external surfaces of any plain carbon steel piping in
accordance to the specified protective coating system.
12.3.11 Each item can then be included in its designated pipe section, or sub-assembly, as per the
assembly drawing, with care being taken to prevent the ingress of any agents of
contamination. The assembly shall incorporate, without further treatment, all necessary free-
issue equipment (valves, bellows etc) provided to the Supplier.

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12.3.12 Unless noted otherwise, all sub-assemblies and sealed pipe sections are to be leak tested with
clean, dry air, or, Nitrogen to 300kPa, hold for at least 30 minutes. If pressure falls by more
than 10kPa, pipe shall be checked for leaks and made good as required. Repeat the leak test
as required following leak rectification. Upon successful leak testing, slowly relieve pressure
and remove leak testing equipment. Please note that the desiccants placed in the piping prior
to painting need to be removed prior to leak testing.
12.3.13 Once testing has been successfully completed, the sub-assemblies and pipe sections can be
totally sealed to prevent the ingress of any agents of contamination. Prior to sealing the pipe
sections, or sub-assemblies, a sachet containing at least 250 grams of an approved desiccant
such as Silica Gel shall be securely fixed to the inner face of the sealing membrane. Large
assemblies shall be provided with multiple desiccant sachets.
12.3.14 Note: the time span between the inhibitor application and assembly/sealing shall be
minimized. If the item has not been assembled and sealed within a period of 1 day from the
start of chemical cleaning, then the procedure must be repeated. This is to prevent
contamination of the piping.

12.4 CLEANING OF STAINLES STEEL PIPES FOR OXYGEN SERVICE PIPING
removed.
12.4.3 Pickle and passivate all the heat affected zones around all the welds using Australian Stainless
Steel Development Association (ASSDA) recognized pickling and passivation liquids, typically
a mix of nitric and phosphoric acid. Follow the manufacturers application instructions. Rinse
and dry thoroughly (Refer to Section 11.5 for details on rinsing).
12.4.4 Degrease, flush, and dry. (Refer to Section 11.5 for details regarding degreasing).
12.4.5 Inspect piping using a ultra-violet light source. Areas that are inaccessible and cannot be
inspected with the UV light (Refer Section 11.2) are to be inspected using paper (Refer
Section 11.2). Acceptability of cleaning shall be determined by Xstrata Technology or its
nominated representative. Should unacceptable levels of trace hydrocarbons be found
during inspection, then, repeat the degreasing, flushing and drying procedure as necessary.
12.4.6 Immediately following inspection and approval of the state of cleanliness by the XT Engineer,
or XT representative, securely seal all screwed ports with caps or plugs and install blank
flanges with gaskets on all flanged openings.
12.4.7 Each item can then be included in its designated pipe section, or sub-assembly, as per the
assembly drawing, with care being taken to prevent the ingress of any agents of
contamination. The assembly shall incorporate, without further treatment, all necessary free-
issue equipment (valves, bellows etc) provided to the Supplier.

REQUIREMENTS
Document No.:
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Rev No.
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ABN 65 118 727 870
REQUIREMENTS
25-Jan-10
Page 17 of 25

12.5 DEGREASING AND RINSING PROCEDURES
12.5.1 Thoroughly review the Applied Australia Pty Ltd Material Safety Data Sheets for Degreasing
Agent No. 4480 and Rust Inhibitor Agent No. 4-320 prior to initiating use.
12.5.2 Use the Xstrata approved Applied Australia Pty Ltd degreasing agent No. 4480 and follow
the manufacturers directions for use. Use fresh water and mix to the approved
manufacturers concentration.
12.5.3 The use of a brush or medium to high-pressure spray equipment combined with hot water
will facilitate removal of contamination.
12.5.4 Remove and wire brush all screwed items including plugs and pipe stubs and wire brush
socket areas to ensure cleanliness.
12.5.5 Rinse promptly and continually with fresh, potable water to remove all traces of the
degreasing agent. The use of medium to high-pressure spray equipment combined with hot
water will facilitate the rinsing process.
12.5.6 Note: Improper rinsing will cause suspended contaminants to redeposit onto the surface.
Also, the surface shall not be allowed to dry between the degreasing phase and rinsing
phase. The resulting film or residue will not be adequately removed during the rinsing phase.
12.5.7 In the final rinsing phase, combine the XT approved Applied Australia Pty Ltd Rust Inhibitor
Agent No. 4-320 and follow the manufacturers directions for use. Use the manufacturers
recommended maximum concentration to achieve maximum protection. Applied Australia
Pty Ltd Rust Inhibitor Agent No. 4-320 is to be applied to plain carbon steel piping only.
Note: Dry all internal surfaces using a hot air blower or with dry, oil free compressed air or
gaseous nitrogen.
13 CLEANING OF HYDRAULIC AND FUEL PIPE-WORK AFTER FABRICATION
removed.
13.1.3 For stainless steel pipes, pickle and passivate all the heat affected zones around all the welds
using Australian Stainless Steel Development Association (ASSDA) recognized pickling and
passivation liquids, typically a mix of nitric and phosphoric acid. Follow the manufacturers
application instructions. Rinse and dry thoroughly (Refer to Section 11.5 for details on
rinsing).
rust inhibitor agents).
13.1.5 On completion of cleaning and drying, circuits for hydraulic and fuel valve racks shall be
flushed with clean working fluid for the specific application.
13.1.6 Circuits shall be sealed with closing flanges or compression fitting caps and clearly labeled as
follows: THIS CIRCUIT HAS BEEN CLEANED AND FLUSHED WITH THE WORKING FLUID
PRIOR TO SHIPMENT.

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REQUIREMENTS
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14 PROTECTIVE COATING APPLICATION
o Protective coating application shall be in accordance with the requirements of Australian
Standard 2313 Guide to the Protection of Iron and Steel Against Exterior Atmospheric
Corrosion except as varied by this specification.
o Conditions during application:
o Paint application shall only be carried when appropriate atmospheric conditions. In order to
determine whether condensation on the substrate may occur, the steel temperature must be
taken and dew point shall be calculated using a hygrometer and the dew point calculator.
The ambient conditions shall be taken prior to commencement of coating application and at
changes of conditions. The results shall be recorded on Quality Control Daily Report and
submitted to the XT Engineer.
o Protective coatings shall not be applied under the following climatic conditions:
When the surface temperature of the item being coated is less than 3 degrees Celsius
above the dew point (see section 8 of AS 2313).
When the surface temperature of the item being coated is higher than 55 degrees
Celsius.
When the surface temperature of the item being coated is less than 10 degrees Celsius.
When the ambient temperature is below 5C.
When the relative humidity is greater than 85%, unless a moisture-cured coat is being
applied.
When the surface being coated is in direct sunlight.
If the weather is deteriorating, or is unfavourable for application or curing (such as high
winds or rain).
If the pot life of the paint has been exceeded.
o Ambient conditions likely to occur at shop and site during coating applications shall be taken
into full account by the Contractor prior to commencing work. If the Contractor believes the
system nominated may suffer application problems due to the ambient conditions, the
Contractor shall notify the XT Engineer. The XT Engineer will advise the action to be taken.
o The same manufacturer shall supply all components in the painting system (primer,
undercoat, finish, etc.)
o Painting Equipment shall comply with manufacturers recommendation for the specific
coating system.
o Mixing:
All paints shall be mixed, thinned and applied in accordance with manufacturers
recommendation. Gelled or otherwise deteriorated coatings shall not be used.
Paint suppliers products (paint & thinners) shall not be mixed in a protective coating
system. Inorganic Zinc primers shall be continuously agitated during application by air
operated stirrer or approved equivalent.

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REQUIREMENTS
25-Jan-10
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14.1 PRIMING
14.1.1 The specified dry film thickness of primer refers to the minimum thickness of primer
measured above peaks. The primer shall be cured in accordance with the manufacturers
published recommendations before application of any subsequent coatings.
14.1.2 The primer shall be applied so as to produce a smooth even coating and shall be double lap
sprayed into all corners and crevices and on welds and seams, except for inorganic zinc
silicate conforming to AS 2105 Type 3 or 4.
14.1.3 Previously cleaned surfaces, particularly where bare metal has been exposed, shall be prime
coated or receive the first coat of a self-priming system within 4 hours of cleaning or before
surface discoloration takes place, whichever occurs earlier.
14.1.4 Any surface showing deterioration before being primed shall be re-blasted at the
Contractors expense.
14.1.5 When unacceptable flash rusting has occurred or substrate deterioration due to wet/hydro
blasting, further blasting must be carried out until specified substrate condition has been
achieved.
14.1.6 If the dried primed surface becomes contaminated, prior to application of a finishing coat the
surface shall be washed with fresh clean water to remove any salt, sand, dust, grit, grease,
cement or other contaminants and allowed to dry thoroughly. If necessary, suitable solvents
shall be used to remove contaminants that are not water soluble and the areas concerned re-
washed with potable water.
14.1.7 The field weld margin surfaces shall be masked after blasting to prevent contamination by
protective coating.
14.1.8 The primer shall be applied by conventional or airless spray to achieve the specified minimum
DFT.
14.1.9 Inorganic zinc silicate conforming to AS 2105 Type 3 or 4 shall not be recoated with the
same primer under any circumstances. Zinc rich epoxy primers must be used for inorganic
zinc silicate primer repair.

14.2 STRIPE COATING
14.2.1 All surface irregularities such as edges and weld seams must be stripe coated after priming
with intermediate coat.
14.2.2 On shallow corroded depressions stripe airless application and wet rolling with lambs wool
roller may be used.
14.2.3 On deep sharp pitting, stripe coating shall be thoroughly brushed into the pits.
14.2.4 Deep pits shall be filled with approved solvent-less epoxy filler.

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Rev No.
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ABN 65 118 727 870
REQUIREMENTS
25-Jan-10
Page 20 of 25

14.3 COATING APPLICATION
14.3.1 The coating Painting Contractor shall apply the protective coating to achieve specified Dry
Film Thickness (DFT). During coating application the wet film thickness shall be regularly
checked for correct gauge. The required wet film thickness shall be calculated and recorded
on Quality Control Check Sheet.
14.3.2 The DFT of each coating application shall be in accordance with the appropriate XT Protective
Coating System Specification.
14.3.3 Recoating times shall comply with the manufacturers recommendations, taking into account
the ambient conditions during the drying period.
14.3.4 Where multiple coats are specified each coating shall be of a different colour or shade to
ensure consistent coverage.
14.3.5 Paintwork shall be subject to visual examination and measurement of the dry film thickness
after the application of each coating.
14.3.6 The Contractor shall be responsible for carrying out all inspection and testing and reporting
to the XT Engineer.
14.3.7 Visual Examination: All surfaces shall be subject to a visual examination after priming and
after application of each top-coat. Each coat of paint shall be free of cracks, wrinkles,
blisters, runs and lumps or any other defects. Whenever these defects occur, the whole
paintwork system of the affected area shall be removed by specified blast cleaning and
replaced at the Contractors expense.

14.4 PLANT ITEMS AND STRUCTURAL SURFACES NOT COATED
14.4.1 The following surface shall not be abrasive blasted and coated, UNO:
Raised faces on pipe and equipment flanges
Faces on pipe and equipment flat face flanges
Stainless steel surfaces
Non-metallic surfaces
Rubber components
Electrical cables
Valve stems and grease fittings
Instruments and gauges
Shafts on running equipment
Threads of adjusting screws
Machined faces
Name-plates
Field weld margins (50 mm). The weld margins shall be abrasive blast cleaned but not
coated until after installation
Other surfaces nominated by the Contract

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Rev No.
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REQUIREMENTS
25-Jan-10
Page 21 of 25

15 REPAIRS TO NEW COATINGS
o Coating damage shall be brought to the attention of the XT Engineer and shall be identified
as a hold point on the ITP.
o Repair procedures shall conform to the specified XT protective coating system and is subject
to approval by the XT Engineer.
o Areas damaged during transport/erection or weld margins shall be thoroughly cleaned and
spot abrasive blasted or power tool cleaned to AS 1627, Part 2 (note; avoid burnishing metal)
and shall be coated using specified XT Protective Coating System.
o Coatings contaminated by embedded dust or excessive overspray, shall be prepared by
sanding or brush blasting and recoated to the specified DFT.

15.1 REPAIR OF DEFECTIVE COATING
15.1.1 All defective work, or work performed not in accordance with this specification, or any
coating found defective or damaged during subsequent handling or installation, shall be
repaired in accordance with this Section. The repair procedures proposed shall be submitted
to the XT Engineer for review and acceptance.

15.2 INCORRECT FILM THICKNESS
15.2.1 Applied coatings that have been dry film thickness tested to AS 3864.3 and are found to be
below the specified dry film thickness, shall be cleaned down as per AS 1627.1 to remove
any surface contamination and chlorides and then recoated with the same material, provided
the tested coating has not exceeded the recoat interval as stated on the Manufacturers
Technical Data Sheets.
15.2.2 Coatings that have exceeded the maximum recoat interval shall be completely removed and
recoated to the correct specified thickness.

15.3 SPOT DEFECTS AND LOCALISED DAMAGE
15.3.1 The damaged or defective areas together with a surrounding overlap area of at least 50 mm
width shall be solvent-cleaned to
-
remove any oil, grease or dust. Any damaged coatings shall
then be removed to an undamaged surface without any signs of loose or flaking paint.
15.3.2 The area shall then be sanded down or abrasive-disc ground, feathering back the abraded
area onto the good coating with a 50 mm overlap. In the event that bare metal is exposed
while removing damaged or flaking coating materials, spot abrasive blasting shall be applied
to remove all particles of old coating and restore the design blast profile
15.3.3 The re-prepared surface shall then be cleaned to remove all abrasive dust, and re-coated
using the original specified protective coating system (prime coat, intermediate coat and
finish coat).

REQUIREMENTS
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REQUIREMENTS
25-Jan-10
Page 22 of 25

16 GALVANISED COATING FOR STEEL
o This Section covers the requirements for galvanising fabricated items of steelwork.
16.1 FABRICATION
16.1.1 The Contractor shall safeguard all items against embrittlement and distortion in accordance
with the relevant requirements of AS 1214, AS 4680, ASTM A143 and ASTM A384.
16.1.2 All welding slag, spatter and burrs shall be removed prior to delivery to the galvaniser. Vent
holes at least 10 mm diameter and if required, lifting lugs to facilitate handling, venting and
draining during the galvanising process shall be provided.
16.1.3 All required bolt holes shall be punched or drilled prior to galvanising to avoid the need for
the applied coating to be subsequently disturbed.
16.1.4 Unsuitable marking paints shall be avoided.

16.2 SURFACE PREPARATION
16.2.1 Surfaces shall be cleaned to remove oil, grease, mill scale, weld slag, markings and other
foreign matter in accordance with AS 1627.1. Items shall be supplied free from paint.
16.2.2 Pickling of steel surfaces shall be performed in accordance with AS 1627.5.
16.2.3 Surfaces requiring abrasive blasting prior to the galvanising process shall have a maximum
profile height of 65 m after blasting.

16.3 ZINC COATING
16.3.1 The items shall be zinc coated by the hot-dip galvanising process to the desired thickness in
accordance with AS 4680. The coating shall be checked for continuity and uniformity of
thickness, and the
-
coated articles shall be generally free from visible defects. The coating
shall be free from voids, blisters, flux spots, inclusions, dross, acid or black spats.
16.3.2 The coating shall be adherent, so that it will not be removed by any reasonable process of
handling or erection. Lumps, globules or heavy deposits of zinc which will interfere with the
intended use of the material will not be accepted.
16.3.3 The mass of galvanised coating shall comply generally with the requirements of Table 8.1 of
this Specification, and the applicable requirements of AS 4680. Testing procedures shall be in
accordance with the relevant section of AS 2331.

REQUIREMENTS
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REQUIREMENTS
25-Jan-10
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Table 16-1 - Coating Requirements for Hot-Dip Galvanised Products
Class of Material
Minimum Mass of Coating
(g. /m
2
)
Products Fabricated of Rolled, Pressed and Forged Steel Shapes,
Plates, Bars and Strip

Plate Thickness Less than 2 mm 350
Plate Thickness 2 mm to 5 mm 454
Plate Thickness over 5 mm 600
Hollow Sections 300
Hardware
Class A - Castings 600
Class B - Rolled; Pressed and Forged articles 600
(except those included in Classes C and D)
Class C - Centrifugal Work 300
Class D - Bolts and Nuts 375

16.4 REPAIRS TO DAMAGED GALVANISED COATINGS
16.4.1 Small areas of 'defective or damaged coating shall be repaired by the application of two 60
m DFT coats of zinc-rich organic coating (cold galvanizing) conforming to AS 3750.9.
16.4.2 Areas to be repaired shall be abrasive disc cleaned in accordance with AS 1627.2.
16.4.3 Remedial painting shall overlap the sound galvanised coating by 50 mm all round.
16.5 PACKAGING OF GALVANISED ITEMS
16.5.1 All galvanised items shall be packaged and strapped with dunnage or wooden spacer
materials to prevent any contact between individual items. Smaller items may be crated.
However, they must be kept dry and free from moisture. General packaging and freight
forwarding specifications are provided in PMA-XT-0010 Packing and Freight Forwarding
Requirements

REQUIREMENTS
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REQUIREMENTS
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17 IDENTIFICATION
17.1 RAW MATERIALS
17.1.1 All materials used, including cleaning agents, solvents, curing agents, thinners, primers, and
any other coating materials shall be clearly labeled to ensure traceability. Each container or
package shall be clearly labeled, at all times, with the following information:
Manufacturer
Product identity code
Chemical or industrial name
Batch Number
Hazchem ID
17.1.2 The manufacturers recommendations for shelf life and storage conditions should be
ascertained prior to shipping to site. Product data sheets, MSDS and other relevant
information shall accompany product.
17.1.3 The Inspector may reject any materials that do not have a correctly completed identification
label.

17.2 STORAGE AND SUPPLY OF PAINT MATERIALS
17.2.1 All coating materials shall be delivered to the factory (shop) or site in the Manufacturer's
original containers with the labels and seals unbroken.
17.2.2 Coating materials shall be stored in the manner recommended by the coating manufacturer.
17.2.3 Transport, storage and handling of coating materials shall be strictly in accordance with the
requirements of the relevant statutory authority and with current trade practices.
17.2.4 All materials which have been stored for longer than the specified shelf life or exposed to
conditions outside the permissible storage conditions shall be discarded and replaced.
17.2.5 All containers shall be the original sealed containers have a clearly marked manufacturers
identification label attached. The XT Engineer may reject any non-original containers or
suspected out of date paints.

REQUIREMENTS
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REQUIREMENTS
25-Jan-10
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18 HANDLING, PACKING AND TRANSPORT OF FINISHED COATED ITEMS
o All equipment that has been coated shall be handled with care to preserve the coating in the
best practicable condition.
o Steelwork shall not be handled until the coating has completely cured and dried hard.
o Web slings or slings covered with a rubber hose or similar soft material shall be used for the
handling of finish coated items.
o From completion of primer coatings to completion of loading the finished coated item on the
transport, all coated items shall be protected by a soft material such as cloth, carpet or
rubber sheeting on areas of contact (e.g. wooden supports and holding down chains or
slings).
o Any damage to finished coated items, whether supplied by the Contractor or not, shall be
repaired and made good in accordance with this specification.
o Items with excessive damage caused by insufficient care shall have the entire coating
removed and be recoated in accordance with this specification. The XT Engineer for the
Contract shall determine if damage is excessive.

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