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LARSEN & TOUBRO LIMITED

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CONTENTS
1. SCOPE

2. REFERENCE DOCUMENTS

3. SURFACE NOT TO BE PREPARED

4. SURFACE PREPARATION

5. MATERIAL & EQUIPMENT

6. STORAGE

7. SELECTION OF PAINT SYSTEM

8. APPLICATION

9. INSPECTION

10. FINISH COAT COLOUR & COLOUR CODING

11. SAFETY

ATTACHMENT

☻ PAINT PROCEDURE OF VENDOR

☻ VENDOR PAINT CATALOG

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1.0 SCOPE

1.1 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.

1.2 E XTENT OF WORK

The following surface and materials shall require shop, pre-erection and field painting:
a) 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.
b) All Uninsulated carbon and low alloy piping fittings and valves (including painting of
identification marks), furnace, ducts, and stacks.
c) All items contained in a package unit as necessary.

d) All structural steel work, pipe , structural steel supports, walkways, handrails, ladders, platforms,
etc.
e) MS chimney without refractory lining & flair lines.
f) Identification colour bands on all piping as required including insulated aluminium clad,
galvanized, SS and nonferrous piping.
g) Identification lettering / numbering on all painted surfaces of equipment / piping insulated
aluminium clad, galvanized, SS and non-ferrous piping.
h) Marking / identification signs on painted surfaces of equipment /piping hazardous service.
i) Supply of all primers, paints and all other materials required for painting other than Owner’s
supply.
j) Over insulation surface of equipments and pipes wherever required.
k) Painting under insulation for carbon steel and stainless steel as specified.
l) Repair work of damage / pre- erection / fabrication shop primer and weld joints at field.
m) Internal surfaces of RCC tanks and structures in Effluent treatment plant.

2.0 REFERENCE DOCUMENTS

2.1 COLOUR CODING Colour coding inspection manual for piping issued
by M&I Refineries Division of IOCL in May 2004

2.2 IS-101 Methods of test for ready mixed paints and enamels

2.3 ASTM American standard test methods for paints and coatings

2.4 ASA A 13.1-1981 Scheme for identification of piping systems:

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American National Standards Institution

2.5 SIS-05 5900-1967 Swedish Standard (Surface preparation standards

for painting steel surfaces)

2.6 SSPC-SP Steel Structures Painting Council, U.S.A

(Surface Preparation Specifications)

2.7 BS-4232 British Standards (Surface Finish of Blast-cleaned

for painting)

2.8 U.S.A (NACE) National Association of Corrosion Engineers

2.9 18-3177-000-V.02-201/A4 General Specification of Shop & Field Painting.

3.0 SURFACE NOT TO BE PREPARED

3.1 Uninsulated austenite Stainless Steel

3.2 Plastic and / or plastic coated materials

3.3 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 SURFACE PREPARATION

4.1 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..

4.2 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

4.2.1 Blast cleaning shall not be performed where dust can contaminate surfaces undergoing such cleaning or during

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humid weather conditions having humidity exceed 85%.

4.2.2 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.

4.2.3 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 ¾”. 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:-

VARIOUS INTERNATIONAL
STANDARDS
SR. Swexish BRITISH
DESCRIPTION SSPC- REMARKS
NO. Standard NACE STANDA
SP
SIS-05- USA RD
USA
5900 BS-4232
1. This method is applied when
Manual or Hand tool cleaning
the surface is exposed to
Removal of loose rust, loose mill
normal atmospheric
scale and loose paint, chipping, SSPC-
ST.2 - - conditions when other
scrapping, standing and wire SP-2
method can not be adopted
brushing. Surface should have a
and also for spot cleaning
faint metallic sheen.
during maintenance painting.
2 Mechanical or power tool
cleaning
Removal of loose rust, loose mill
scale and loose paint to degree
SSPC-
specified by power tool chipping, ST.3 - -
SP-3
descaling, standing wire brushing,
and grinding, after removal of
dust, surface should have a
pronounced metallic sheen.
3 Blast cleaning (air & water) there
are four common grades of blast
cleaning
3.1 White metal Blast cleaning to Where extremely clean
white metal cleanliness. surface can be expected for
Removal of all visible rust. Mill prolong life of paint system.
sale, paint & foreign matter 100%
cleanliness desired surface
profile.
SSPC-
SA.3 NACE#1 First Quality
SP-5

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VARIOUS INTERNATIONAL
STANDARDS
SR. Swexish BRITISH
DESCRIPTION SSPC- REMARKS
NO. Standard NACE STANDA
SP
SIS-05- USA RD
USA
5900 BS-4232
3.2 Near White metal The minimum requirement
for chemically resistant paint
systems such as epoxy, vinyl,
polyurethane based and
SSPC- Second
SA 21/2 NACE#2 inorganic zinc silicate paints,
SP-10 Quality
also for conventional paint
systems used under fairly
corrosive conditions to obtain
desired life of paint system.
3.3 For steel required to be
Commercial Blast
painted with conventional
Blast cleaning until at least two-
SSPC- paints for exposure to mild
third of each element of surface SA 2 No.3 Third Quality
SP-6 corrosive atmosphere for
are is free of all visible reduces
longer life of the paint
with desired surface profile
system.
3.4 Brush-off Blast
Blast cleaning to white metal
cleanliness, removal of all visible
SSPC- No.4
rust, mill scale, paint & foreign SA 1
SP-7
matter.
Surface profile is not so
important.

5.0 MATERIAL & EQUIPMENT

5.1 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 STORAGE
6.1 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 SELECTION OF PAINT SYSTEM

7.1 Selection of the paint system shall vary with type of environment envisaged in and around the plant.

7.2 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 -90 to 400 SSPC-SP-10 1coat of F-9 65-75 No over coating is

to be done
7.2.2 401 to 500 SSPC-SP-10 1coat of F-12 40-50 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 2 coats of F-12 40-50 For operating temperature
(for repair only) less than 80oC irrespective
SSPC-SP-10 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. Design Surface Paint System Total DFT In Remarks
Temperature In Preparation Microns
o
C
7.4.1 -14 to 80 SSPC-SP-3 1 coat of F-8 100
7.4.2 81 to 500 SSPC-SP-3 1 coat of F-12 20

7.5 PAINT SYSTEM FOR SHOP AND FIELD PAINTING

7.5.1 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 Field Primer Finish Paint In
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 μ DFT/ coat
fabrication of primer 1 coat of F-9
primer F-9) @ 65 -75 μ 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 μ
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 @ 20 μ DFT / resistance of F-11
fabrication of primer 1 coat of F-9 COAT from paint
primer F-9) (for @ 65 -75 μ 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 Repair of 2 coats of F-11 @ 105 Test certificates for heat
(for repair of pre prefabrication 20 μ DFT / COAT resistance of F-12 from
fabrication of primer 1 coat of 2 x 20=40 paint manufacturer
primer F-9) (for F-9 @ 65 -75 μ (OR) 1 coat of should be enclosed. F-
repair of pre DFT / coat as engineered 12 requires heat curing
fabrication of per the clause siloxane coating as per manufacturer’s
primer F-9) 7.3.1 in table @ 50 μ DFT/coat recommendations.
7.3
7.5.1.4 401 to 500 SSPC-SP-10 Repair of 2 coats of F-11 @ 60 Test certificates for heat
prefabrication 20 μ DFT / COAT resistance of F-12 from
primer 1 coat of 2 x 20=40 paint manufacturer
F-12 @ 20 μ (OR) 1 coat of should be enclosed.
DFT / coat as engineered
per 7.3.2 in siloxane coating
table 7.3 @ 50 μ DFT/coat

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 Surface Preparation Paint System Total DFT Remarks
Temperature Field Primer Finish Paint In
In oC Microns
(min.)
7.5.2.1 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)

-14 to 80 SSPC-SP-10 Repair of 2 coats of F-6B @ 305 F-9, F-6B, F-2 can be
prefabrication 100 μ DFT / applied at ambient
primer 1 coat of COAT + 1 coat of temperature
F-9 @ 65 -75 μ F-2 @ 40 μ
DFT / coat as DFT / coat =240
per the clause μ
7.3.1 in table
7.3
7.5.2.2 -14 to 80 SSPC-SP-10 Repair of 2 coats of F-6A @ 265 F-9, F-6A, F-2 can be
prefabrication 100 μ applied at ambient
primer 1 coat of DFT/ coat temperature
F-9 @ 65 -75 μ 2X100=200 μ
DFT / coat as
per the clause
7.3.1 in table
7.3
7.5.2.3 External side un-insulated storage vessel for petroleum products
Ambient to SSPC-SP-10 Repair of 2 coats of F-11 @ 105-115 Test certificate for heat
250 prefabrication 20 μ resistance of F-11 from
primer F-9 as per DFT/coat paint manufacturer
the clause 7.3.1 2X20=40 μ should be enclosed.
in table 7.3
7.5.2.4 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 @ 105 or115 F-12 shall be applied in
fabrication primer 20 μ DFT / coat = the field before taking
F-9 as per 7.3.1 2X20=40 μ or the system into service
in table 7.3 one coat of as it needs hot curing at
engineered high temperature.
siloxane coating
@ 50 μ DFT /
coat

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Sr. No. Operating Surface Paint System Total Remarks

Temperature Preparation Field Primer Finish Paint DFT In
In oC Microns
(min.)
7.5.2.5 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 pre- 2 coats of F-12 @ 105or 115 F-12 shall be applied in
fabrication primer 20 μ DFT / coat = the field before taking
F-9 as per 7.3.2 2X20 =40 μ or 1 the system into service
in table 7.3 coat of as it needs hot curing at
engineered high temperature.
siloxane coating
@ 50 μ DFT /
coat
7.5.2.6 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 μ applied at ambient
F-9 as per 7.3.1 DFT/coat temperature
in table 7.3 =2X100=200 μ
7.5.2.7 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 μ DFT/coat + applied at ambient
F-9 as per 7.3.1 1 coat of F-2 @ temperature
in table 7.3 40μ DFT /coat
7.5.2.8.1 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 125 μ DFT/coat = for using under
primer 1 coat of 2X125=250 μ corrosive soil over
F-9 @ 65 -75 μ 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
7.5.2.8.2 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 100 μ for using under
primer by 1 coat DFT/coat corrosive soil over
of F-9 @ 65 -75 =2X100=200 μ coating of F-9 should
μ DFT / coat as be avoided as it would
per the clause lead to mud cracking.
7.3.1 in table
7.3
(CONTINUED IN NEXT PAGE)

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Sr. No. Operating Surface Preparation Paint System Total DFT Remarks
Temperature Field Primer Finish Paint In
In oC Microns
(min.)
7.5.2.9 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
7.5.2.9.1 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
F-9 @ 65-75 μ epoxy coating foundation and before
DFT / coat as @125 μ DFT / welding.
per clauses coat=2X125=250
7.3.1 in table μ
7.3
OR OR
1coat of F-15 2 coats of F-15 240
epoxy phenolic epoxy phyenolic
primer coating coating system
@ 80 μ DFT / @ 80 μ DFT
coat /coat=2X80=160
7.5.2.9.2 151 to 400 SSPC-SP-10 Repair of 2 coats of (F-14) 315
prefabrication specially
primer by 1 coat formulated coal tar
F-9 @ 65-75 μ epoxy slioxane
DFT / coat as coating @125 μ
per clauses DFT /
7.3.1 in table coat=2X125=250
7.3 μ
7.5.2.10 Carbon steel stack, chimney, furnace & flue gas duc
7.5.2.10.1 Upto 80oC SSPC-SP-3 1 coat of F-8 (A1 100
operating grade) @ 100 μ
temp. DFT / coat
Irrespective of
design temp.
7.5.2.10.2 81 to 250 SSPC-SP-10 Repair of 2 coats of F-11 105
prefabrication @20 μ DFT /
primerF-9 as per coat
7.3.1 of table 7.3 2X20=40
7.5.2.10.3 251 to 400 SSPC-SP-10 Repair of 2 coats of F-12 105
prefabrication @20 μ DFT /
primerF-9 as per coat
7.3.1 of table 7.3 2X20=40

Sr. No. Operating Surface Paint System Total Remarks

Temperature Preparation Field Primer Finish Paint DFT In

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In oC Microns
(min.)
7.5.2.10.4 401 to 500 SSPC-SP-10 Repair of 1 coat of F-16 A/ 165
prefabrication Epoxy-Slioxane
primerF-9 as per coating @ 100 μ
7.3.1 of table 7.3 DFT / coat
7.5.2.10.5 All gratings
Upto 80oC SSPC-SP-2 2 coats of F-7 @
operating 100 μ DFT/coat
temp. 2X100=200

7.5.3 PAINTING UNDER INSULATION FOR INSULATED (HOT, COLD & SAFETY)
CARBON STEEL, LOW ALLOY STEEL, LOW TEMPERATURE CARBON

Sr. No. Operating Surface Preparation Paint System Total DFT Remarks
Temperature Field Primer Finish Paint In
In oC Microns
(min.)
7.5.3.1 Insulated carbon steel, low alloy steel and LTCS piping and equipment and tanks
7.5.3.1.1 -45 to 125 oC SSPC-SP-10 Repair of 2 coats of F-14 @ 315 For other temperature
operating prmierF-9 @ 65 125 μ DFT/ coat= ranges no painting is
temp. But -75 μ DFT. 2 x 125=250 or 3 required under
design temp. coats of F-15= insulation
up to 150 oC 3 x 80 = 240
7.5.3.1.2 Operating SSPC-SP-10 Repair of 2 coats of F-12 @ 105-115
temperature prmierF-9 @ 65 20 μ DFT/ coat=
-45 to 125 oC -75 μ DFT. 3 x 20=60
But design
temperature
151 -400 oC
7.5.3.2 Insulated stainless steel including alloy -20 piping

Sr. No. Operating Surface Paint System Total DFT In Remarks

Temperature Preparation Microns (min.)
Field Primer Finish Paint
In oC

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7.5.3.2.1 Below 0 oC to Aluminium sheeting with aluminium foil and “Chloride free mineral sealant If the piping &
all minus coating barium chromate” shall be applied. equipments are already
temperature erected then surface
7.5.3.2.2 0 to 120 SSPC-SP-10 (15- None 2 coats of F-14 @ 250 or shall be prepared by
25 μ surface 125 μ DFT/ coat= 240 cleaning with emery
profile) 2 x 125= 250 or 3 paper and wash / flush
coats of F-15= with chloride free DM
3 x 80=240 water followed by
7.5.3.2.3 121 to 400 SSPC-SP-10 None 3 coats of F-12 @ 60 wiping with organic
20 μ DFT/ coat= solvent.
3 x 20 =60 or 1 All the coating
coat of poly materials for SS shall
slioxane or be free from leachable
coating ( F-16 chlorides.
A/B ) @ 75 μ
DFT/ coat
7.5.3.2.4 401 to 600 SSPC-SP-10 None 2 coats of heat 40
resistant silicone
aluminium paint @
20 μ DFT/ coat=
2 x 20 = 40
7.5.3.3 No painting required for insulated monel, incoloy and nickel lines.

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 Surface Preparation Paint System Total DFT Remarks
Temperature Field Primer Finish Paint In
In oC Microns
(min.)
7.5.4.1 Up to 80 SSPC-SP-10 1 coat of P-6 @ 2 coats of F-7 @ 290 For C.S.
40 μ DFT/ coat 125 μ DFT/ coat=
2 x 125= 250
7.5.4.2 Up to Non SSPC-SP-3 1 coat of P-4 @ 2 coats of F-7 @ 300 For non ferrous
ferrous and 8-10 μ DFT/ 125 μ DFT/ coat= surfaces
brass tube coat 2 x 125= 250
sheets 1 coat of P-6 @
40 μ DFT/ coat

FIELD PAINTING SYSTEM FOR NON-FERROUS TUBE SHEET

Sr. No. Operating Surface Preparation Paint System Total DFT Remarks
Temperature Field Primer Finish Paint In

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In oC Microns
(min.)
7.5.4.3 UP TO 80 Non SSPC-SP-10 1 coat of p-6 @ 8 2 coats of F-7 @ 300
ferrous and μ DFT/ coat 125 μ 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 Total Remarks
Temperature Preparation Field Primer Finish Paint DFT In
In oC Microns
(min.)
7.5.5.1 -14 to 80 (for SSPC – SP -10 1 Coat of F-9 @ 3 coats of F-6A 365
C.S/ 65-75 μ DFT / @100 μ DFT /
M.S.Item): coat coat
Screens, Walk 3x100=300
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
7.5.5.2 -14 to 80 (CS / SSPS – SP -10 1 Coat of F-9 @ 2 coats of F-6A 265
MS item) for 65-75 μ DFT / @100 μ DFT /
vertical pump coat coat
and piping in,
Bio-sludge
sump and
pump, Filter
feed sump and
pump, process
sump, sanitary
sump, Transfer
sump, MS
Slop oil tank

Sr. No. Operating Surface Preparation Paint System Total DFT Remarks
Temperature In
Field Primer Finish Paint
In oC Microns

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(min.)
internal,
scrapping
mechanism in
Clarifier,
Screw Pump
7.5.5.3 -14 to 80(All Blast cleaning to As per SMMS- As per SMMS-EIL 3 mm Epoxy screed lining
RCC surfaces SSPC-SP guide EIL specification specification for shall be used as per
such as tanks, lines and Acid for Epoxy screed Epoxy screed specific instructions
structures, etching with 10- lining no. 6-06- lining no. 6-06- from Engineer-in-
drains, etc) in 15% HCI acid 209(Latest 209(Latest charge at site
Process Sump, followed by revision) revision)
TPI separator through water
(Process and washing.
oil ), Aeration
tank, transfer
sump, etc.
7.5.5.4 Up to 60 deg. SSPC – SP -10 Rubber lining as 4.5 mm
C C.S/MS dual per SMMS-EIL
media filters spec. 6-06-204
(Internal),Che (Latest revision)
mical dosing
tanks internal
such as DAP,
Urea

7.5.6 COATING SYSTEM FOR EXTERNAL SIDE OF UNDERGROUND CARBON STEEL PLANT PIPING AND
TANKS

Sr. No. Operating Surface Preparation Paint System Total DFT Remarks
Temperature In
In oC Field Primer Finish Paint Microns
(min.)
7.5.6.1 Carbon steel plant piping ( Underground )
7.5.6.1.1 Yard Coating
7.5.6.1.1.1 25 to 60 SSPC – SP -10 1 coat of 4 mm thick coaltar 4 mm CTE coating shall
synthetic fast coating wrapping conform to 120 / 5 as
drying primer as per AWWA-C- per BS : 4164
type-B as per 203 in 2 layers of
AWWA-C- each 2 mm
203(1991) thickness

Sr. No. Operating Surface Preparation Paint System Total DFT Remarks
Temperature In
In oC Field Primer Finish Paint Microns

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(min.)
7.5.6.1.2 Over the Ditch Weld Joint coating
7.5.6.1.2.1 25 to 60 SSPS - SP -10 1 coat of Same as 12.1.1.1 4 mm
synthetic fast (OR) heat
drying primer shrinkable PE
type-B as per Sleeves
AWWA-C- conforming to DIN
203(1991) 30672 stress class
“C”
7.5.6.2 Carbon steel plant piping ( Underground )
7.5.6.2.1 61 to 90 SSPC – SP -10 1 Coat of F-9 @ 3coats of F-7@100 365
65-75 μ DFT / μ DFT / coat
coat 3x100=300

91 to 150 SSPC – SP -10 1 Coat of F-9 @ 3coats of F-14 @ 365 (OR)

65-75 μ DFT / 100 μ DFT/Coat 225 for
coat (OR) 3 coats of the F-15
F-15 @ 75 μ system
DFT/coat 3x75 =
225
151 to 400 SSPC – SP -10 1 Coat of F-9 @ 2 coats of F-16 215
65-75 μ DFT / A/B @ 75 μ
coat DFT/coat =
2x75= 150
7.5.6.3 External side un-insulated underground storage tank
7.5.6.3.1 -40 to 80 SSPC – SP -10 1 Coat of F-9 @ 3coats of F-7@100 365
65-75 μ DFT / μ DFT / coat
coat 3x100=300

-90 to 41 SSPC – SP -10 1 Coat of F-9 @ 2 coats of F-16 215-225

81 to 400 deg. 65-75 μ DFT / A/B @ 75 μ
C coat DFT/coat =
2x75= 150

7.5.7 FIELD PAINT SYSTEM FOR CARBON STEEL AND ALLOY STEEL STORAGE TANKS (INTERNAL)

Sr. No. Operating Surface Preparation Paint System Total DFT Remarks

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Temperature Field Primer Finish Paint In

In oC Microns
(min.)
7.5.7.1 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)
7.5.7.1.1 -14 to 80 SSPC – SP -10 1 Coat of F-9 @ 3coats of F-7@100 365 F-7 should be suitable
65-75 μ DFT / μ DFT / coat for immersion service
coat 3x100=300 of the products given.

7.5.7.2 Bare shall inside floating roof tanks and cone roof tanks for products mentioned in 13.1
7.5.7.2.1 -14 to 80 SSPC – SP -10 Phosphate 2 coats @ 10 μ 20
treatment with 2 x 10 =20
phosphating
chemicals (2
coats)
7.5.7.3 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.
7.5.7.3.1 -14 to 80 SSPC – SP -10 1 Coat of F-9 @ 3coats of F-7@100 365 F-6 should suitable for
65-75 μ DFT / μ DFT / coat immersion service of
coat 3x100=300 petroleum product like
ATF, kerosene, petrol,
etc.

7.5.7.4 Bare shell of inside of floating cum cone roof tanks for products gasoline, naphtha, kerosene, motor spirit
7.5.7.4.1 -14 to 80 SSPC-SP-10 1 coat of F-9 @ none 65-75 No covering is allowed.
65-75 μ DFT / Same as per pre-
coat erection primer, if any
7.5.7.5 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.
7.5.7.5.1 -14 to 80 SSPC-SP-10 2 coats of P-6 @ 2 coat of F-6 @ 280 F-6 shall be suitable for
40 μ DFT / coat 100 μ DFT / coat immersion service
2 x 40 = 80 2 x 100 = 200
7.5.7.6 D.M. ( Demineralised water) and hydrochloric acid (HCL): internal shell, bottom plate & all accessories
7.5.7.6.1 -14 to 60 SSPC-SP-10 Natural rubber lining as per SMMS specifications 6-
06-204

Sr. No. Operating Surface Preparation Paint System Total DFT Remarks
Temperature In
In oC Field Primer Finish Paint Microns
(min.)
7.5.7.7 EG tanks ( Internal shell, bottom plate roof and all accessories)

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7.5.7.7.1 all SSPC-SP-10 3 coats vinyl chloride co-polymer amercoat 23 @ 75 225

μ / coat
7.5.7.8 Inside pontoon and inside of double deck of all floating roofs
7.5.7.8.1 -14 to 80 SSPC-SP-10 1 coat of F-8 @ 200
100 μ DFT / coat
7.5.7.9 Internal surface of amine & sour water storage tanks
7.5.7.9.1 -14 to 80 SSPC-SP-10 1 coat of F-9 @ 3 coats of F-15 @ 215 - 225 215-2
65-75 μ DFT / 75 μ DFT / coat
coat 2 x 75 = 150

PRIMERS & FINISH COATS

PRIMERS

P-2 : Chlorinated rubber zinc phosphate primer

P-4 : Etch primer / wash primer

P-6 : Epoxy zinc phosphate primer

FINISH COATS / PAINTS

F-1 : First quality corrosion resistant synthetic enamel

F-2 : Acrylic- Polyurethane finish paint

F-3 : Chlorinated rubber finish paint

F-6A : High build epoxy finish coating cured with polyamine hardner

F-6B : High Build epoxy finish coating cured with polyimide hardner

F-7 : High Build coal tar epoxy coating

F-8 : Self priming surface tolerant high build epoxy coating

F-9 : Inorganic Zinc silicate coating

F-11 : Heat resistant synthetic medium based aluminium paint

F-12 : Heat resistant silicone aluminium paint

F-14 : Specially formulated polyamine cured coal for epoxy coating suitable

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upto 150 deg C

F-15 : Epoxy Phenolic Coating

F-16A : Epoxy slioxane coating: Amercoat 738

F-16 B : Epoxy slioxane coating: Berger 938

8.0 APPLICATION

8.1 COATING PROCEDURE AND APPLICATION

8.1.1 Surface shall not be coated in rain , wind or in environment where injuries airbome elements exists, when the steel
surface temperature is less than 5˚F above dew point when the relative humidity is greater than 85% or when the
temperature is below 40˚F.

8.1.2 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.

8.1.3 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.

8.1.4 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.

8.1.5 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.

8.2 AIR SPRAY APPLICATION SHALL BE IN ACCORDANCE WITH THE

FOLLOWING:

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.

8.2.2 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.

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8.2.3 Ingredients shall be kept properly mixed in the spray pots or containers during application by continuous
mechanical agitation.

8.2.4 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.

8.2.5 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.

8.2.6 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.

8.2.7 All runs and sags shall be brushed out immediately or the paint shall be removed and the surface repainted.

8.2.8 Areas inaccessible to the spray gun shall be painted by brush; if not accessible by brash, daubers or sheepskins
shall be used.

8.2.9 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.

8.2.10 Edges of structural shapes and irregular coated surfaces shall be coated first and an extra pass made later.

8.2.11 If a spray gun shows choking immediately de-choking procedure shall be followed.

8.3 AIRLESS SPRAY APPLICATION

Airless spray application shall be accordance with the following procedure; as per steel structure,
paint manual Vol—I 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 BRUSH APPLICATION OF PAINT SHALL BE IN ACCORDANCE WITH THE FOLLOWING

8.4.1 Brushes shall be of a style and quality that will enable proper application of paint

8.4.2 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.

8.4.3 Paint shall be applied into all corners.

8.4.4 Any runs or sags shall be brushed out.

8.4.5 There shall be a minimum of brush marks left in the applied paint.

8.4.6 Surface not accessible to brushes shall be painted by spray, daubers or sheepskin.

8.5 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 manufacturer’s specification for the
paint.
Paint shall be protected from rain, condensation, snow and freezing until dry to the fullest extent practicable.

8.7 REPAIR OF DAMAGED PAINT SURFACE

8.7.1 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

• 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)

8.7.3 Paint application

8.7.4 Shop priming / Pre-erection priming with F9 or F12 shall be done only on blasted surface

8.7.5 Shop priming / Pre erection priming with F-9 shall be done only with airless spray.

8.7.6 For large flat surface field painting shall be done by airless spray otherwise brush can be used.

8.8 DOCUMENTATION

8.8.1 A written quality plan with procedure qualification trials and for the actual work

8.8.2 Daily progress report with details of weather conditions, particular applications, no. of coats and type of materials
applied, anomalies, progress of work versus programme

8.8.3 Result of measurement of temperatures relative humidity, surface profile, film thickness, holiday detection, adhesion
tests with signature of appropriate authority

8.8.4 Particulars of surface preparation and paint application during trials and during the work.

8.8.5 Details of non- compliance, rejects and repairs

8.8.6 Type of testing equipments and calibration

8.8.7 Code and batch numbers of paint materials used

8.9 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 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.
8.9.2 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 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.
8.9.4 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.
8.9.5 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.
8.9.6 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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