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Knexir Consultants Pvt. Ltd.

Consulting Engineers
Tel.: 91-22 61547800. Fax.: 91-2225111092
Website : www.knexir.in Email : Knexir@knexir.in

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ORDER DOCUMENT
FOR
PAINTING WORK

Revision

R0

R1

14-05-2013

19-07-2013

Prepared By

Faisal Farooqui

Faisal Farooqui

Checked By

K C Sanjay Kumar

K C Sanjay Kumar

Approved By

Jagdish Pathak

Jagdish Pathak

For Enquiry

For Order

Date

Status

R2

R3

Knexir Consultants Pvt. Ltd.


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INDEX
1.0

GENERAL INFORMATION: ..................................................................................................................... 3

2.0

TECHNICAL SPECIFICATION FOR PAINTING ............................................................................................ 4

2.1

GENERAL ............................................................................................................................................................. 4

2.2

SCOPE ................................................................................................................................................................. 4

2.3

CODES & STANDARDS .............................................................................................................................................. 5

2.4

EQUIPMENT .......................................................................................................................................................... 7

2.5

RECEIPT AND STORAGE............................................................................................................................................. 7

2.6

SURFACE PREPARATION, COATING APPLICATION .............................................................................................................. 7

2.7

PROTECTIVE COATING & PAINTING MATERIAL .............................................................................................................. 14

2.8

PAINTING SYSTEM ................................................................................................................................................ 14

2.9

PAINTING COLOUR CODES ....................................................................................................................................... 14

2.10

IDENTIFICATION OF EQUIPMENT, PIPING ETC. ............................................................................................................... 14

2.11

INSPECTION & TESTING .......................................................................................................................................... 16

2.12

FIELD SAFETY AND HYGIENE ..................................................................................................................................... 17

2.13

GUARANTEE........................................................................................................................................................ 18

2.14

QUALIFICATION CRITERIA OF PAINTING CONTRACTOR ...................................................................................................... 18

2.15

DOCUMENTATION: ............................................................................................................................................... 18

ANNEXURE I - PAINTING MATERIAL INDEX ............................................................................................................................ 21


ANNEXURE II PAINTING SYSTEM SCHEDULE .......................................................................................................................... 21
ANNEXURE III COLOUR CODE ......................................................................................................................................... 22
SKETCH 1 - WITH PRIMARY COLOUR BAND ........................................................................................................................... 25
SKETCH 2 -WITH PRIMARY & SECONDARY COLOUR BAND......................................................................................................... 26
SKETCH 3 - WITH PRIMARY & SECONDARY COLOUR BAND WITH DIRECTION BY ARROWS .................................................................. 27
SKETCH 4 - COLOUR BANDS WITH HAZARD MARKINGS............................................................................................................. 28

3.0

PAINTING PROGRAMME .................................................................................................................... 29

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GENERAL INFORMATION:
M/s. Carlsberg India Pvt. Ltd.
5th Floor, Paras Twin Towers, Tower B,
: Sector-54, Gurgaon,
Harayana-122 002

1.0

Client

2.0

Plant location

3.0

Project

: Green Field Bihar

4.0

5.0

Site data

Access to Site

Ambient data
(As per ISHARE)

M/s. Carlsberg India Pvt. Ltd.


Patna , Bihar

DBT (0C)

WBT (0C)

RH (%)

Summer

42.2

25.6

26

Monsoon

32.2

28.3

78

Winter

10.0

6.7

60

By Road

: Patna

Railway Station

: Patna

Nearest Airport

: Patna

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2.0

TECHNICAL SPECIFICATION FOR PAINTING

2.1

General
This engineering standard specification covers the requirements for painting including surface preparation,
method of application, inspection of paints / coating and painted surface for equipment, piping, structures,
electrical, instrumentation equipment for the plants engineered by KCPL
Building / Concrete Painting is not covered under this Specification. For Building / concrete Protection
Painting refer Civil Specification.

2.2

Scope

a.

Scope of work covered in the specification shall include, but not limited to the following:

This specification defines the requirements for surface preparation, selecting and method of application of
paints on external surfaces of equipment, vessels, machinery, piping, ducts, steel structure, electrical and
instrument items. In general all shop fabricated/manufactured equipment will be delivered to job site with
painting in accordance with the requirements of this Specification.

The entire painting job shall be done as per the paint materials specification and apply as per the
specifications for surface preparation, paint system and application method given in the specification.

b.

Extent of Work

All un-insulated CS and SS equipment like columns, vessels, drums, storage tanks, heat exchangers, pump
etc.

All un-insulated carbon and low alloy steel piping, fittings, flanges and valves (Including painting
identification marks), furnaces, ducts and stacks.

Equipment and piping contained in a package unit as necessary.

All structural steel work, pipe structural steel work, walkways, handrails, ladders, platforms etc.

Identification colour bands on all piping as required including insulated aluminium / galvanised clad,
galvanised, SS and non-ferrous piping.

Identification lettering/ numbering on all painted surfaces of equipment/ piping insulated aluminium /
galvanized clad galvanized, SS and non-ferrous piping.

Hazardous content marking/identification signs on painted surfaces of equipment/piping.

Supply of all primers, paints and all other materials required for painting other than owners supply.

Painting under insulation for carbon steel and stainless steel piping, vessels, storage tanks etc, if required.

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Equipment, piping inside pits or trenches.

Repair and repainting of damaged and defective painting of shop applied items as per the instructions of
engineer in charge of site.

All galvanised piping, structural and equipment to be repaired on damaged at site with suitable coating
materials as per the instruction of engineer in charge at site.

c.

The standard specification excludes the following

Painting of equipment, piping, mechanical structures or package items based on manufacturer


recommendation. (All package items shall be painted in accordance with this Spec.)

Non Ferrous materials like Aluminium.

Austenitic stainless steel & Galvanised iron.

Plastic and plastic coated materials.

Application of paints using methods other than brushing or spraying.

Painting for temporary installation.

Coating and lining

d.
2.3

Pipes and equipment shall be painted only after the mechanical completion, testing on systems are
completed including hydro testing as well as after completion of steam purging wherever required.

Codes & Standards

a.

The latest edition of the following standards including all revisions and addendum shall be applicable.
Works shall also be in accordance with the Paint Manufacturers recommendations.

IS-5

Colours for ready mixed paints and enamels.

IS-101 Method of test for ready mixed paints and enamels.

IS-158 Spec. for ready mix paints.

IS-161 Heat resistant Paint

IS-2074 Specification for ready mixed paints, red oxide zinc chrome primer.

IS-2339 Aluminium paint for general purposes in dual container

IS-2379 Colour code for identification of pipelines

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IS-2932 Specification for enamel, synthetic, exterior (a) undercoating (b) finishing

A 13.1 American standard scheme for identification of piping by colour coding.

BS-729, 1981 Hot Dip Galvanised Coatings on Iron and Steel Articles

BS-4800, 1981 Paint Colours for Building Purposes

b.

Surface Preparation Standards:

Steel Structure Painting Council (SSPC-SP)

Swedish Standards Institution (SIS) (SIS 05 5900-1967)

International Organisation for Standard (ISO) (ISO 8501-1) : 1988

NACE National Association for Corrosion Engineers

BS-4232 Surface finish of blast cleaned surface for painting.

IS 1477 Part I Code of Practice for Painting of Ferrous metal in building (Pre Treatment)

If there is any conflict between the requirements of the above mentioned codes and standards and this
engineering specification, the requirements of the specification shall prevail. All conflicts shall be referred
to KCPL/Owner for clarification before proceeding for the work.

c.

The paint manufacturers latest approved published instruction shall be followed as far as practicable at all
times. Particular attention shall be paid to the following.

Proper Attention to avoid exposure as well extremes of temperature

Surface preparation prior to painting

Mixing & thinning

Application of paints and recommend limit on time intervals between coats.

The paint materials for any paint system including primer, intermediate coating, finished coating and
thinner shall be from a single approved manufacturer.

d.

Any painting work (Including surface preparation) on piping or equivalent shall commence only after the
system tests have been completed and clearance for taking up painting work is given by the engineer in
charge in writing.

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Equipment

a.

All tools, brushes, rollers, spray guns, abrasive materials, solvent, hand/power tools for cleaning,
scaffolding materials, shot/wet abrasive blasting, water blasting equipment, air compressors, industrial
vacuum cleaners etc. required to be used shall be suitable for the work and all in good order and shall be
arrange by the contractor at site and insufficient quantity.

b.

Mechanical mixing shall be used for paint mixing operations in case of two-pack system except engineer in
charge may allow the hand mixing of small quantity at his discretion.

2.5

Receipt and Storage

a.

Painting material shall be received, unloaded and stored in a room, which is well ventilated.

b.

In cases where paints are stored outside, adequate protection shall be provided to prevent damage to the
drums.

c.

Warning signboards shall be displayed at places where paints and solvents are stored.

d.

Paints shall not be stored in plant area where there is a fire risk.

e.

Paints and solvents shall be stored and records shall be maintained to ensure their usage before expiry
date.

f.

Containers shall be handled with care. Container of Paint, catalyst and thinners shall not be opened prior
to use except for spot inspection.

g.

Adequate number of fire extinguishers shall be provided in the stores where paint and solvents are stored.

h.

Adequate ventilation and gas masks shall be provided while painting in confined areas.

2.6

Surface Preparation, Coating Application

a.

Preparatory Work:

i.

The agency undertaking work shall estimate quantity of primer and paint required for the job and
arrange to procure the same prior to commencement of the job.

ii.

Approved brands of paints shall only be used (shall be mentioned supplier wise)

iii.

Check, verify the year of manufacture, Batch No. and expiry date of the paint before starting the work.

iv.

Read the paint manufacturers instruction regarding applications, Incase of conflicting requirement with
this specification, Engineer in charge shall be consulted.

v.

Necessary steel scaffolding, landing mats, etc. required to carry out the job is to be arranged.

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vi.

All workmen deployed on the job shall have personal protection gear such as safety shoes, helmets,
safety belts and goggles.

vii.

Paint shall not be mixed near electrical panels.

viii.

Arranged adequate quantities of consumables such as sand papers, wire brushes, paint brushes and
cloth.

ix.

Arrange sufficient number of air compressor of adequate capacities with spray guns and other
accessories.

x.

Ensure that calibrated DFT (Dry Film Thickness) tester/ elcometer is available at shop/ site.

xi.

Maintain testing and calibration certificate for elcometer.

xii.

Arrange to provide abrasive blasting equipment with all necessary accessories.

xiii.

Ensure that all electrical appliances are tested and properly earthed.

xiv.

Provide galvanised sheets, tarpaulins etc. to protect equipment and men during abrasive blasting
operation.

xv.

Provide adequate gas masks, goggles, hand gloves and other personal protection gear to the workmen
undertaking abrasive blasting.

b.

Surface Preparation:
In order to achieve maximum durability one or more of following methods of surface preparation shall be
followed, depending on the condition of steel surface and as instructed by engineer in charge. Adhesion of
the paint film to surface depends largely on the degree of cleanliness of the metal surface. Proper surface
preparation contributes more to the success of the paint protective system.

Manual or hand tool cleaning

Mechanical or Power tool cleaning

Blast cleaning

For the adequate performance of the painting system, it is absolutely essential that the surfaces to be
painted are adequately prepared. The surface should be dry and free from oil and grease, dust, weld
splatter, burrs, flux, rust, loose scale, dirt and any other foreign matter before any coating is applied.
All surface preparation will be carried out in accordance with the requirement set out in ISO 8501-1: 1988
Preparation of Steel Substrates before Application of Paints and Related Products Visual Assessment
for surface cleanliness

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Manual of hand tool cleaning
Manual or hand tool cleaning is used only where safety problems limit the application of other surface
preparation procedure and hence does not appear in the tables of paint systems
Hand tool cleaning normally consist of the following.
 Hand descaling and /or hammering
 Hand scraping
 Hand wire brushing
On completion of cleaning, loose material shall be removed from the surface by clean rags and the
surface shall be brushed, swept dedusted and blow off with compressed air / steam to remove all
loose matter. Finally the surface may be washed with water and dried for effective cleaning.

Mechanical or Power tool cleaning (As per SSPC-SP3)


Power tool cleaning shall be done by non-sparking type brass mechanical striking tools, chipping
hammers, grinding wheels, rotating brass wire brushes. On completion of cleaning the detached rust,
mill scale etc. shall be removed by clean rag and/or washed by water or steam and thoroughly dried
with compressed air jet before application of paint.

Blast Cleaning (NOT APPLICABLE)


 Surface Preparation prior to blast cleaning.
Prior to abrasive blast cleaning the surface shall be free from moisture, oil greases and heavy
deposits of rust. Excessive deposits of rust shall be removed using impact cleaning tools prior to
the commencement of abrasive blast cleaning.
Oil and grease shall be removed using an emulsifying solvent, and the surface shall be washed with
clean water and allowed to get dried completely prior to the commencement of abrasive blast
cleaning. Wiping with a rag soaked in solvent for the removal of oil and grease from the
contaminated surfaces shall not be accepted as adequate.
 Equipment for Abrasive Blast Cleaning
The compressed air to be used for abrasive blast cleaning shall be dry and free from oil. Adequate
separators and traps shall be installed in the coolest part of the system; they shall be regularly
emptied to prevent the carry over of oil and water.
Accumulations of oil and water shall be removed from air received by regular purging. Blasting
nozzles shall be replaced when wear reaches 50%. Air compressors shall not deliver air at
temperatures in excess of 110oC.

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 Abrasives to be used in Blast Cleaning
The abrasive used for abrasive blast cleaning may be selected from the following:


Steel grit

Steel shot

Malleable iron shot

Crushed or chilled iron grit

Chopped steel wire

Aluminium oxide

Blast furnace slag

Copper Slag

Vasilgrit (a proprietary grade based on inert aluminium silicate)

Sand: Should sand be considered as the blasting medium, it shall be delivered to site in
sealed bags. Each bag shall be identified against a Batch No. and each batch has a third party
certificate. The test certificate shall confirm that the blast medium conforms to the
requirements of US-MIL-S-22262 with a maximum chloride level of 0.03%.

 Abrasive Blast Cleaning


The surface shall be blast cleaned using the abrasives at pressure of 7 kg/cm2 (g) at appropriate
angle and distance depending on nozzle size maintaining constant velocity and pressure.
Abrasive Blast Cleaning shall remove all mill scale, rust and other corrosion products, paint and any
other foreign matter to achieve a surface cleanliness of SA 2, accordance with ISO 8501-I with a
surface roughness not exceeding 100 peak to valley eigt, it a minimum peak to valley
eigt of 40.
Surfaces, which become wet due to rain or moisture, shall be re-blasted prior to application of the
primer. Abrasive blast cleaning shall overlap by at least 25 mm on any adjacent painted surface.
 Environmental Conditions for Surface Preparation
Surface preparation by abrasive blast cleaning shall not be carried out when the following
conditions prevail:


The surface temperature of the substrate is less than 3oC above the ambient dew point and
when the relative humidity is greater than 85%. Or the substrate temperature is more than
60oC.

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Abrasive blast cleaning shall not be carried out during the hours of darkness unless
adequately equipped facility for the purpose is available.

 Surface preparation after abrasive blast cleaning: All surfaces that have been prepared using
abrasive blast cleaning will normally have traces of blast debris and dust removed from the
surface. The surface including all pockets and corners shall be cleaned by vacuum cleaning, blowing
with dry oil free compressed air, or brushing with a clean brush made from hair, bristle or fiber.

 Surface preparation for hot dipped galvanised steel, stainless steel and non-ferrous metals.
Generally these surfaces are not painted.
If, however painting is required on these surfaces, they shall be lightly abrasive blast cleaned using
aluminium oxide or inert aluminium silicate. Copper from furnace slag shall not be used on
stainless steel. Any zinc salts that have formed on galvanised surfaces shall be removed using clean
water or a solvent wash and thoroughly dried before the abrasive cleaning is undertaken.
 Surface Preparation of Concrete Surfaces (NOT APPLICABLE):
Concrete surfaces that require painting shall be clean, dry and free from laitance and have a
degree of roughness to ensure proper adhesive of the paint. The surface shall be blast cleaned or
power wire brushed to obtain the degree of roughness required.
Etching with dilute hydrochloric acid and washing with excess water shall be accepted as a last
choice only. Painting shall not commence on concrete surfaces until the surface has dried to
humidity of 4% by wt or less.
 Surface preparation classification is indicated in Table-I below
 Surface prepared shall be compared with relevant standard using a comparator.
 After surface preparation and prior to any coating application the substrate shall be checked for
soluble salt contamination using a suitable salt contamination meter. Maximum allowable is 5
gm/cm2

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Table I
Surface Preparation Classification

Metod of
Cleaning
Solvent Cleaning

Through Hand
Tool Cleaning

Classification
Grease and Oil
cleaning

Cleaning with solvents, vapour alkali, emulsion or


steam to remove oil, grease, soil, salts.

Hand and
Power Tool
Cleaning

Thorough scrapping and wire brushing machine


brushing- grinding etc. The treatment shall remove
loose mill scale, rust and foreign matter. Finally,
the surface is cleaned with a vacuum cleaner, clean
dry compressed air or a clean brush. It should then
have a faint metallic shine.
Very thorough scrapping and wire brushing,
machine brushing-grinding etc. The treatment shall
remove loose mill scale, rust and foreign matter.
Finally, the surface is cleaned with a vacuum
cleaner, clean dry compressed air or a clean brush.
After removal of dust, the surface shall have a
pronounced metallic shine.
By using oxy acetylene flame dehydrate and
remove rust loose mill scales and tight mill scales
followed by wire brushing
By using wheel or nozzles (dry or wet) using grit or
shot all visible rust, mill scales and foreign matter is
removed.

Very thorough
Hand and Power
Tool Cleaning

Hand and
Power Tool
Cleaning

Flame Cleaning
of new steel
Blast Cleaning to
usually clean
steel
Through Blast
Cleaning

Procedure & Degree of Steel Surface finis

Removal of
rust, loose mill
scale
Removal of all
visible rust,
mill scales by
blast.
Commercial
Blast Cleaning

Light Blast
Cleaning

Blast Cleaning

Pickling

Pickling

Weathering
followed by
blast cleaning
Very through
blast cleaning

Weathering

Near White
Blast Cleaning

Thorough blast cleaning. Almost all mill scale, rust


and foreign matter shall be removed. Finally, the
surface is cleaned with a vacuum cleaner, clean dry
compressed air or a clean brush. It shall then be
grayish in colour.
Blast Cleaning of all except tightly adhered residue
of mill scales rust, coating exposing numerous
flecks of underlying metal
Acid pickling or electrolytic pickling to complete
remove mill scales (may reduce resistance of the
surface to corrosion if not primed immediately)
Weathering to remove all particle of mill scale
followed by blast cleaning to one of the above
method.
Very thorough blast cleaning. Mill scale, rust and
foreign matter shall be removed to the extent that
the only traces remaining are slight stains in the

Reference Standard
SIS / ISO
St 1

St 2

St 3

F1

Sa 3 100% Pure
Surface

Sa 2 Nearly
80%

Sa 1

Sa 2
95%
Pure

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Metod of
Cleaning

Classification

Procedure & Degree of Steel Surface finis


form of spots or strips. Finally, the surface is
cleaned with a vacuum cleaner, clean dry
compressed air or a clean brush.

Note :- Nearest equivalent of above can be used


Legends :
SIS :

Swedish Standard Institution SIS 05-5900-1967

ISO :

International Organisation for Standardisation ISO 8501-1:1998(E)

Reference Standard
SIS / ISO

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Protective Coating & Painting Material


Contractor shall furnish from paint manufacturer, all the characteristics of paint materials on printed
literature, along with test certificate for all the specified characteristics given in this specification for the
supplied batch of material. All paint material shall be first quality and conform to the characteristic
mentioned in this specification.
Refer to Annexure-I

2.8

Painting material index

Painting System
The paint system should vary with the type of environment envisaged in and around plant, the service
temperature and the cost effectiveness. These parameters are defined as part of this specification.
Refer to Annexure II

2.9

Painting System Schedule.

Painting Colour Codes


The colour codes recommended in this specifications as per Indian standards.
Refer to Annexure III: Painting colour codes.
The basic identification colours as indicated in Annexure III are applied to the entire surface of equipment
except on precision-machined surfaces, non-ferrous and threaded parts. On the pipes, the basic colour is
applied over the entire surface of uninsulated pipes and further identification of service, colour bands as
defined in Annexure shall be painted.

2.10

Identification of Equipment, Piping Etc.


Equipment number shall be stenciled in black or white on each equipment after painting.
Line number in Black or White shall be stenciled on all pipelines at more than one location as directed by
engineer in charge.

a.

Flo Direction

Flow direction bands are described in Sketch 1 and 2.

Arrows can also be used to indicate the flow direction as described in Sketch 3

The arrows shall be in white or black colour. Following sizes are recommended:
 For pipes diameter 1 to 6 dia., arrow to fit in a 25 mm x 100 mm rectangle.
 For pipes diameter 8 dia and above, arrow to fit in a 80 mm x 150 mm rectangle.

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b.

In case of flow of fluid is possible in either direction; two arrows shall be indicated one above the other
and both in same colour.

Arrows and band markings shall be made at the unit battery limits and then on convenient location at
the point of use. It is recommended to adopt one method for the entire plant.

Hazardous Mediums
Where the piping system carries a hazardous product, a panel of equal diagonal stripes (black and yellow
colours) shall be superimposed on the pipe on both ends of the basic identification panels as detailed in
Sketch-4.

c.

Details of Code Indications

Colour:
The Line nos. and equipment nos. shall be painted either in white or in black in order to contrast
clearly with the colour of paint on the pipe or equipment. For insulated lines, the code indications
shall be painted over the cladding of the insulation.

Requirements:
The full name or well-known abbreviations of chemical and symbol of fluid flowing (as per Project
Spec.) inside a pipeline shall be indicated. The line number shall also be painted on the pipelines. The
pressure or temperature of the fluid inside the pipeline shall not be indicated.

Location:
The code indication as described above shall be painted at following locations or such other places
where quick identification is deemed necessary.
Pipelines: At all junctions, both sides of valves, both sides of service appliances and at intervals of 25
m on straight pipe lengths.
Note: For long straight lengths of pipelines e.g. transfer lines, the interval of 25 m for code indication
may be varied at the discretion of the Client/KCPL

d.

Size:
The recommended size of lettering to be used for code indications on the insulated as well as uninsulated
pipes shall be as per following:
For Pipes

Diameter 2

25 mm letters

For Pipes

Diameter 2 4

40 mm letters

For Pipes

Diameter 6 and above

80 mm letters

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Code Indication for Small Diameter Pipes:


Code indication marking by paint may not be done for uninsulated pipelines of nominal diameter 1 and
below and for insulated lines less than 1 diameter. For such pipes, the indication markings shall be
punched on lead tags and then secured to the pipe. Such tags shall be provided at locations as described
earlier. The size of the tag and the method of tying it with pipeline shall be as per advice of Engineer in
charge.

f.

Lettering for Equipment:


Lettering for the equipment should be marked on each equipment at a clearly visible location.
The letters should have following minimum height:

2.11

For Equipment with Diameter 1 m

50 / 80 mm

For Equipment with Diameter 1 m to 5 m

100 mm

For Equipment with Diameter 5 m to 15 m

300 mm

For Equipment with Diameter 15 m to 50 m

600 mm

For Equipment with Diameter more than 50 m

900 mm

Inspection & Testing

a.

Inspection of various stages during painting is essential to ensure quality of painting. Inspection shall be
performed by owner authorized Field Superintendent.

b.

Surface preparation shall be as per specification; the prepared surface shall be compared with standard
comparator charts available in standards such as SIS or ISO. The basis of acceptance shall be based on
visual comparison only.

c.

Standard surface finish comparator specimens are available, which are approved by reputed test house,
these may also be used after obtaining clients or consultant approval.

d.

Visual examination of the painted surface shall be conducted to check for flaws such as unfinished surface,
drips, wrinkles, blisters, peels, cracks, stains, pin holes, crawls, dust settlement and air pockets.

e.

Area where such defects are noticed shall be marked using some paint of different colour.

f.

Areas where there are no such defects shall be accepted after visual examination.

g.

Thickness of primer and finish coats shall be measured using dry film thickness meter or elco-meter or
owners accepted equal. Thickness shall be measured in accordance with specification of SSPC-PA-A-73T.

h.

Location for verifying thickness shall be decided by engineer-in-charge depending on the size and shape of
the item painted.

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i.

Total three sets of readings shall be carried out at a location, one at the main location and two at the
adjacent points. The average of these three measurements shall be taken as the measured value.

j.

The coating thickness shall be deemed to be accepted if the following conditions are satisfied:

Wet Film Thickness


Use steel type (or disposable type for one day only) each. Wet film thickness measured by using a wet
film gauge of steel or aluminium calibrated to read in mils or microns (25 microns 1 mil).
When using this gauge, the applicator divides the desired dry film thickness by the % volume solids of
the coating as expressed in a decimal (taking into account the amount of thinning done) to yield the
necessary dry film thickness.

Dry Film Thickness:


An Elometer, or mikrotest, or similar approved gauge is used to measure thickness to the nearest
micron. It shall be calibrated against a standard sand blasted surface to SA 2-1/2.
The acceptable tolerance in dry film thickness shall be in accordance with SSPC-PA2.
The Piping Contractors Superintendent shall have in his possession at all times a wet film thickness
gauge for continuous check of the west film as applied.

k.

Consultants/ Client may draw sample of paint before or during application for analysis.

l.

Adhesion test shall be performed after the finish coating has dried up, using a scraper comb with 1 mm gap
between teeth. Adhesion shall exceed 80%.

m.

All painting material including primers and thinners brought to site by contractor for application shall be
procured directly from the manufacturer as per the specification and shall be accompanied by
manufacturers test certificates. Paint formulations without certificates are not acceptable.

n.

Engineer in charge at his discretion, may call for tests of paint formulation. Contractor shall arrange to
have such tests performed including batch wise test of wet paints for physical and chemical analysis. All
cost incurred in carrying out tests shall be borne by the contractor. Defective work shall be corrected by
the Painting/Coating Contractor at his sole expense.

2.12

Field Safety and Hygiene


While performing surface preparation and painting, safety and hygiene conditions shall be observed by the
contractor. Following care shall be observed.

a.

Workmen should be provided with all personal protective gears such as safety shoes, safety goggles/
masks, hand gloves, aprons, safety belts, helmets etc.

b.

Smoking should be totally prohibited in and around painting area and paint storage area.

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c.

Adequate ventilation and lighting shall be provided while painting in a confined area.

d.

While performing shot blasting activity, the area shall be covered adequately so that no shots fly around.

e.

Proper tubular double scaffolding with metallic clamps and landing mats shall be used while working on
higher elevations.

f.

If painting has to be carried out in an almost airtight environment, workmen shall use gas masks.

2.13

Guarantee
The contractor shall guarantee that the chemical and physical properties of paint materials used are in
accordance with the specifications contained herein / to be provided during job execution. The painting
work shall be guaranteed for at least 2 years without any detrimental failures such as loss of adhesion,
under film corrosion, corrosion spots and blisters etc. under the corrosive conditions prevailing in the
plant.
The contractor shall produce test reports from manufacturer regarding the quality of the particular batch
of painted surface. The Engineer in charge shall have the right to test wet samples of paint at random for
quality as per the paint materials specification given in this specification. Batch test report of the
manufacturer for each batch of paints supplied shall be made available by the contractor.

2.14

Qualification Criteria of Painting Contractor


Painting contractor who is awarded any job under this specification must have necessary equipment,
machinery, tools and tackles for surface preparation, paint application and inspection. All the paint
materials should be supplied from approved manufacturer. The contractor must have qualified, trained,
experienced surface preparator, paint applicator, inspector and supervisors. The contractors supervisor,
inspectors, surface preparators, paint applicators must be conversant with the standards referred in this
specification. The contractors capacity, capability and competency requirement for the job shall be
quantified in the tender document and shall be assessed by Client/ KCPL before awarding contract.

2.15

Documentation:
The following documents shall be complied and forwarded to consultant. This shall be equipment wise/
line wise:

a.

Type and Make of primer applied

b.

Type and Make of paint applied (Intermediate & Final)

c.

Batch Certificate Number

d.

Expiry date of paint

e.

Surface Preparation Examination Report

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Doc. No.
Revision No.
f.

Dry Film Thickness Readings for Primer Coats

g.

Dry Film Thickness Readings for Intermediate & Finish Coats

h.

Check List

i.

Final Acceptance Certificate

j.

Paint Manufacturers QA/ QC Report

k.

Name of the manufacturer

l.

Factory Location

m.

Date of manufacturer

n.

Batch No.

o.

Product Name

p.

Drying Time

q.

Hold up Property

r.

Glossiness

s.

Specific Gravity

t.

Viscosity

u.

Generic Name

v.

Key Composition

Resin

Pigments

Curing Agent

Solvent Name

w.

Density

x.

Fineness

y.

Colour

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z.

Date of Expiry

aa.

Pot Life

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Annexure I - Painting Material Index


Application
Type

Dry film
tk.

Description

Max.
Humidity

Temp.
Hig

Temp. Lo

35

85%

45oC

10oC

35

85%

45oC

10oC

PRIMER

01

Zinc Chromate Primer

II

INTERMEDIATE COAT

02

Synthetic Enamel Paint

III

FINAL COAT

03

Synthetic Enamel Paint

35

85%

45oC

10oC

04

High Build Epoxy For SS

100

85%

45oC

10oC

MAKES :- ASIAN PAINTS / BERGER PAINTS

Annexure II Painting System Scedule


I Coat

Sr.
No.

Description of Surface

01

II Coat
III Coat

Final
Coat

Total DFT

(SHOP)

(FIELD)

Structural Steel Work

120

02

Piping System

120

03

Tanks

120

04

Bands for SS Piping

100

Remarks

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Annexure III Colour Code


1. Colour Code for Equipments & Structural
Sr.
No.

Contents

Tankages

Structural Steel Work

Colour
Light brown

2.1

Frame work, Columns, Beams and Pipe Supports (Unless galvanized)

Light grey

2.2

Stairs, platforms, Floor plates, Kickplates (Unless galvanized)

Light grey

2.3

Ladder, Ladder Cages, Handrails (Unless galvanized)

Black with yellow bands

2. Colour Code for Piping:


Sr.
No.

Contents

Ground Colour

Second Colour
Band

First Colour Band

WATER
1

Cooling

Sea green

French blue

Boiler feed water

Sea green

Gulf red

Condensate

Sea green

Light brown

Drinking

Sea green

French blue

Signal red

Treated

Sea green

Light orange

Fire water

Fire red

Crimson red

Cold water down service from Sea green


storage tanks

French blue

Canary yellow

Domestic, hot

Sea green

Light grey

Sea, river, untreated

Sea green

White

10

Filtered water

Sea green

Light brown

11

Soft water

Sea green

Light brown

Signal red

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12

Chilled water

Sea green

Black

Canary yellow

13

Sprinkle and hydrant water

Sea green

White

Signal red

14

Waste water

Sea green

Canary yellow

Signal red

AIR
15

Compressed, up
including 15 Kg/cm2

to

and Sky blue

16

Plant air

Sky blue

Silver grey

17

Instrument air

Sky blue

French blue

18

Dry vacuum

White

19

Wet vacuum

White

Dark violet

20

Very high pressure steam

Aluminium to IS 2339

Signal red

21

High pressure steam

Aluminium to IS 2339

French blue

22

Medium pressure steam

Aluminium to IS 2339

Gulf red

23

Low pressure steam

Aluminium to IS 2339

Canary yellow

24

Drainage

Black

OIL
25

Light diesel fuel

Light Brown

Brilliant green

26

High speed diesel fuel

Light Brown

27

Furnace fuel

Light Brown

French blue

OTHERS
28

Ammonia

Canary Yellow

Dark violet

29

Chlorine

Canary Yellow

Dark violet

Light Orange

30

Acetylene

Canary Yellow

Service Brown

31

Freon

Canary Yellow

Light grey

Dark violet

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32

Nitrogen

Canary Yellow

Black

33

Oxygen

Canary Yellow

White

34

Ethylene Glycol

Dark Admirality grey

Brilliant green

35

Ethylene Di-chloride

Dark Admirality grey

Gulf red

36

Acetone

Dark Admirality grey

Black

37

Methanol

Dark Admirality grey

Deep buff

38

Sulphuric Acid

Dark violet

Brilliant green

Light orange

39

Hydrochloric Acid

Dark violet

Signal red

Light orange

40

Brine

Black

White

41

Mercury

Black

White

Brilliant green

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Doc. No.
Revision No.

Sketc 1 - Wit Primary Colour Band


B

Basic Identification Colour

Primary Colour Band

Colour Band B (Same Colour as Band


A) located in the down-stream of band
A indicates the direction of flow.
In case of both direction flow, BandB should be located each side of BandA

Pipe

Size of Letters for


Line No.

100

50

100

25 mm

2 4

100

50

100

40 mm

6 16

D/2

80 mm

For the pipes sizes more than 16


A = 1 x 400 = 400 Max.
B = 400 / 2 = 200 Max.
C = 1 x 400 = 400 Max.

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Sketc 2 -Wit Primary & Secondary Colour Band


G

Basic Identification Colour


Secondary Colour Band - F
Primary Colour Band - E
Colour Band G (Same
Colour as Band E)
located in the downstream of Band E
indicates the direction
of flow.
In case of both
direction flow, Band-G
should be located each
side
E

Size of Letters for


Line No.

100

50

50

50

25 mm

2 4

100

50

50

50

40 mm

6 16

D/2

D/2

80 mm

Pipe

For the pipes of area > 16


E

400 Max.

200 Max.

G =

200 Max.

400 Max.

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Sketc 3 - Wit Primary & Secondary Colour Band Wit Direction By Arros

Basic Identification Colour


Secondary Colour Band K
Primary Colour Band (J)
For pipes 1 6 arrow size
should be 25 mm x 100 mm
For pipes 8 and above
arrow size should be 80 x
150 mm

Size of Letters for


Line No.

100

50

25 mm

2 4

100

50

40 mm

6 16

D/2

80 mm

Pipe

For the pipes of sizes more than 16 the dimensions


J = 400 Max.
K = 200 Max.

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Sketc 4 - Colour Bands it Hazard Markings


R

P/2

11-001-16-BBCIH

Hazard Marking Strips of


Black & Yellow B
Secondary Colour Band - M
Primary Colour Band - L
Direction of Flow N as
shown in sketch 1 & 2
(same colour as L)
The colour band N can be
replaced by arrow as shown
in sketch 3

Size of Letters for


Line No.

100

50

50

100

100

25 mm

2 4

100

50

50

100

100

40 mm

6 16

D/2

D/2

80 mm

Pipe

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3.0

PAINTING PROGRAMME

a.

Equipment and Piping Painting work is required to be completed within the time stipulated in the main
Contract.

b.

Key completion dates of various areas of work shall be specified at the time of award of Contract.

c.

The Site Planning Engineer of the Contractor shall be required to work out detailed erection programme
periodically as per completion requirements indicated by Consultant.

d.

The dates of completion for various milestones will be worked out by the Contractor jointly with the
Consultant. It will be the Contractors responsibility to execute the job totally as per agreed programme.

e.

Bi-monthly review meetings will be held at SITE to assess the progress and revise the schedule to ensure
completion as per Contract.

f.

Contractor mobilization to Site is to suit the completion targets and other than Force Majure, no excuses
for delay in completion is acceptable.

g.

The contract envisages liquidated damages (mentioned elsewhere in this document) for delay in
completion and the Contractor to bear the same in mind.