TITLE OF THE DOCUMENT : SURFACE PREPARATION AND PAINTING PROCEDURE

PROJECT NAME :

PROJECT NUMBER :

PLANT

CONTRACTOR :

VENDOR DOCUMENT NO. : - - -

Permission to proceed does not constitute acceptance or approval of design calculations, analysis, test
methods or materials developed or selected by supplier and does not relieve supplier from full
compliance with contractual obligations

1. Approved
2a. Revise and Resubmit - Work may proceed subject to incorporation of changes indicated
2b. Revise – Work may proceed. Do not resubmit until it is final
3. Review not required
4. Rejected

Client Approval (Name and signature)

RC ISSUED FOR APPROVAL PG PG GK

RB ISSUED FOR APPROVAL PG PG GK
RA ISSUED FOR APPROVAL PG PG GK
REV. DATE DESCRIPTION PREPARED CHECKED APPROVED
 PROJECT TITLE: - Project no:

PAGE : : 2

OF 21

DOCUMENT TITLE: REV. C

DATE 07/11/2018

INDEX
1. REFERENCE DOCUMENTS/PARTIES ............................................................ 3
1.1. Documents ......................................................................................................... 3
1.2. Definitions ....................................................................................................... 3
2. SCOPE ................................................................................................................. 3
3. APPLICATION AND RESPONSIBILITIES ............................................................ 3
3.1 Application ..................................................................................................... 3
3.2 Responsibilities .............................................................................................. 4
4. DESCRIPTION ..................................................................................................... 4
4.1 General Requirements ..................................................................................... 4
4.2 Surface Preparation ......................................................................................... 5
4.3 Coating Materials ............................................................................................. 6
4.4 Paint Application .............................................................................................. 6
4.5 Safety Requirements ....................................................................................... 7
4.6 Testing – Inspection ......................................................................................... 8
Table 1. ................................................................................................................. 8
5. PAINTING SYSTEM.............................................................................................. 9
Table 2 .................................................................................................................. 9
Table 3 .................................................................................................................. 9
6. REPAIR OF DEFECTS ................................................................................. 10
7. HANDLING AND TRANSPORTATION................................................................ 10
8. DOCUMENTATION............................................................................................. 10
Attachment A* ......................................................................................................... 11
Attachment B........................................................................................................... 12
Attachment C .......................................................................................................... 19
 PROJECT TITLE: - Project no:

PAGE : : 3

OF 21

DOCUMENT TITLE: REV. C

DATE 07/11/2018

1. REFERENCE DOCUMENTS/PARTIES

1.1. Documents
S-000-13A0-001_R2_0001: General specification for painting
NACE RP-0188: Discontinuity (Holiday) Testing of New Protective Coatings on Conductive
Substrates

1.2. Definitions
EMPLOYER ORPIC
Project EPCC for SR-AP Firewater Integration Project
CONTRACTOR
Works Subcontractor a Construction company to which the CONTRACTOR has
subcontracted part of the field works.
Project Number 0.17.006

2. SCOPE
The procedure is indented to give the appropriate instructions for surface preparation and
painting against atmospheric corrosion. The instructions apply to the following items:
1. Newly purchased piping materials (pipes, valves, fittings and flanges)
2. Prefabricated items (vessels, piping spools)
3. Structural material and prefabricated structural items
4. Painting of existing facility modifications works (includes TIE-ins)

3. APPLICATION AND RESPONSIBILITIES

3.1 Application
This instruction is applied to personnel performing the surface preparation/painting of
CONTRACTOR or the Works’ subcontractor.
 PROJECT TITLE: - Project no:

PAGE : : 4

OF 21

DOCUMENT TITLE: REV. C

DATE 07/11/2018

3.2 Responsibilities
QA Dept. of the CONTRACTOR shall submit this procedure once approved by EMPLOYER to
Production Dept.
The applicable painting system shall conform to the specifications of the project.
The appointed Production Engineer is responsible for the receipt, check of quality and storage
of the paints. In his responsibilities are also to ensure that all requirements of this instruction
are implemented during sandblasting and painting works.
In case subcontractors perform sandblasting and painting works, the inspection described
herein shall be followed in full by an appointed Quality Engineer or Production Engineer of
CONTRACTOR. Manufacturer’s recommendation shall be followed for storage of coating
material at site. Expired material shall not be used at all and shall be removed from site, if any.

4. DESCRIPTION
4.1 General Requirements
Surface preparation and painting shall be performed in accordance with the herein mentioned
instructions.
The painting material shall be stored in a location that is protected from deleterious weather
conditions, well ventilated and free from excessive heat, open flame or other sources of
ignition. Conditions of storage shall also conform to paint manufacturer recommendations.
Paint shall be mixed and thinned in accordance with manufacturer’s instructions immediately
prior to application. Only thinners of a type recommended by the paint manufacturer shall be
used.
Thin-film coating are normally not acceptable for use on equipment on the project, with
exception in non-corrosive environment. Examples of unacceptable thin-film coatings are
electroplating, thin paint coating, ‘’cold-galvanizing’’, etc.
The surfaces listed below shall be shielded to prevent damage during sandblasting or/and
painting operations. After completion of operations all materials used for shielding and sealing
applications shall be removed.
 Lining surfaces
 Non-ferrous metal surfaces
 Galvanized steel surfaces except for color identification
 Aluminized steel surfaces
 Stainless steel surfaces except insulated surfaces with operating temperature
between 50 – 120 °C
 Internal surfaces of equipment and pipes
 Bolts/nuts of flanged connections
 Insulation jacketing metal sheet
 PROJECT TITLE: - Project no:

PAGE : : 5

OF 21

DOCUMENT TITLE: REV. C

DATE 07/11/2018

 Interior wall surfaces, heating tubes and portions with heat resistant treatment of
furnaces, boilers, etc.
 Screwed items of valves, gasket surfaces, finished machine parts of equipment and
piping components.
 Bevels of open spools subject to welding at later stage (including 50mm of metal
adjacent to the bevel)

4.2 Surface Preparation

Surface preparation works shall conform to this procedure. If for any reason these instructions
are not applicable or cannot be followed, manufacturer’s recommendations shall be
considered or any other proposal shall be subjected to an agreement between EMPLOYER and
CONTRACTOR.
All equipment and structures shall be fully protected from mechanical damages, ingress of
abrasives and dust from blast cleaning. Sags, droplets and paint over-spray (inclusive dry-
spray) shall be avoided. Adjacent areas not to be painted or already finished shall be
protected. On completion of the work in any area, all masking materials, spent abrasives,
equipment etc. shall be removed. Water soluble contamination, e.g. salt, if observed, shall be
removed by high pressure fresh water cleaning.
For touch up activities, prior to cleaning, oil and grease shall be removed with a solvent wash.
After the solvent wash the surface shall then be washed down with clean fresh water to
remove dirt and residues. (Any solvent used in the cleaning of stainless steel surfaces shall be
an organic solvent free from metallic elements and have less than 50ppm inorganic halogen
content).
Sharp edges, corners shall be rounded to radius Rmin = 2mm
Dust shall be blown off with air free of oil.
Abrasive blasting will only be performed by experienced operators. Operators shall follow all
the relevant health and safety instructions of CONTRACTOR.
Sand grit shall be used for abrasive blasting operations. The abrasives for blasting must be free
from oil, grease, moisture etc. The sand shall be either silica or flint. Soft sand shall not be
used. The roughness of the cleaned surface shall meet the recommendations of the primer
paint manufacturer. In case of stainless steel, sweep blasting with non-metallic abrasive and
chloride free shall be used.
The surfaces shall not be blasted under any of the following conditions:
 Relative humidity greater than 85%
 When temperature is less than 5 oC
 During raining while the work is outside
 Any observable moisture on the surface
 The abrasive is wet
 PROJECT TITLE: - Project no:

PAGE : : 6

OF 21

DOCUMENT TITLE: REV. C

DATE 07/11/2018

 When coating is carried out or the coating is left for drying and curing in adjacent
areas
 When the surface temperature is not 3 oC above dew point temperature
All prefabricated surface preparation works are subject to SA 21/2, areas which deliberately
will remain uncoated (areas adjacent to bevel), surface preparation will be commenced again
at site to St2 or St3, whichever practical. Welds performed at site, prior coating, shall be
subject of surface preparation to St2 or St3. Primer shall be applied within 4 hours after the
preparation is finished

4.3 Coating Materials

All materials shall be supplied in manufacturers original containers, durably and legibly
marked with a description of the contents.
This shall include the specification number, the color reference number, the intended method
of application, batch number, date of manufacture and manufacturers name, initials or
recognized trademark.
All coating materials of the full system, including the thinner shall be originated from the same
manufacturer.

4.4 Paint Application

Paint shall be applied by brushing, roller, air spraying, airless spraying or a combination of
these methods.
Roller application of the first primer coat is not acceptable, except site applications.
The method of application shall follow the paint manufacturer’s instructions.
For each coat, a stripe coat shall be applied by brush to all welds, corners, behind angles, edges
of beams etc. and areas not fully reachable by spray to obtain the specified coverage and
thickness.
Painting works shall not be performed, when any of the following conditions are present:
1. Any observable moisture or flash rust that can be traced on the surface of the item
2. Temperature (metal or ambient) falls below 5oC.
3. When the surface temperature is not 3 oC above dew point temperature
4. Relative humidity (RH) is greater than 85%
5. Dust is present that can contaminate the paints or freshly coated surface.
6. Dirt or other detrimental materials have re-contaminated the surface. If
contamination has occurred, then the entire contaminated coating shall be cleaned
back to bare metal and then re-coated in accordance with the requirements of
specifications.
 PROJECT TITLE: - Project no:

PAGE : : 7

OF 21

DOCUMENT TITLE: REV. C

DATE 07/11/2018

7. Following weld defects: spatter, rough capping, slags, arc strikes and undercuts (which
dimensions are not accepted by ASME B31.3 code), sharp rough edges and burrs.
8. When the previous coat has not been allowed to fully cure
9. Under high wind conditions which can cause excessive over spray and other defects.
10. If rains showers are expected before the coating can completely dry and painted
surfaces will be exposed to the rain.
11. Painting shall be applied after post weld heat treatment
12. If a period of 4 hours after surface preparation is exceeded, coating is not allowed
unless the surface is prepared again. At least primer coating shall be completed before
the period of 4 hours has passed
Paint manufacturer’s recommendations shall be consulted in each case for possible special
temperature requirements.
Surfaces shall not be recoated until the previous coat has properly dried or cured, as per
coating material manufacturer’s recommendations. The surface may be considered ready for
recoating when the next coat can be applied without the development of paint film
irregularities, such as lifting or loss of adhesion of the undercoat.
Welds performed at site may be primed before hydrotest.
Where the required thickness is not achieved, additional coats shall be applied until the proper
thickness is obtained. Application shall be such, that the film thickness will not affect
appearance or service life of the paint.
For steel structures, piping and pressure vessels fabricated in shop or site the applicable
system is that of table 2. (system no. 1)

4.5 Safety Requirements

A protective hood with a positive fresh air shall be used during blast cleaning operations. A
filter type dust mask shall be used during hand tool or power cleaning operations in enclosed
areas or in other situations where excessive concentrations of dust results.
Protective clothing, such as gloves, goggles and aprons shall be worn during pickling or solvent
cleaning operations. Hands should be cleaned with waterless hand cleaner after exposure to
solvents. Clothing or protective equipment wet with solvents or paint should be promptly
removed and laundered before reuse.
Care must be exercised as working takes place in closed confined area, especially when
spraying. All necessary tests shall be performed for oxygen sufficiency. Operators shall wear
fresh air masks. When the volatile solvents are flammable, the concentration in the air shall
be kept to one quarter or less of the lower explosive limit by adequate exhaust or ventilation
facilities. The solvent concentration shall be periodically controlled.
 PROJECT TITLE: - Project no:

PAGE : : 8

OF 21

DOCUMENT TITLE: REV. C

DATE 07/11/2018

4.6 Testing – Inspection

Visual inspection by the Quality or Production Engineer of the Contractor of materials,
equipment for surface preparation and for coating application shall be carried out to ensure
conformance with the relevant technical and safety requirements of this work instruction and
the suppliers recommended practices.
Before commencing work on surface preparation and coating the atmospheric temperature
and the relative humidity shall be measured and recorded to determine the dew point.
Readings may have been repeated depending on changes in climatic conditions.
Surface preparation average profile (Rz) per batch shall be between 40 to 75μm.
The dry film thickness each coating layer shall be checked according the table 1. The individual
gage measurements minimum thickness permitted could be 80% of the specified minimum
thickness. The mean value of all gage readings should be equal or above the specified
thickness of table 2 paragraph 5. Maximum permitted DFT value shall not exceed 25% of the
specified maximum thickness.
Adhesion check shall be performed with test method A (X-cut) after the final layer is applied.
The relative humidity and the temperature as well as the measurements of the dry film
thickness shall be recorded into the ‘’Painting Inspection Record’’ (see attachment A).
The relative humidity should be measured at least one time before commencement of work
in cases that surface preparation and painting is being applied in a control environment.
Especially for the Underground piping, holiday test will be performed at 100% of the coated
area with a High Voltage Electrical Inspection Equipment. (Suggestive inspection voltage
3000V, as per NACE Recommended Practice 0188)

Table 1.
Area/length of inspection Minimum number of Maximum number of
(m2 or m) measurements measurements allowed to
be repeated
Up to 1 5 1
Above 1 to 3 10 2
Above 3 to 10 15 3
Above 10 to 13 20 4
Above 30 to 100 30 6
Above 100 Add 10 every additional 20% of the minimum
100m2 or 100m number of measurements
Area above 1000 m2 or m, should be divided into smaller areas
 PROJECT TITLE: - Project no:

PAGE : : 9

OF 21

DOCUMENT TITLE: REV. C

DATE 07/11/2018

5. PAINTING SYSTEM
The coating and the color code (RAL) which will be applied on each item should be that of
table 2 below. Final DFT may be varies depending on the manufacturer’s recommendations.
For underground piping, the system of table 3 will be applied.

Table 2
Coating System no. 1 (Piping above ground <120°)
Surface preparation SSPC-SP10(SA 21/2): Near white blast cleaning
(shop):
Surface preparation SSPC-SP2(St2) or SSPC-SP3(St3): Hand tool or Power tool cleaning
(site):
Layer Type Commercial name DFT(μm)-Minimum
Hempel’s Hempadur 17360
1st layer Zinc rich epoxy 75
(Avantguard 750)
Hempel’s Hempadur Mastic
2rd layer High Solid build epoxy 150
MIO 45881
Hempel’s Hempathane Topcoat
3th layer Acrylic polyurethane 50
55210/55610
Total DFT 275

Color designation as per RAL system

ITEM RAL
Steel Structures, platforms frames, ladders 7035
Nearest to Munsell 5R 4/14 (Code of
Firefighting piping materials (including valves)
Hempel 53320)
Notes: Datasheets in attachment B

Table 3
Coating System no. 2
Surface preparation (shop): SSPC-SP10(SA 21/2): Near white blast cleaning
Surface preparation (site): SSPC-SP2(St2) or SSPC-SP3(St3): Hand tool or Power tool cleaning
Layer Type Commercial name DFT(μm)
As per manufacturer’s
High Solid Build Hempel’s Hempadur
recommendation to achieve the 125-200 per layer
Epoxy Mastic MIO 45881
required thickness
Total DFT 500-600μm

Color designation as per RAL system will be chosen the nearest to Munsell

ITEM RAL
Nearest to Munsell 5R 4/14
Firefighting piping materials underground
(Code of Hempel 53320)
Notes: DFT is as per manufacturer’s recommendation, datasheet in attachment C.
 PROJECT TITLE: - Project no:

PAGE : : 10

OF 21

DOCUMENT TITLE: REV. C

DATE 07/11/2018

6. REPAIR OF DEFECTS
Wherever damaged painting is observed, but primer is not exposed, surface shall be cleaned
with appropriate thinner and rinsed with water dumped in a clean cloth. Subsequent mid-coat
and final coat will be applied by a roller. In case primer or metal is exposed, the defected area,
along with an adjacent 25mm around it, shall be prepared by a hand tool or power tool.
Subsequently the full system will be applied to the required DFT. An alternative primer may
be used to accommodate the change in surface preparation from SA21/2 to St2 or St3, as per
manufacturer’s recommendations. For galvanized surfaces if any, the repair shall be done by
a hand or power tool for surface preparation and apply a Zinc rich epoxy layer (for example
Hempadur Zinc 17360) by brush, roller, spraying from aerosol can or spraying by an agitated
pot.

7. HANDLING AND TRANSPORTATION

Care shall be taken to prevent damage to both the uncoated and the coated pipe. Coated pipe
may, under no circumstances be dragged or rolled over the ground. When handling the pipes,
non-metallic slings, spreader bars, or protected hooks, shall be used. The coated pipe
shall be stacked in such a manner that the exterior coating does not contact a hard surface,
which may damage the coating.
During transportation, the pipes shall be stacked and secured such that they cannot be
damaged (abrasion, penning).

8. DOCUMENTATION
The package of quality records for painting works, shall consist of the following documents:
▪ Surface preparation and Painting Inspection Reports
▪ Product Datasheets of coating materials to be applied at the final manufacturer’s data
book.
 PROJECT TITLE: - Project no:

PAGE : : 11

OF 21

DOCUMENT TITLE: REV. C

DATE 07/11/2018

Attachment A*
Contractor:
INSPECTION FORM No: REVISION :

Client:

PAINTING INSPECTION RECORD DATE : PAGE :

Project:

Project No.: Specification ref.: REPORT No:

Minimum Required Dry Film Thickness(μm)

1st Layer(μm) 2nd Layer(μm) 3rd Layer() 4th Layer() / RAL

Ambient Condition
Item Operator Painted Item Surface Relative
Week
No: I.D Description(S.N.) Temp. Humidity
(ºC) (%)

Inspection equipment:

Blasting: SA 2 ½:

Check of Roughness(μm) :

Adhesion check on Primer for Items

Adhesion check on Intermediate for Items

After Painting: Spot Measurements of dry film thickness

Item No or painted
Reading No 1st (μm) 2nd(μm) 3rd(μm) 4th(μm)
item description

For Metron

*Report may change to accommodate site requirements.

 PROJECT TITLE: - Project no:

PAGE : : 12

OF 21

DOCUMENT TITLE: REV. C

DATE 07 1/2018

Attachment B
PROJECT TITLE: - Project no:

PAGE : : 13

OF 21

DOCUMENT TITLE: REV. C

DATE 07/11/2018
PROJECT TITLE: - Project no:

PAGE : : 14

OF 21

DOCUMENT TITLE: REV. C

DATE 07/11/2018
PROJECT TITLE: - Project no:

PAGE : : 15

OF 21

DOCUMENT TITLE: REV. C

DATE 07/11/2018
PROJECT TITLE: - Project no:

PAGE : : 16

OF 21

DOCUMENT TITLE: REV. C

DATE 07/11/2018
PROJECT TITLE: - Project no:

PAGE : : 17

OF 21

DOCUMENT TITLE: REV. C

DATE 07/11/2018
PROJECT TITLE: - Project no:

PAGE : : 18

OF 21

DOCUMENT TITLE: REV. C

DATE 07/11/2018
 PROJECT TITLE: - Project no:

PAGE : : 19

OF 21

DOCUMENT TITLE: REV. C

DATE 07/11/2018

Attachment C
PROJECT TITLE: - Project no:

PAGE : : 20

OF 21

DOCUMENT TITLE: REV. C

DATE 07/11/2018
PROJECT TITLE: - Project no:

PAGE : : 21

OF 21

DOCUMENT TITLE: REV. C

DATE 07/11/2018