Professional Documents
Culture Documents
PACKAGE 6
Revision
Remarks Issued Date Return Date
No.
00 ISSUE FOR REVIEW 26-FEB-2010
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form, or by means of electronic,
mechanical, photocopying, recording, or otherwise, without the written permission of Rotary Engineering Limited.
REFINERY TANK FARM
PACKAGE 6
Revision History
TABLE OF CONTENTS
1 SCOPE 3
2 REFERENCE 4
3 DEFINITIONS 4
4 PERSONNEL QUALIFICATION 4
5 GENERAL 5
7 SURFACE PREPARATION 5
12 COLOUR SCHEDULE 16
14 RECORD 16
15 ATTACHMENTS 17
1. SCOPE
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Page 3 of 17
BLASTING AND PAINTING PROCEDURE
SA-JER-TFAAA-PSCL-508022 Rev.00
FOR STRUCTURAL STEEL
REFINERY TANK FARM
PACKAGE 6
This procedure defines the minimum technical requirements of Blasting & Painting for Steel
Structures which is required coatings in order to meet Project specification, Coating
Manufacturer recommendations, Reference code and standards in REFINERY TANK FARM
PACKAGE 6 Project.
2. REFERENCE
Document No Title
3. DEFINITIONS
COMPANY – SAUDI ARAMCO TOTAL Refining and Petrochemical
Company (SATORP), Kingdom of Saudi Arabia
CONTRACTOR – ROTARY Engineering Ltd (REL) / Petrol Steel Co. Ltd. (PSCL)
4. PERSONNEL QUALIFICATION
4.1.1 All operation shall be performed by skilled workmen
4.1.2 All Coating Inspector shall be qualified as per the requirements specified in
Schedule “Q” (Attachment -1)
5. GENERAL
Approved Blasting & Painting Specification for Steel structure (Ref. SA-JER-TRAAA-PSCL-
648020) shall be followed to indentify the followings:
Surface to be coated
Method of surface preparation
Required anchor profile
Required coating system
Selection of painting materials
Technical data sheet shall be supplied, clearly indicating all the features and
requirements of the products (i.e. max/min over coating times for the specified DFT,
max/min DFT, max temperature resistance etc.).
Paints and Thinners shall be stored in well-ventilated building or shelter. Shelter storage
temperature shall not exceed 35°C unless stated otherwise in Paint Data Sheet.
All paint material must be used within the manufacturer specified period. Paint shall be
used in strict rotation according to batch number and shelf life.
Paints which have exceeded the shelf life shall be set aside and removed from painting
storage area. Expired paint shall not be used.
The paint materials shall be stored in optimal conditions for their best conservation.
Temperature sensitive and self polymerization Paint materials shall be stored in air
conditioned storage area.
Temporary storage of paint materials covered with canvas, tarpaulins shall not excess 14
days.
7. SURFACE PREPARATION
7.1 General
Any surface that has to be blasted shall be removed of all the contaminants such as oil,
greases, chemicals or soil shall be removed prior to blasting by the use of suitable broom
brush. During cleaning, all weld areas and attachments shall be given special attention
to ensure all welding flux and spatter is removed by the use of files scrapers, chipping,
hammers, power or hand brushes or grinders fitted with flexible grinding discs.
7.2.1 All blasting equipment shall have current Inspection Certificate from an
independent third party and the same will be ensured by the CONTRACTOR
Painting Inspector prior to using the equipment.
7.2.2 Abrasive blasting shall be done by using the manual blast cleaning method.
7.2.3 When compressed air is used, air lines shall be provided with effective, well
maintained oil and water traps. Efficient well maintained air filters shall be
provided to control dust.
7.2.4 The pressure and volume of the compressed air supply for blast cleaning shall be
fulfill the requirements of blasting machine manufacturer and suitable for the
surface to be blast.
7.2.5 Compressed air supply quality check shall be done by Blotter Test at the start
and midpoint of each 8 hour shift. The Blotter Test shall be done as follows,
Attach a piece of blotter or absorbent paper to a clip board, then hold it
approximately 450-650mm in front of the blast nozzle during air flow only with
a nozzle pressure of approximately 50 psig for one minute. Satisfactory
results shall be no water or oil contamination on the blotter. The blast system
shall be operated for at least 5 minutes under actual field conditions at the
specified pressures prior to making the blotter test.
7.3 Abrasives
7.3.1 Abrasives selection as per SSPC-SP-COM.
7.3.2 Sand or other materials producing silica dust shall not be used.
7.3.3 The abrasives shall be free from oil, grease, moisture etc.
7.3.4 Re-used steel abrasive shall be clean, sharp and free from contaminants. First
time prior to start using the re-used steel abrasive shall be showed to
CONTRACTOR and COMPANY Inspector for approval. After that
CONTRACTOR Painting Inspector will inspect at a regular basis to ensure the
quality of the re-used steel abrasive shall meet the above requirements.
7.4 Identification
7.4.1 Prior to blasting all material are to be checked to ensure the correct materials are
being processed.
Doc No: Title:
Page 6 of 17
BLASTING AND PAINTING PROCEDURE
SA-JER-TFAAA-PSCL-508022 Rev.00
FOR STRUCTURAL STEEL
REFINERY TANK FARM
PACKAGE 6
7.4.3 Materials are to be identified and have proper storage and placed on designated
area before and after blasting/painting.
7.5 Blasting
7.5.1 Blasting shall not be done outside normal daylight work hours unless authorized
by COMPANY or CONTRACTOR Inspector.
7.5.2 Blasting operations shall not be carried out unless surfaces to be prepared are
3°C above ambient air dew point.
7.5.3 After blast cleaning and before application of the priming coat the surface shall be
cleaned to remove dust and abrasives and in particular from pockets and
corners. This can be done by vacuum cleaning or by blowing with dry oil-free
compressed air.
7.5.4 Due care shall be exercised to prevent the abrasive grit entering inside
equipment and pipe work. On completion of blasting operations, the inside of
equipment and piping shall be inspected and cleaned out if the presence of
abrasive grit is detected.
7.5.5 Any surface showing signs of handling contamination after basting shall be
suitably cleaned and re-blasted.
7.6.2 In particular, stainless steel and non-ferrous surfaces shall be protected from
blasting, overspray and coatings intended for carbon steel. The CONTRACTOR
painting supervisor shall ensure protection of all equipment that is not to be
painting or liable to be affected by the presence of abrasive or paint. Special
attention shall be given to avoid splashes of zinc-based paint on equipment of
austenitic steel to prevent high temperature cracking corrosion.
7.8.1 Anchor profile shall be followed as per Blasting & Painting specification for Steel
structural (SA-JER-TRAAA-PSCL-648020), unless otherwise the surface profile
for carbon steel surfaces after blast cleaning shall have a min/max height of
50/70 microns with rough peaks to 100 microns (Rz).
7.9 Inspection
7.9.1 After completion of surface preparation, the CONTRACTOR Painting Inspector
shall carry out the inspection activities as per Section-10 in this procedure.
8.1 General
8.1.1 The Selection of Coating systems & Coating materials shall be strictly followed as
per Blasting & Painting Specification for Steel structural (Ref. SA-JER-TRAAA-
PSCL-648020) and the same shall be ensured by the CONTRACTOR Painting
Inspector.
8.1.2 CONTRACTOR Painting Inspector & Painting Supervisor shall strictly follow the
instructions and recommendations as prescribed by the Coating Manufacturers
for the preparation and application of all coating materials.
8.2.2 All Painting equipment to be checked to ensure that there is no residual paint
from previous application in the containers or hoses and paint guns.
8.2.3 The pressure and volume of the compressed air supply for spray application shall
fulfill the requirements of Spray machine and Painting Manufactures
8.2.4 When compressed air is used, air lines shall be provided with effective, well
maintained oil and water traps. Efficient well maintained air filters shall be
provided to control dust.
8.3.2 Coating shall only be applied when suitable weather conditions prevail and the
same will be ensured by CONTRACTOR Painting Inspector.
8.3.3 Coating shall not be applied under the following conditions or when such
conditions are likely to prevail before the coating is cured:
The steel temperature is less than 3°C above the dew point
8.3.5 Coating which is contaminated during curing, for example by dust, condensation
or rain, shall, if deemed necessary by COMPANY or CONTRACTOR Painting
Inspector be removed and redone.
8.4.2 Coating for two-pack or multiple packs coating system shall be mixed in the
proportions and under the conditions recommended by the Manufacturer.
8.4.3 The mixed coating shall be used within the regulated pot life and shall not be
used on expiry of its “pot life”.
8.4.5 For inorganic zinc primers, after mixing the silicate binder and the zinc powder,
the mixed product shall be sieved prior to application and continuously power-
stirred during application.
8.4.6 The mixed coating shall match with other prepared products of the same coat.
8.5.2 All personnel entering in to the blasted surfaces shall wear rubber-soled shoes
with clean disposable covers, sweet bands and dirt-free gloves.
8.5.3 Coating may be applied by the following four methods as approved or specified
by the coating Manufacturer,
For airless spray the size of spray nozzle tips, air pressure, etc., shall be
used as per the Paint Data Sheet and recommended by the equipment
supplier.
Each coat shall be applied uniformly and completely over the entire
surface. All skips, runs, drips and sags shall be brushed out immediately
For the initial coat of paint to corners, edges, crevices, holes, weld or
irregular surfaces prior to spray application.
Brush or rollers used shall be of a suitable size and shape and shall be
kept clean by use of Paint Manufacturer’s recommended solvents.
Where rollers are used, the nap shall be of sufficient length to work the
coating well in the surface.
8.6 Priming
8.6.1 The priming coat shall be applied as soon as possible after the surface
preparation has been carried out and before any contamination of the cleaned
surface.
8.6.3 Angles, corners, sharp edges, bolt or rivet heads, weld seams and other surface
irregularities shall be stripe-coated by brush. This coat shall be the same product
as the primer.
8.6.4 After completion of Primer coat, CONTRACTOR Painting Inspector shall perform
the inspection as per Section 10 in this procedure.
8.7.2 When more than one coat is required, the Coating Manufacturer’s
recommendations on over coating time shall be complied with.
8.7.3 Wet film thickness shall be checked during coating by painter to ensure that the
full coating thickness will be achieved in the specified number of coats (as
recommended by the Coating Manufacturer).
8.7.4 A final coat shall be applied in accordance with the undercoat over coating time
recommended by the Coating Manufacturer
8.7.5 The final coat shall provided a smooth, even finished coating surface, where
gloss finish coats are applied, the surface shall be a smooth gloss finish with no
breaks in the surface.
Where it is necessary to apply more than one coat of a particular product to obtain a
specified dry film thickness, then the first coat shall be selected sufficiently different in
color, in order to distinguish from the subsequent coats.
8.10.2 Metal contact surfaces “i.e. bolted joints in structures” – should be coated with
one full layer of the specified primer on both surfaces immediately before bolting
up. Fretting surfaces where friction grip is required shall not be coated.
8.10.3 When painting is carried out before installation, all reasonable steps as
mentioned in section 9 in this procedure shall be taken by CONTRACTOR
Painting Supervisor to reduce damage to the coating system before and during
installation and the same will be ensure by the CONTRACTOR Painting
Inspector.
Coated items shall be handled with equipment such as wide belt slings, web belts, and
wide padded skids selected to prevent damage to the coating.
Handling equipment likely to cause damage to the coating shall not be used.
Items such as chains, cables, hooks, tongs, metal bars and narrow skids shall not be
permitted to come in contact with the coating.
Coated items shall be loaded, padded, and secured for transport in such a manner that
the coating will not be damaged in transit.
Coated items shall be separated so that the items do not bear against each other.
Coated items shall be stacked off the ground using suitable means (e.g. parallel height
ridges of rock-free sand, wooden timbers placed under the uncoated pipe ends) to avoid
damages of the coating.
10.1.1 All Inspection activity shall be carried out as per the approved Project Quality
Plan (Ref. SA-JER-TFAAA-PSCL-496501) in the various phases of execution
and inspection.
10.1.2 Request for Inspection (RFI) shall be raised to COMPANY for inspection as per
the approved Blasting and Painting ITP for Steel structural (Ref. SA-JER-TF661-
PSCL-316602).
10.2.2 Inspection frequency for cleaning of rust etc. shall be one in each area where
surface preparation has been completed, regardless large or small, before
coating.
10.2.3 Anchor pattern shall be inspected by using Testex Tape (Press-O-Film) at where
surface preparation has been completed.
10.2.4 Anchor profile value shall be inspected in Testex tape by using calibrated Dial
gauge Micro meter. The values shall be within the acceptable limit given in
Section 7.8 in this procedure. This shall be ensured by CONTRACTOR Painting
Inspector and the Testex Tape shall be attach with the Painting inspection Report
(Ref. PSCL-SATORP-QAQC-010)
INSPECTION INSPECTION
S.No. INSPECTION ITEM
FREQUENCY IMPLEMENTATION
One point / 5 -20 m² Wet Film Thickness
1 Wet Film Thickness
(Min. 10 pints / Day) gauge
2 Dry Film Thickness One point / 3 – 5 m² Dry Film Thickness
Measurement of wet film thickness (WFT) has to be done only for reference
and shall not be recorded.
Measurement of film thickness is less than 80% of the nominal dry film
thickness (DFT) is not acceptable.
If the dry film thickness does not meet the specified value, additional coats
shall be applied as per section 11 in this procedure, except for inorganic zinc
(zinc silicate) primers that shall be re-blasted and re-applied at the required
dry film thickness (DFT)
Inorganic zinc (zinc silicate) primers applied at dry film thickness greater than
100µm or showing mud-cracking shall also be re-blasted and re-applied at
the required DFT.
One test panel shall be prepared and tested for each Painting System
as specified in the Blasting & Painting Specification for Steel structural
(Ref. SA-JER-TRAAA-PSCL-648020). And also adhesion pull-off test
shall be carried out at any location where there is evidence of any sort
of failure in any coating including, but not limited to, lifting of coats or
loss of adhesion between layers in coating system.
The chloride and soluble salt concentrations shall be less than 10 ppm and
the pH shall be natural (between 6 and 8).
When the above ppm & pH levels are exceeded, the surfaces shall be either
steam cleaned or high pressure water washed before blasting. The cleaned
surface shall be retested to verify that the contaminant levels are within the
acceptable range.
The above test shall be carried out by the CONTRACTOR Painting Inspector
and the result shall be recorded in the Coating/Blasting report (Ref.
ATTACHMENT-1).
11.2 Areas which are to be over coated shall be thoroughly cleaned free from grease, oil
and other contaminants and shall be dry.
11.3 The surfaces shall then be prepared to the standard as specified. Edges of sound
coating around the repair area shall be feathered back approximately 50 mm for a
smooth transition. If necessary, vacuum blasting equipment shall be used for surface
preparation.
11.4 Subsequently additional compatible coats shall be applied (if required), until they
meet the specification. Those additional coats shall blend in with final coating on
adjacent area
11.5 Damaged surface shall be touchup with the coating as per the approved specification
(Ref. SA-JER-TRAAA-PSCL-648020) or Coating Manufacturers’ Recommended
paints shall be used. The repair coat shall overlap sound coating.
13.3 Safety shields, helmets, goggles, respirators, ear protection and protective clothing
shall be use or worn then and where necessary during all operations.
13.4 Material Safety Data Sheet shall be always available at coating area for ready
reference.
13.5 Only competent personnel are permitted to operate the equipment and such persons
shall be tested by a competent person.
13.6 To prevent uncontrolled and reduce air emissions, the works shall be conducted in a
controlled environment.
13.8 Waste generated such as paint containers, spent abrasive shall be properly stored
prior to removal by approved waste collectors.
14. RECORD
15. ATTACHMENTS
15.1 ATTACHMENTS – 1 Blasting / Coating Report (PSCL-SATORP-QAQC-010)