Professional Documents
Culture Documents
For Akbar
Chinnasamy
Jegadeesan
Chinnasamy
Jakkeriya Jegadeesan
2015.04.13
2015.04.13 2015.04.13
15:43:49
+08'00' for
15:49:05
+08'00' for 15:49:21 +08'00'
CONTENTS
1.0 SCOPE
3.0 RESPONSIBILITY
4.0 SAFETY
M219-S-SP-001 Rev 0
Global Process Systems Sdn Bhd. Document No. : M219-S-SP-0001
Revision No . : 1
Page : 2 of 10
1.0 SCOPE
1.1 This procedure describes the minimum requirements for external surface preparation and painting
for fabricated components on the MOPU Process Facilities for the Petrofac Cendor Field
Development.
This procedure and the painting systems specified herein are not intended for use by
equipment/component Vendors. Vendor’s standard procedures and offshore marine painting
systems may be used provided that the proposed painting system has been reviewed by the
Purchaser.
3.0 RESPONSIBILITIES
3.1 Coating Superintendent: Is responsible for planning and managing coating operations, ensuring that
procedures are adhered to and that coating personnel are familiar with procedures and systems.
Ensuring personnel are adequately trained and fully aware of any potential safety hazards within the
department.
3.2 QA/QC Manager: Oversees the entire operation with regards to quality and documentation.
3.3 QC Coating Inspector: Is responsible for controlling the quality of the work which includes but is
not restricted to, checking and recording environmental conditions before and during operations,
ensuring all appropriate clauses of the specification and manufacturers data sheets are complied
with and any deficiencies are immediately brought to the attention of the superintendent or
responsible foreman. Check all areas of the procedure have been completed. Stage by stage
inspection and testing.
3.4 Painting/Blasting Foreman: Are responsible for controlling shop floor activities, monitoring paint
stocks, ensuring personnel are familiar with specifications and coating systems. Liasing with
inspectors on all preparation and coating application activities. Regular toolbox talks and safe
working practices.
M219-S-SP-001 Rev 0
Global Process Systems Sdn Bhd. Document No. : M219-S-SP-0001
Revision No . : 1
Page : 3 of 10
4.0 SAFETY
4.1 General
Everyone working in GPS facilities will adhere to local and statutory regulations and the GPS HSE
manual. Paint manufacturers Safety Data Sheets will be available and instructions for handling and
storage will be followed. Fire extinguishers will be placed in accessible locations close to the
storage, application and mixing areas.
5.1 Material
Abrasive will be Garnet of a minimum mesh 30 size to achieve the specified blast standard of SSPC-
SP10 and, profile amplitude. The garnet will be dry and oil free and will conform to permissible
soluble salt content levels. Average profile height shall be 40 – 80 microns.
5.2 Equipment
Mobile air compressors will supply compressed air and the air will be dry and oil free with a nozzle
pressure of 100 PSI. 200ltr mobile blast pots with remote control handles (dead man) will be used.
Equipment will be earthed and hoses will be carbon impregnated to prevent static electricity build
up. Venturi shaped, tungsten carbide lined nozzles will be used and replaced when wear reaches
50% of its original diameter.
5.3 Access
Access platforms will be of tubular scaffolding, which will be erected as and when required.
Wherever it is possible the scaffold will be erected so as not to impede or hinder access for correct
surface preparation and coating application.
Prior to starting surface preparation all items will be checked for faults that could be deemed to be
detrimental to the paint coating i.e. rough welds, burrs, weld splatter, laminations etc. Faults will be
rectified before surface preparation commences. See section 7.0.
5.5 Degreasing
Any oil or grease will be removed by scraping off heavy deposits, brushing on degreaser or
emulsion cleaner followed by high-pressure fresh water washing. The use of solvents for degreasing
of large areas cannot be considered a safe practice however, solvent swabbing may be considered
for removing small spots of oil or grease.
M219-S-SP-001 Rev 0
Global Process Systems Sdn Bhd. Document No. : M219-S-SP-0001
Revision No . : 1
Page : 4 of 10
Before blast cleaning all items will be tested for soluble salts as per specification parameters to
reduce the possibility of salt being forced into the profile by high velocity blasting. If salt
contamination is above the acceptable level fresh water washing will be done until an acceptable
level is achieved. This test can be repeated before application of primer/first coat if required.
5.7 Protection
Items attached to or in the vicinity of the surface to be painted, which do not require painting will be
protected during the whole operation i.e. finish coated items, flange faces, bearings, nameplates,
machined faces etc. Edges to be welded at a later date will not be painted after blasting they will be
taped to 50mm each side of the weld area.
Blast cleaning will not take place under the following conditions:
a) Rain, fog, mist, airborne dust or sand or if there is moisture on the surface.
b) Steel temperature is within 5 °C of the dew point.
c) Steel or ambient air temperature is below 10 °C .
d) Relative humidity is greater than 80%.
e) If there is a possibility of the above occurring within 2 hours or less.
Blast cleaning will normally take place between the hours of 0700 and 1800. Blasting outside of
these hours will only take place in exceptional circumstances if conditions permit or the
environment can be controlled with de-humidifiers.
Experienced blasters will perform abrasive blast cleaning and the standard will conform to the
requirements of the relevant systems specified herein and, manufacturers data. Any defects
uncovered by blasting will be rectified and the area re-blasted to standard.
5.10 Cleaning
After blasting the surface will be thoroughly cleaned by one or more of the following
methods.
M219-S-SP-001 Rev 0
Global Process Systems Sdn Bhd. Document No. : M219-S-SP-0001
Revision No . : 1
Page : 5 of 10
6.1 Materials
One manufacturer will supply all paint materials and thinners. Multiple coat systems will
be of a different colour for each coat.
6.2 Storage
All paint materials and thinners will be stored in an air-conditioned container, according to the
manufacturers recommendations and data sheets. Special attention will be paid to the safety aspect
of storing paints. The following will be monitored and recorded.
a) Shelf life.
b) Batch numbers.
c) Labelling of tins.
d) Condition of tins i.e. broken seals or damaged tins.
6.3 Equipment
Airless or conventional spray pumps with paint manufacturers recommended nozzle sizes and
pressures will be used. Brushes and rollers will be used for stripe coating and areas that may be
inaccessible to the spray gun. All equipment will be thoroughly cleaned before and after use with
manufacturers recommended cleaner/thinner. Wet film combs will be used to control the uniformity
of film thickness.
6.5 Mixing
Paint will be checked before mixing for any deterioration during storage. Any doubts about
the integrity of the material will be brought to the attention of the manufacturer and advice
will be sought on the course of action. Thinning will only take place on the manufacturers
recommendation and to there specified maximum volume. Only a volume of paint, will be
mixed, that can be used within the pot life and paint that has exceeded the pot life will not
be used. Paint will be thoroughly mixed using mechanical power stirrers.
M219-S-SP-001 Rev 0
Global Process Systems Sdn Bhd. Document No. : M219-S-SP-0001
Revision No . : 1
Page : 6 of 10
A stripe coat will be applied to ensure the DFT on areas on areas it is difficult to obtain
accurate readings i.e. welds, edges, interstices, corners etc. Multiple brush coats of this type
may be required to attain the DFT in areas inaccessible to the spray gun.
Will be applied by experienced applicators within 4hrs of cessation of blast cleaning and before any
degradation of the surface preparation occurs. All painting will take place away from blasting
operations to reduce the risk of airborne contamination.
Will be applied by experienced applicators within the manufacturers recommended over coating
times. Each coat will be of a different colour to the previous coat to identify the stage of the work
and aid the applicator.
Will be applied by experienced applicators within the manufacturers recommended over coating
times. Attention will be paid to the opacity of the finish to ensure good finish and no grinning
through of previous coats.
2. Areas with inadequate coating thickness shall be thoroughly cleaned, abraded and addition
compatible coats shall be applied until they meet the required film thickness. These
additional coats shall blend with the final coating on adjoining areas.
3. Damaged area where steel surfaces are not exposed shall be washed with detergent / fresh
water solution to remove all contamination, then rinsed using clean fresh water and be
allowed to dry. The coating around the damaged area shall be chamfered to ensure
continuity, the applicable paint system shall then be applied.
4. Damaged area down to bare metal shall be surface prepared by re-blasting (depending on
area affected) or power tool cleaning to SSPC-SP 3 with a visual standard of St3 (ISO 8501-
1) and, coating shall be applied.
5. Surface preparation at defects or damaged areas shall be extended over the surrounding
sound coating for a minimum of 25 mm on all sides and the edges shall be tapered.
6.11 Inspection
All inspection and testing will be carried out as per section 7.0 by qualified and experienced
personnel. A manufacturers technical representative shall be available as and when required.
6.12 Documentation
M219-S-SP-001 Rev 0
Global Process Systems Sdn Bhd. Document No. : M219-S-SP-0001
Revision No . : 1
Page : 7 of 10
Painting Records (see section 8.0) will be used and all aspects of inspection and testing, as required
by the client, will be fully documented and recorded. The Painting Record will be filled in by the
painting Q.C. and, presented to the manufacturers representative and clients representative for
approval and signature where applicable.
The selected paint manufacturer is Carboline. Other manufacturers of similar quality and
specification may be considered subject to prior written approval of GPS.
For all coating work, paint specimens must be taken and retained at site for possible reference in the
event coating failure. Retained paint specimens must be kept at least until warranty period has
expired. For these paint specimens, a record shall be kept of paint system and color. Specimen
shall always be stored in a dark, dry and cool place. Unless otherwise specified, paint specimens
shall be prepared as follows:
15 Primer (1)
15 Primer (2)
150 mm 15 Intermediate
75 mm
M219-S-SP-001 Rev 0
Global Process Systems Sdn Bhd. Document No. : M219-S-SP-0001
Revision No . : 1
Page : 8 of 10
INSPECTION OF
TO CHECK i) Condition of rust Grades A, B, C & D
STEELWORK
ii) Oil or Grease solvent wipe in accordance with SSPC-SP-1
iii) Removal of sharp edges, weld spatter, debris etc.
INSPECTION OF
ABRASIVE TO CHECK i) Grade / mesh size / type
ii) Salt free and general
utility
CHECK
WEATHER TO CHECK
i) No blasting shall be conducted when the surface is less than
CONDITION 5 °C above the Dew Point or when RH is greater than 80%.
After Blasting
M219-S-SP-001 Rev 0
Global Process Systems Sdn Bhd. Document No. : M219-S-SP-0001
Revision No . : 1
Page : 9 of 10
INSPECTION OF
SURFACE TO CHECK
i) Dust free surface to blow off / vacuum off dust
ii) Dust / pollution free environment. No painting to be applied
when blasting work is being carried out nearby
INSPECTION OF
TO CHECK
PAINT MATERIAL
After Painting
Notes
1 The net film thickness shall be spot checked as an initial indication of the expected dry film
thickness using net film gauges (digital Elcometer or equivalent)
2. (i) Dry film thickness shall be measured with a coating thickness gauge digital Elcometer or
equivalent)
(ii) The specified minimum dry film thickness shall not be exceeded by more than 50% with
the exception of areas such as welds, crevices, etc i.e. where such requirement is not
practical.
(iii) A maximum of 10% of the reading may be below the specified dry film thickness but
no single reading shall be less than 90% of the specified dry film thickness.
3. The test shall be carried out in accordance with BS 3900 Part E6.
4. Profile height and film thickness gauges shall be calibrated before use.
M219-S-SP-001 Rev 0
Global Process Systems Sdn Bhd. Document No. : M219-S-SP-0001
Revision No . : 1
Page : 10 of 10
PAINTING RECORD
Contract : MOPU facilities for Petrofac Cendor Field Derevelopment, Malaysia
GPS Project Ref Ref.: O-M-05-219
Substrate Material:
A SURFACE PREPARATION
C PAINT
Manufacturer : Carboline
Primer 2nd Coat 3rd Coat Final Coat
Paint Type/Code No.
Min. Dry Film Thickness
Overcoat Time (hours)
Finish Colour
D PAINTING CONDITIONS
M219-S-SP-001 Rev 0
Global Process Systems Sdn Bhd. Document No. : M219-S-SP-0001
Revision No . : 1
APPENDIX : A
APPENDIX A
PAINT SYSTEMS
M219-S-SP-001 Rev 0
Global Process Systems Sdn Bhd. Document No. : M219-S-SP-0001
Revision No . : 1
APPENDIX : A
Abbreviations :
C.S : Carbon Steel
L.A : Low Alloy Steel
A.S.S. : Austenitic Stainless Steel
H.D.G. : Hot Dipped Galvanised
N.A. : Not Applicable
M219-S-SP-001 Rev 0
Global Process Systems Sdn Bhd. Document No. : M219-S-SP-0001
Revision No . : 1
APPENDIX : A
Where no specific RAL code is indicated above this is because certain painting systems have limited
standard colours.
Super Duplex, Cupper Nickel (90/10) and GRE/GRP components shall not be painted.
Austenitic Stainless Steel items such as electrical and instrument enclosures, cable trays etc. shall not be
painted. Austenitic Stainless Steel piping systems shall be painted as indicated in the above table
M219-S-SP-001 Rev 0
Global Process Systems Sdn Bhd. Document No. : M219-S-SP-0001
Revision No . : 1
APPENDIX : A
• Work Place
• Grade (SSPC)
4. Primer
• Work Place Yard Yard
• Material Carbozinc 8701 Carbozinc 11
• Dry film Thickness ( m) 50 50
1 1
• Number of Coat
Airless Spray Airless Spray
• Application Method
5. Intermediate Coat
• Work Place Yard
• Material Carboguard 893
• Dry film Thickness ( m) 200 NIL
1
• Number of Coat
Airless Spray
• Application Method
6. Finish Coat
• Work Place Yard Yard
• Material Carbothane 834 Thermaline 1248
• Dry film Thickness ( m) 50 40
1 1
• Number of Coat
Airless Spray Airless Spray
• Application Method
7 Total Dry Film Thickness 300 90
( m= Micrometer)
8 Field Welded Parts & Touch-up
Parts
• Work Place Field Field
• Surface Preparation
• Metal Surface SP10 SP10
• Film Surface SP 3 SP 3
P I F P F
M219-S-SP-001 Rev 0
Global Process Systems Sdn Bhd. Document No. : M219-S-SP-0001
Revision No . : 1
APPENDIX : A
5. Intermediate Coat
• Work Place Yard
• Material Thermaline 4631
• Dry film Thickness ( m) NIL 20
1
• Number of Coat
Airless Spray
• Application Method
6 Finish Coat
• Work Place Yard Yard
• Material Thermaline 400 Finish Grey Thermaline 4631
• Dry film Thickness ( m) 100 20
1 1
• Number of Coat
Airless Spray Airless Spray
• Application Method
P F P I F
M219-S-SP-001 Rev 0
Global Process Systems Sdn Bhd. Document No. : M219-S-SP-0001
Revision No . : 1
APPENDIX : A
5. Intermediate Coat
• Work Place Yard
• Material Carboguard 893
• Dry film Thickness ( m) 150 NIL
1
• Number of Coat
Airless Spray
• Application Method
6 Finish Coat
• Work Place Yard Yard
• Material Carboguard E20 Thermaline 1248
• Dry film Thickness ( m) 50 20
1 1
• Number of Coat
Airless Spray Air Spray
• Application Method
P I F P F
100 150 50 40 40
• Dry Film Thickness ( m)
1 or more 1 or more 1 or more 1 or more 1 or more
• Number of coat
Airless Spray, Airless Spray Airless Spray Air Spray, Air Spray,
• Application Method Brush, Roller Brush , Roller Brush, Roller Brush, Roller Brush, Roller
9 Remarks
M219-S-SP-001 Rev 0
Global Process Systems Sdn Bhd. Document No. : M219-S-SP-0001
Revision No . : 1
APPENDIX : A
5. Intermediate Coat
• Work Place
• Material
• Dry film Thickness ( m) NIL
• Number of Coat
• Application Method
6 Finish Coat
• Work Place Yard
• Material Thermaline 4631
• Dry film Thickness ( m) 25
1
• Number of Coat
Air Spray
• Application Method
P F
• Material
Thermaline 4631 Thermaline 4631
25 25
• Dry Film Thickness ( m)
1 or more 1 or more
• Number of coat
M219-S-SP-001 Rev 0
Global Process Systems Sdn Bhd. Document No. : M219-S-SP-0001
Revision No . : 1
APPENDIX : A
The below tabulation provides a basic indication of the applicable RAL colour codes.
The below requirements are additional to the general requirements tabulated above
Bought out equipment such as Pumps, Motors, Field Instrumentation, Plate & Frame type
Exchangers, Turbines etc.may be supplied in the Vendors standard colour (except red)
All Firefighting Equipment and Safety Equipment shall be supplied with Signal Red final colour.
M219-S-SP-001 Rev 0