Kudankulam Nuclear Power Project Rev.No.

: 2
HCC P 15 17 05 Page No: 1 of 8
Date of Rev:
Procedure for painting of carbon steel embedded parts,
26.05.05
support structures, liners & ventilation ducts.

REVISION

Rev No. Date of Rev Description

Rev. 2 26.05.05 NPCIL comments incorporated

Rev. 1 18.04.05 Painting of EPs, Support structures & Liners included
Rev. 0 17.04.2002 First Issue

Prepared By Reviewed By Approved By Issued By

Name Sunil Karvir S. Datta K.R.Visvanath K. Umapathi

Designation Engineer - QA In-Charge(QM) Project Manager Doc. Controller

Signature

Date 26.05.05 26.05.05 26.05.05 26.05.05

 Kudankulam Nuclear Power Project Rev.No.: 2
HCC P 15 17 05 Page No: 2 of 8
Date of Rev:
Procedure for painting of carbon steel embedded parts,
26.05.05
support structures, liners & ventilation ducts.

1.0 PURPOSE:

This procedure explains the methodology adopted for painting the Carbon Steel EPs
support structures, Liners and internal surfaces of ventilation ducts. Paintings of
external surfaces of ventilation ducts are not required as per specifications. This
procedure is to be adopted in lieu of painting system specified in Drawing of Reactor
Building and Reactor Auxiliary Buildings.

2.0 Scope:

This procedure is applicable for painting of C.S. embedded parts, support structures,
Liners and ventilation system ducts, which are fabricated and erected in Reactor &
Reactor Auxiliary Buildings at Kudankulam Project Site by HCC.

3.0 References:

1. Technical specification – Sec. V (XVII).

2. Relevant approved drawings of embedded parts, ducts and support structures

3. Procedure No. HCC P 15 17 41 – for Grit Blasting of embedded parts & Ventilation
ducts.

4.0 Paint Material Specification:

Following paints are approved by NPCIL

1. Zinc Anode 304 for primer and Protectomastic for finish coat of Berger make, or
2. APCOSIL 605 for primer and APCODUR CF641 for finish coat of Asian Paints
make

5.0 Description

5.1 Methodology / Sequence of work

1. Procurement of paint material & other consumables.

2. Qualification of the paint sample.
3. Qualification of Painters.
4. Equipment & Storage.

Prepared by Reviewed by Approved by

 Kudankulam Nuclear Power Project Rev.No.: 2
HCC P 15 17 05 Page No: 3 of 8
Date of Rev:
Procedure for painting of carbon steel embedded parts,
26.05.05
support structures, liners & ventilation ducts.

5. Surface preparation by Grit blasting / Acid pickling.

6. Application of primer and inspection after curing
7. Application of paint – Subsequent coats & curing.
8. Inspection & Testing of paint application / Acceptance.
9. Transportation to site and erection including touch up repair if required.
10. Precautionary methods
11. Maintenance of Records

PROCUREMENT OF PAINT MATERIAL & OTHER CONSUMABLES:

5.1.1. HCC shall estimate the surface area and would ensure the quantity of the paint is
sufficient enough. For the purpose of computation on an average coverage of 4 Square
meter per liter per coat is taken for primer and 5 Square meters per liter per coat is
taken for the subsequent coats. Quantum normally does not exceed 2% of the paint
requirement. Other consumables required also shall be procured along with paint.

QUALIFICATION OF THE PAINT SAMPLE:

5.2.1. At the time of paint supply, samples will be drawn from each batch and tested in
accordance with the specifications as applicable. Paint suppliers batch test certificate
for primer and paint shall be obtained and reviewed by HCC for onward submission
to NPCIL for approval.

EQUIPMENT AND STORAGE :

5.3.1. Zinc anode 304 primer shall be applied by conventional spray only. Equipment for
painting are conventional method of spraying equipment with suitable sizes. The
spraying equipment consists of Air compressor and spray gun. Brush can be used for
paint repair or touch up only.

5.3.2. Equipment for Grit blasting shall be as per procedure No. HCC P 15 17 41.

5.3.3. All paint material shall be stored safely with good ventilation, handled carefully and
account of consumption recorded regularly. The paint drums/tins should have the
following details:
i) Brand Name
ii) Batch Number with date of manufacturing
iii) Manufacturers name
iv) Quantity in Liters / Kg.
v) Mixing Ratio in case of multiple packs.

Prepared by Reviewed by Approved by

SURFACE PREPARATION BY GRIT BLASTING:
 Kudankulam Nuclear Power Project Rev.No.: 2
HCC P 15 17 05 Page No: 4 of 8
Date of Rev:
Procedure for painting of carbon steel embedded parts,
26.05.05
support structures, liners & ventilation ducts.

5.4.0 Surface preparation shall be ensured by Grit blasting as per Procedure No. HCC P 15
17 41 or Acid pickling as per Procedure No. HCC P 15 17 40 before starting painting
work.

Cleaning after grit blasting shall be carried out to remove dust.

APPLICATION OF PRIMER AND INSPECTION AFTER CURING :

5.5.1 The primer application should be commenced within 4 hours of blasting operation or
else flash rust is likely to occur in humid/marine environments. The surface on which
primer is applied shall be protected from wind, dust and abrasion by working in
covered area.

5.5.2 The primer and thinner shall be mixed and applied in accordance with manufacturer
instructions. The product should be mixed as per manufacturer’s data sheet. Mixing
shall be generally done using electric powered stirrer. However, for small quantities
hand mixing can be permitted. Care should be taken to mix the quantity as relevant to
the area available for painting. Application should be completed within the pot life of
the paint. Thinner 870 alone should be used; addition depends on the spraying
technique, for which the data sheet is to be referred. Dry spraying is not allowed.

5.5.3 Continuous stirring or frequent stirring of the mixed paint is very important, as the
zinc dust tends to settle to the bottom of the container. Primer paint when applied
should be free from sagging, chalking, mud cracks, dry spray, over spray and the
required DFT is achieved in a single coat application. Second coat of the primer is not
recommended.

5.5.4 Touch up with brush is also not advisable. The primer achieves touch dry in a
maximum of 30 minutes. However it is fit for handling only after 3 – 4 hours. Hard
dry is achieved after over night drying for the purpose of recording paint-coat
thickness. The dry film thickness is measured with DFT gauge.

5.5.5 Edges where welding is to be done along with 3thk. flanges, shall also painted as
above. The flanges shall be secured to air ducts by continuous welding prior to
application of primer protective coat. Air ducts with a diameter of up to 1000mm
must be assembled of sections not more than 2 M long. These sections are welded to
each other by making a continuous joint over the outer surface of the flange.

Prepared by Reviewed by Approved by

 Kudankulam Nuclear Power Project Rev.No.: 2
HCC P 15 17 05 Page No: 5 of 8
Date of Rev:
Procedure for painting of carbon steel embedded parts,
26.05.05
support structures, liners & ventilation ducts.

5.5.6 Painted products (EPs etc.) shall be protected from dust till it dries up.

5.5.7 Environment control such as humidity and temperature measurement shall be carried
out and painting shall be done at the levels specified by paint manufacturer. As a
general rule, surface temperature should be atleast 3oC above due paint but not above
50oC. Unless otherwise specified by paint manufacturer relative humidity shall not
exceed 85%

APPLICATION OF PAINT – SUBSEQUENT COATS & CURING :

5.6.1 The final coat shall be normally applied by airless spray. However for small areas,
application by brush is permissible. It comes in two pack; base and catalyst and the
mixing is done after individual stirring of base and catalyst separately. The mixing
ratio shall be as per manufacturers recommendation. The stirring should be done to
achieve a homogeneous mixture of base and catalyst. Thinner addition depends on the
technique of application, refer data sheet supplied by the manufacturer.

5.6.2 While supplying care should be taken to start from edges corners and a tie coat is first
applied on all welded joints. The application is then taken uniformly to cover all
areas. To the maximum extent possible, each coat of material shall be applied as a
continuous uniform film. Any spots or areas missed in the application shall be
recoated and permitted to dry. At least two coats of the paint shall be applied to
achieve the total dry film thickness of 200 microns.

5.6.3 Brushes shall be of a style and quality that will enable proper application of paint.
Round or oval brushes are most suitable for rivets, bolts irregular surfaces, and rough
or pitted steel. Wide flat brushes are suitable for large flat areas, but they shall not
have width over three inches. Paint shall be applied into all corners. Any runs or sags
shall be brushed out. There shall be a minimum of brush marks left in the applied
paint.

5.6.4 No coat shall be applied until the preceding coat has dried and cured as per
manufacturers recommendation. The material shall be considered dry for re-coating
when another coat can be applied without the development of any film irregularities
such as lifting or loss of adhesion of undercoats. Necessary corrective action shall be
taken to rectify defects.

Prepared by Reviewed by Approved by

 Kudankulam Nuclear Power Project Rev.No.: 2
HCC P 15 17 05 Page No: 6 of 8
Date of Rev:
Procedure for painting of carbon steel embedded parts,
26.05.05
support structures, liners & ventilation ducts.

5.6.5 No paint shall be force dried under conditions, which will cause checking, wrinkling,
blistering formation of pores, or detrimentally affect the condition of the paint. No
drier shall be added to paint on the job unless specifically called for in the
manufacturer’s specification of the paint. Paint shall be protected from rain,
condensation, contamination, and freezing until dry to the fullest extent possible. The
painting shall be done indoors as far as possible.

INSPECTION & TESTING OF PAINT / ACCEPTANCE :

5.7.1 Visual inspection is first done to establish uniform coating and to spot out faulty
application. Dry film thickness is measured with an elcometer.

5.7.2 When specified in drawing, adhesion test shall be done on samples during painter
qualification.

5.7.3 Acceptance of the paint work is done after satisfactory results of tests carried out by
thickness measurement by elcometer and on final acceptance, inspection reports shall
be duly filled indicating the item number and signed off.

5.7.4 Incase of localized defect in paint coating, the defect area shall be repaired locally
with brush after removing the defect by sand paper. Incase the metal surface is
exposed, it will be cleared to SA2 standard before applying repair coat.

Prepared by Reviewed by Approved by

 Kudankulam Nuclear Power Project Rev.No.: 2
HCC P 15 17 05 Page No: 7 of 8
Date of Rev:
Procedure for painting of carbon steel embedded parts,
26.05.05
support structures, liners & ventilation ducts.

5.7.3 TYPE OF COATING AND THE INDIVIDUAL / TOTAL DRY FILM THICKNESS
ARE LISTED BELOW: (MICRON THICKNESS) UNLESS OTHERWISE
SPECIFIED IN DRAWING.

Paint DFT for Total DFT Number of

Item Remark
Coating each paint (Minimum) coats
60 to 80
1.Zinc
microns ONE
Anode 304
Ventilation Only for Internal
Duct 220 microns Surface
2. Protecto
125 to 150 ONE
Mastic
microns
Protectomastic
Coat will be
1.Zinc 60 to 80 applied only
ONE
Anode 304 where so
EPs specified in
220 microns
2. Protecto 125 to 150 drawing
ONE
Mastic microns

Support
1.Zinc 60 to 80
Structures & ONE
Anode 304 microns _
Liners
240 to 260
without
2. Protecto 175 to 200 microns
Aluminium TWO
Mastic microns
Metalization
*Including
Support
Aluminium
Structures &
1.Protecto Metalization,
Liners with 125 to 150 125*
Mastic ONE Total DFT shall
Aluminium microns microns
be 375 Micron
Metalization
(Minimum)
The above stated coating thickness may be changed in special cases, if required as per
working drawings.

TRANSPORTATION TO SITE AND ERECTION:

 Kudankulam Nuclear Power Project Rev.No.: 2
HCC P 15 17 05 Page No: 8 of 8
Date of Rev:
Procedure for painting of carbon steel embedded parts,
26.05.05
support structures, liners & ventilation ducts.

5.8.1 After completion of fabrication and application of paint, the parts shall be transported
to site and erected at its final location. Following precautions shall be taken during
transportation and erection to avoid damage to painted surface.

a) The parts shall be properly packed using wooden planks and gunny bags etc:- and
loaded on to the transportation vehicle so that coated surface damages are avoided.

b) For handling nylon / polymer sling ropes shall be used.

c) Wherever any damage to painted surface is noticed after transportation, those areas
shall be touched up with a coat of EPILUX – 4.

PRECAUTIONARY METHODS:

5.9.1 HCC should ensure well ventilated areas for painting, sufficient lighting arrangements
and care should be taken to see that no welding / gas cutting is carried out where
painting work is in hand or near the storage area. All the equipment with all its
accessories shall be cleaned regularly and to be arranged in a systematic way for
proper accessibility and performance

5.9.2 The paints shall not be kept directly under sunlight or close to flame / welding areas.
Drums should be properly closed if part of the paint is drawn for painting. No mixed
paint with catalyst or with thinner should be poured back in to the unmixed paint
containers. Stacking of paints is normally done to a stack of four or five containers
one above the other to a height of five feet only. The paints should be drawn from the
stores on first come first served basis.

5.9.3 Stirring of paints at regular intervals shall be done during application of paints.
Brushes and loose paint containers being used, shall be cleaned thoroughly after every
use.

5.9.4 Mixing pots for paints and brushes shall be cleaned immediately after completion of
paintings. Clean condition of brushes and mixing pots shall be ensured before mixing
and application of paint.

MAINTENANCE OF RECORDS:

5.10.1 Necessary records are to be maintained by HCC and should be readily available as
and when, demanded by NPCIL relevant authorities.

Prepared by Reviewed by Approved by