R Work Instruction Title: Section: GUIDELINES FOR HR PAINTING & INSPECTION WI/ PRD / 01 REQUIREMENTS FOR STANDARD PRODUCT LINE Baye F Rev Description ee ak Date 0 | itil release Process | Engg. | 03-07-00 Engineer_| Manager ‘a | Section 4 & Table-1 corrected, Table-2 added; | Process | Engg. | 95.974 Para 4.3 & 4.4 interchanged. Engineer Manager B Section 4, Para 4.3.2 revised to include 3 in 1 Process | QA, Engg. & 03-03-14 solution and MSDS included in Annex A & B Engineer_| Mig. Heads Table-1 and Table-2 modified to include = ae © | details of Carboline make Thermaline 4674 Engineer | Mfg, Heads | 9205-16 paint D_ | Paint viscosity specification included —i-—E E | Gun Air pressure range included =. ee 12-01-18 Paint Curing time, Inspection method aul 3] F | included teu) is ao XOMOX Sanmar Ltd - Pacific Valves Division Page 1 of 74 Work Instruction Title Section: GUIDELINES FOR HR PAINTING & INSPECTION WI/ PRD/04 REQUIREMENTS FOR STANDARD PRODUCT LINE Ren F 1.0 2.0 3.0 40 5.0 6.0 1. PURPOSE: The purpose of this procedure is the minimum requirements for paint materials, surface preparation, application and inspection of protective coating system to be used on the exterior surfaces of valve & valve accessories. SCOPE: This procedure covers all standard product line valves, actuators and related equipments intended for High Temperature services between 177°C and 649°C (350°F and 1200°F), Any special instruction mentioned in Assembly Order / Routing takes precedence over this standard, RESPONSIBILITIES: 3.1 Product Engineering is responsible for Issuance and Maintenance of this procedure, 3.2 Process Engineering is responsible for adherence of this procedure. COATING / BLASTING MATERIAL RECEIPT / INSPECTION: After receipt of blasting & painting material, check material for Supplier’s name, Product name, Batch number, Shelf life, Date of manufacture, grading etc. Check material as per certificate received with material BLASTING EQUIPMENT: The blasting equipment to be used is in good condition and well maintained. The compressed air shall be free of water and oil. Blasting nozzles shall be replaced when the specified minimum blast pressure, surface cleanliness and surface roughness can no longer be achieved. ABRASIVI Abrasives used for blast cleaning shall be free from oil, grease, moisture, dust, rust & chloride contamination etc. Blasting shall be done using steel grit or non-metallic abrasive such as Aluminium oxide. ~ XOMOX Sanmar Ltd - Pacific Valves Division Page 2 of 7R Work Instruction Title: Section: GUIDELINES FOR HR PAINTING & INSPECTION WI/PRD/01 REQUIREMENTS FOR STANDARD PRODUCT LINE RS F 7.0 8.0 PRECAUTIONS TO BE TAKEN BEFORE BLASTING / PAINTING: After completion of assembly, inspection & testing of valve, valves should be taken for Painting as per the relevant WI & paint product data sheet ‘The Nameplate, Tag plate shall be removed & fixed only after completion of painting or wherever required masking shall be done to prevent from blasting & painting. Heavy duty masking tape shall be used to ensure the abrasive particles do not enter the sealing areas or joints of the valve. Machined surfaces such as Butt Weld Ends, Flange Serrations, Stem, Tapped holes, ec, to be masked. Unless otherwise specified in the Assembly Order, DO NOT Paint Actuator or Gear Operators. Painter shall close the valve bores with suitable end caps or enclosures. Deposits of oil, grease, crayon marks, and foreign particles (if any) shall be removed from all external surfaces. Gasket sealing area and stem protrusion to be masked properly to avoid ingress of abrasive particles in the joints. After cleaning and immediately before coating dust & loose abrasive particles shall be removed. SURFACE PREPARATION: Valve external surface preparation shall be done by chemical cleaning or abrasive Blasting Standard SSPC-SP 10 (Near white metal blast cleaning) or as specified by the customer. Blast Cleaning shall not be carried out when the temperature of the Surface is less than 3°C above the dew point & when the relative humidity of air is greater than 85%, except for inorganic zinc silicate up to 90%. Dry compress air shall be free from oil, moisture & other dust contaminant prior to use in blast cleaning & painting application. For Stainless Steel substrate sweep blasting with non-metallic abrasive such as Aluminium oxide or Garnet shall be used to achieve required surface profile based on Primer DFT or as recommended by paint manufacturer. XOMOX Sanmar Ltd - Pacific Valves Division Page 3 of 7R| Work Instruction Title: Section: GUIDELINES FOR HR PAINTING & INSPECTION ‘WI/PRD/01 REQUIREMENTS FOR STANDARD PRODUCT LINE =a FE 9.0 5, After cleaning and immediately before coating, dust and loose abrasive particles shall be removed with the compressed air. Compressed air shall be free from oil, moisture. Use wire brush, wherever require for cleaning. 6. Painting should commence within 4 Hrs. of blasting or before any visible rusting occurs, whichever is less. Bare hand contact on the blasted surface shall be avoided by using of clean hand gloves. 7. Profile measurement of blasted surface shall be done using Testex tapes coarse (20 to 50 Micron) (cr) "X” Coarse (37-115 micron). Surface profile needle gauge shall also be Used to check the surface profile (ensure the Calibration of surface profile needle gauge & zero the gauge on Smooth piece of the glass) before starting the inspection. MIXING OF COATING: 1. Materials shall be stored in accordance with manufacture’s recommendations. Paint mixing ratio shall be as per Table-1. 2. Mixing in open containers shall be done in a well-ventilated area away from sparks/flames. Mechanical stirrer mixing should be done to form the homogeneous mixture of paint. 3. No thinner shall be added, unless necessary for proper application, Thinning shall be as per Table-1. Care should be taken that no loose debris or foreign matter is mixed/added to the paint 4. Paint gun air pressure shall be maintained 2.5-3.5 bar. 5. Paint viscosity shall be maintained as per listed in Table ~ 1 below. Viscosity shall be measured by using Ford B-4 Cup. Table “1 Details of Paint ‘Substrate Viscosity | No. of | Final DFT Paint Details Mixing ratio | spec (Sec) | coats | (microns) i Carboline make, High | aint may be 7 thinned up to. ‘emperature Silicone | "My wi 30 - 40 2 | Min. 50 | Aluminium — Carboline i Thermaline - 4674 Thinner #10 XOMOX Sanmar Ltd - Pacific Valves Division Page 4 of 7| Work Instruction Title: Section: GUIDELINES FOR HR PAINTING & INSPECTION WITPRD/01 REQUIREMENTS FOR STANDARD PRODUCT LINE oe FE Paint may be Carbon | Carboline make, High thinned up to & Temperature Silicone ‘ Alloy | Aluminium ie ee an Steels: Thermaline - 4631 Thinner #10 COATING AND APPLICATION: 10.0 1, Substrate temperature should be less than 50°C and must be at least 3°C above dew point temperature. 2. Coating shall not be performed in following conditions :~ a) If measured relative humicity is greater than 85%, except for inorganic zine silicate up t0 90%; b) If there is @ deposition of moisture in the form of rain, condensation ete. upon the surface. 3. Surface shall be coated with a complete application of primer as soon as possible. Each coat of material shall be applied as a continuous film of uniform thickness & to the maximum extent possible. 4, Brush/ Roller stripe coat shall be used to ensure adequate film thickness at corner, edges, and any other areas which are not accessible by spray application. 11.0 INSPECTION AND TESTING: 1. Each coat shall be inspected prior to application of the next coat and shall be in a proper state of cure and dryness before the application of succeeding coat, Curing time & recoating interval between coats shall be as per Table - 2. 2. Final curing shall be done by air curing or by using IR lamp. Refer Table ~ 3 for Time range to curing by IR lamp. z Tables oe ene Thermaline 4631 Thermaline 4674 Final Final Surface Temp | Between Goats |_Cure _| Surface Temp | Between Coats | Cure 10°C BHours | 10 Hours 10°C |__B Hours _| 10 Hours. 20°C. 3Hours __|_6 Hours 20°C. SHours | 6 Hours 30°C. 4 Hour 2 Hours 30°C 2Hours | 3 Hours XOMOX Sanmar Ltd - Pacific Valves Division Page 5 of 7Ry Work Instruction Tile Section: GUIDELINES FOR HR PAINTING & INSPECTION WI/PRD/01 REQUIREMENTS FOR STANDARD PRODUCT LINE Ren F Table=3 ‘Curing Time for painted valves using IR lamp Valve Time (mins) area 10 Gate & Globe Sue" 18 42"-16" 20 18" -24" 30 2"-4" 8 lone e’- 10" 12 12"-16" 16 18" 24" 25 3. Valve shall be checked visually for pinhole, run down, sagging like surface defects, If found, shall be marked for repair as per Clause no. 13 of this procedure, 4, Allinstruments used for testing and inspection will be properly calibrated and maintained in good working conditions 5. Coating shall not be applied in less than the number of coats specified in system. The dry film thickness shall be checked & measured by suitable instrument. Instrument to be calibrated before each measurement. 5a) Reading of DFT shall be taken on the painted surface after fully cured. Average of all recorded reading shall be taken & should be consider for evaluation of final result, 5b) Reading shall be taken on plane surfaces, since curvature, comers or edges may display the invalid readings. 5c) The number of reading to be taken as per Table 4. 5d) The arithmetic mean of all the individual dry film thickness (DFT) shall be equal to or greater than the specified dry film thickness; 5e) All individual dry film thickness shall be equal to or above 80% of the specified DFT. 5f) Randomly selected valves (Minimum one number) after due curing shall be verified for DFT measurement as per applicable procedure and results shall be recorded in the painting register. This activity shall be done daily basis. XOMOX Sanmar Ltd - Pacific Valves Division Page 6 of 7Work Instruction Title: Section: GUIDELINES FOR HR PAINTING & INSPECTION WI/PRD/01 REQUIREMENTS FOR STANDARD PRODUCT LINE — FE Table 4— Sampling Plan : Minimum Number OF pice ot vae Measurements za 5 "= 10" 8 12-16" 12 18°- 24" 45 12.0 REMEDIAL WORK: 1, The Non-conforming area shall be identified & marked clearly on the external surface. Coated surfaces that are damaged during handling or shipment shall be repaired. 2, The edges of unacceptable paint surface shall be feathered using coarse emery paper, hand wire brushes, or mechanically operated tools (grinders, chippers or wire brush). 3. It is recommended and mandatory to use the same paint system & manufacturer for all touch-up & rework with which the basic painting is done. 4, DFT & visual inspection shall be carried out to check repair performance. XOMOX Sanmar Ltd - Pacific Valves Division Page 7 of 7