T12 X01 004 Maintenance Coating Manual

RasGas Company Limited
Maintenance Coating Manual

Group: Operations Technical Document No: T12-X01-004
Department: Static Equipment Engineering Revision: 0
Section: Corrosion Engineering Sheet: 1 of 70
TABLE OF CONTENTS
Page
Section Description
Ref.
1.0 Introduction .......................................................................................................................................5
1.1 Purpose....................................................................................................................................5
1.2 Scope........................................................................................................................................5
1.2.1 Definitions and Overall Document Layout for Protective Coating Specifications and Scopes of Work
for RasGas Operations (Onshore and Offshore) ..............................................................................................5
1.2.2 General Safety And Hazard Considerations............................................................................................6
1.3 Definition.................................................................................................................................7
1.4 References ...............................................................................................................................8
1.5 Roles & Responsibilities ......................................................................................................11
1.5.1 Operations Technical Manager........................................................................................................11
1.5.2 Static Equipment Engineering Manager ..........................................................................................11
1.5.3 Head of Corrosion Engineering .......................................................................................................11
1.5.4 Coating Engineer .............................................................................................................................12
1.6 Procedures ............................................................................................................................13
1.6.1 Inspection Requirements: ................................................................................................................13
1.6.1.1 General inspection requirements ...................................................................................................13
1.6.1.2 Inspection System Requirements ..................................................................................................13
1.6.1.3 Inspection of Equipment, Materials and Access Facilities............................................................15
1.6.2 Mandatory Requirements For All Painting Works ..........................................................................15
1.6.2.1 Mandatory Procedures: .................................................................................................................15
1.6.2.2 Additional Mandatory Procedures for ‘Tidal Zone’ Painting works:............................................16
1.6.2.3 Exceptions:....................................................................................................................................16
1.6.3 Pre- Blasting Operations And Post Blasting Operations .................................................................17
1.6.3.1 Pre-Blasting Operations ................................................................................................................17
1.6.3.2 Post-Blasting operations................................................................................................................17
1.6.4 Surface Preparation..........................................................................................................................17
1.6.4.1 Surface Preparation Method- Carbon Steel...................................................................................17
1.6.4.2 Surface Preparation Method- Stainless Steel, Galvanized Steel, Nickel Alloy.............................18
1.6.5 General Coating Guidelines (For All Surfaces):..............................................................................19
1.6.5.1 Application Guidelines..................................................................................................................19
2.0 Coating Systems (Scopes and Specifications)................................................................................21
2.1 Section 1- Uninsulated Carbon Steel Coating System (Non-impact areas), above the splash zone, operating
at Ambient up to +100°C....................................................................................................................................21
2.2 Section 2- Uninsulated Carbon Steel Coating System in the Splash Zone, Tidal Zone and Sea Water Intake
structures operating at Ambient upto +100°C ....................................................................................................24
2.3 Section 3- Uninsulated Stainless/Galvanized Steel, Nickel Alloy Coating System operating at ambient up to
+100°C................................................................................................................................................................26
2.4 Section 4- Uninsulated Carbon Steel Coating Specification, above splash zone, for Impact Areas like deck
plates/troughs/base plates/ lay down areas/flooring............................................................................................28
2.5 Section 5- Uninsulated Carbon Steel, Stainless Steel, Galvanised Steel, Nickel Alloy operating at +101°C
upto +150°C (flex. Upto +200°C) ......................................................................................................................30
2.6 Section 6-Uninsulated Carbon Steel, Stainless Steel, Nickel Alloy surfaces operating at +151°C upto +540°C
** ........................................................................................................................................................................32
2.7 Section 7- Insulated Carbon Steel, Stainless Steel, Galvanised Steel operating at ambient below +120°C .34
2.8 Section 8- Insulated Steel surfaces operating at elevated temperatures (operating at +120°C and above)...35
2.9 Section 9- Uninsulated Carbon Steel Coating System in Internal, Air -conditioned areas ...........................37
2.10 Section 10- Insulated/Un-insulated Carbon/Stainless steel subject to cyclic Temperatures of +5 °C to
+300°C................................................................................................................................................................39
2.11 Section 11- COMPOSITE WRAP REPAIR SYSTEM (Protection System # RMC-CR-11).....................41
3.0 Training and Support - ...................................................................................................................52
4.0 Verification and Measurement - ....................................................................................................52
5.0 Feedback and Continual Improvement -.......................................................................................52
6.0 Appendices .......................................................................................................................................53
Appendix A.-Tables...........................................................................................................................54
Table 12 A. Corresponding Degrees Of Paint Rusting Standards .................................................................54
Table 12 B. Corresponding Surface Preparation Standards ...........................................................................54
Table 12 C.-Typical Painting And Wrapping Quality Inspection And Test Plan Checklist ..........................55
Table 12 D (Painting- Daily Inspection Report –Template Below)...............................................................57
Appendix B: Approved Paint Vendors And Products ...................................................................58
Appendix C: Warranty Requirements............................................................................................59
Appendix D: Specific Rasgas Offshore/Onshore Painting- Finish Colour Designation (Ignore
Table No. Below) ...............................................................................................................................60
Appendix E: Specific Rasgas Painting Safety Guides....................................................................64
Appendix F: Coating System Index.................................................................................................68
Custodian of this Manual: Coating Engineer
Owner of this Manual: Operations Technical Manager
Document No: T12-X01-004 Revision No: 0 Sheet: 2 of 70

Document Part: 000 RasGas Use Only Issue Date: 23-Sep-08
Internal Controls
Validation
To assure Management’s, Shareholders’ and External Agencies’ confidence in Company’s policies
and practices; RasGas Internal Audit may verify without notice, compliance with this Manual.
Signature Page and Revision History
Prepared
by SIGNED 16-Sep-08
Coating Engineer Date
Rehan Ahmed
Verified
by SIGNED 17-Sep-08
Head of Corrosion Engg Date
David N. Robson
Verified SIGNED 21-Sep-08

by Static Equipment Engg. Manager Date
Dr. Ayman Abdulsalam
Endorsed
SIGNED 22-Sep-08
by
Maintenance Manager Date
Omar A. Al Misnad
Approved SIGNED
by 23-Sep-08
Operations Technical Manager Date
Bill Chase
Revision
Authorization
Rev. Changed Changed
Date Verified Endorsed Approved
No. Section By
Rehan Dr. Ayman Omar A. Al
0 23-Sep-08 Bill Chase
Ahmed Abdulsalam Misnad
Summary of
Revisions
Rev.
Date By Description of Key Changes
No.
0 23-Sep-08 Rehan Ahmed Issued For Implementation

Manual Distribution List
Introduction
The Distribution List shows current users of this procedure. Procedure users will be provided with the
data link for this document. To receive an electronic copy, contact the Head of Documents / Standards.
Procedure Users
Procedure User Job Title

Hamad Al Muhannadi Operations Manager
Bill Chase Operations Technical Manager
Jabor Al-Mesaifri Head of Documents and Standards
Shk. Khaled Al-Thani Manufacturing Manager
Dr Ayman Abdulsalam Static Equipment Manager
Atul Dhokte Offshore Asset Manager
Ali O. Bamatraf Utilities Asset Manager
Hassan Ibrahim Offsites Asset Manager
Mohammed H.F. Shikari Train 1,2 & Helium Asset Manager
Indra Sakti Train 3,4,5 & AGI Asset Manager
Paul Creswell Train 6 & 7 Asset Manager
Fabian E. Earle A/AKG 1 & 2 Asset Manager
Khaled Al Hemaidi Barzan Asset Manager
Omar A. Al-Misnad Maintenance Manager
Kannan Palanisamy Maintenance Superintendent- Static Eqpt.
Sofian Yoesbar Maintenance Engineering Specialist -Sta.
Kal Balachandran Maintenance Planning Superintendent
John Umberger POBP Advisor
Ronald Scharffenorth Operations Safety Advisor
Teuku Umar Head of Operations – Train-1/2/HeRu
Mohammed Reazuddin Head of Operations – Train-3/4/AGI
Srinivasan S Muthukumar Head of Operations – AKG-1
Syed Zainulabdin Head of Operations – Offsites
Balkrishna Kapdi Head of Operations- Train 5,6 & 7
Khaled Alvi Head of Operations- Offshore
Mohammed Al -Sada Head of Operations- Offshore
Ramalingeswara Nemani Head of Operations- Utilities
David N.C. Robson Head of Corrosion Engineering
Cecilie Haarseth Head of Programmatics Engineering
Soliman Khalaf Head of Integrity Engineering
Ajit Singh A/Head, Mechanical & Pipelines Engineering
Nukala Lakshmana A/Head of Civil & Structural Engineering
Rehan Ahmed Coating Engineer

1.0 Introduction
1.1 Purpose
The Purpose of this manual is to provide the necessary tools to execute the Maintenance Coating
refurbishment programs on the RasGas Onshore and Offshore facilities. This is as required by the
following RGEE 6.6 Docs.
• T12-X01-003-Corrosion Program Manual
• T12-X03-013-Monitoring & Inspection Programs-5YR External Coating Frame Program
• T12-X03-013-Monitoring and Inspection Programs Coating-Condition Inspection Program.
1.2 Scope
1.2.1 Definitions and Overall Document Layout for Protective Coating Specifications and
Scopes of Work for RasGas Operations (Onshore and Offshore)
Scope of Work and Paint Specification

The Maintenance Coating Manual establishes and documents processes and specifications for the
identification, conduct, and management of Coating Refurbishment activities necessary to maintain
RasGas, hereafter referred to as RasGas facilities, in a safe and reliable condition. The content of this
manual is guided by the provisions and requirements of the following:
RasGas Design Basis Memorandum (DBM) and applicable Materials Design Basis
Memorandum (MDBM)
RasGas Elements of Excellence (RGEE) System 6-6, Facility Integrity Management, including:
− RasGas Facility Integrity Management System Manual (FIMS)
− Associated Equipment Integrity Guides (EIGs)
− Corrosion Integrity Manual
− Corrosion and Inspection Management Technical Reference Manual TRM-01
Maintenance and reliability (M&R) Equipment Strategy Process, including application of
equipment criticality assessment and Equipment Degradation Documents (EDDs)
Internationally recognised SSPC, NACE and ISO standards
The Essence of this scope is to remove or refurbish the existing coating and corrosion products from
RasGas Primary, secondary and Tertiary steel by means of Dry Abrasive Blast Cleaning or
otherwise, then recoat/wrap as per this specification.
The following specification is applicable to all Onshore and Offshore Primary, Secondary and
Tertiary steel items within the designated coating packages above the lowest atmospheric tide level
(for marine exposure), including, but not limited to, Structural steel, Tubulars, Cranes, Pedestal,
Staircases, Piping, Vessels, Tanks, Stairs, Handrails, Ladders, Stringers, Supports, Pipelines, Piping,
Valves, Horizontal accumulators, Knock Out pots, Stacks, Chimneys, Flues, Compressors, Fans,
Base-plates, Junction Boxes, Buried Vessels, Towers, Columns, Heat exchangers, Reactors,
Gratings, vendor packaged and skid mounted equipment, miscellaneous appurtenances, and other
equipment.
All insulated steel piping (hot or cold) within the scope shall not be coated unless requested for by
the client’s representative (only when line is shutdown/inactive).

All internal of piping/Vessels/tanks are not included in this scope, see separate scope (ref: EPS 35 B-
81 Painting-Internal Coatings-Tanks, Vessels, Piping and Tubulars) for the internal service condition
and respective coating.
All fireproofed steel surfaces are not included in this scope, see separate scope for these surfaces
(ref: S-EPS 70-B-08: Passive Fire Proofing for Offshore Structures; RGX-S-00-13B0-001: Passive
Fire Proofing for Onshore Structures).
The individual coating systems have been identified in the below-mentioned sections as follows:
• Section 1 for the coating procedure of Un-insulated Carbon Steel, (non-impact areas),
atmospheric exposure, operating at Ambient temp. upto +100°C
• Section 2 for the coating procedure of Un-insulated Steel in the Splash Zone, Tidal Zone and Sea
Water intake structures operating at Ambient upto 100°C
• Section 3 for the coating procedure of Un-insulated Stainless Steel and Galvanized Steel and
Nickel Alloy surfaces operating at ambient upto +100°C
• Section 4 for the coating procedure of all carbon steel surfaces, (above the splash zone), which
are subjected to impact, abrasion and collection of water/salt/grease/oil/mild chemicals/mild
acids/mild alkalis/solvents
• Section 5 for the coating procedure of all carbon steel, stainless steel, galvanised steel and
Nickel Alloy surfaces subjected to elevated temperatures (operating at +101°C upto +150°C,
with flex temp. upto +200°C)
• Section 6 for the coating procedure of all carbon steel, stainless steel, and Nickel Alloy surfaces
subjected to elevated temperatures (operating at +151°C upto +540°C)
• Section 7 for the coating procedure of all Insulated steel surfaces operating at ambient
temperatures (operating upto +120°C)
• Section 8 for the coating procedure of all Insulated steel surfaces subjected to elevated
temperatures (operating at above +120°C)
• Section 9 for the coating procedure of steel surfaces in an Air Conditioned environment
(Interior).(For Interior flooring where impact possible, Follow Section 4)
• Section 10 for the coating procedure of Insulated and Uninsulated Carbon/Stainless Steel
surfaces subjected to repeated cyclic temperatures between +5 Deg. C and +300 Deg. C
• Section 11 for the Composite wrap repair system, atmospheric exposure.
1.2.2 General Safety and Hazard Considerations
All RasGas Safety Procedures, Rules and Regulations shall be adhered to at all times. Under no
circumstances shall they be compromised. In case of conflict between this document and the RasGas
safety document, the latter shall prevail. Additionally, the relevant personnel from RasGas need to
be informed as soon as the problem is detected and no longer than 24 hours (in writing) of the
conflict
*NB (Special attention to be paid to EPS-35-B-70 Section 6, Guidance note 13, EGE 35-B-1 Section
10 and relevant JSA’s pertaining to the works to be carried out – see appendix G)

1.3 Definition
Glossary of Terms and Abbreviations
ALARP As Low as Reasonably Practicable (http://www.hse.gov.uk/risk/theory/alarp.htm)

ASTM American Society for Testing and Materials
BS British Standard
Company Ras Gas Co. Ltd.
Contractor Ras Gas Designated/Appointed Coating Contractor
COSHH Control Of substances Hazardous to Health (http://www.hse.gov.uk/coshh/)
CSWIP Certification Scheme for Welding and Inspection Personnel, UK
CUI Corrosion under Insulation
DFT Dry Film Thickness
DSC Differential Scanning Calorimetry
ERS British Gas Approved Training Scheme for Painting Inspectors (formerly referred
as ‘ERS’)
GRP Glass reinforced Polymer
HATE Hydraulic Adhesion Tester
ISO International Standards Organisation
IZS Inorganic Zinc Silicate
LAT Lowest Atmospheric Tide (level)
LEL Lower Explosive Limit
LUX Intensity/degree of luminance
LV/HV Tester Low voltage/High Voltage Tester
MIO/Mio Micaceous Iron Oxide
MSDS Manufacturer’s Safety Data Sheet
NACE National Association of Corrosion Engineers
NA Not available
NTS Norwegian Technical Standards, Norway
OPCO Operating Company
PS Painting System
QA/QC Quality Assurance/Quality Control
Ri Degree of Rust as per Rusting Standards (ISO 4628-3/SSPC Vis 2)
RMC RasGas Maintenance Coating
Sa Swedish Standard for Surface Preparation (blast cleaned) on Cast Iron & Steel
Surfaces
SP Surface Preparation Standard (SSPC standard)

Shore Hardness Methods for determining the hardness of materials by means of durometer
SSPC Steel Structural Painting Council
St Swedish Standard for Hand/Power Tool Surface Preparation on Cast Iron & Steel
surfaces
TBA To be advised/announced
TDFT Total Dry Film Thickness
TLV Threshold Limit Value
TPI Third Party Inspector
TSA Thermally Sprayed Aluminum
TWI The Welding Institute
WFT Wet Film Thickness
μm Micrometer (microns)
1.4 References
Reference Standards and Codes

The latest editions of the following Standards, Codes and Specifications shall apply.
Painting and Coating - General
RGX-S-0013A0-001 RasGas Specification for Painting -General Requirements

RGX-S-00-13A0-004 RasGas Specification for Painting- Manufacturing Facilities
RGX-S-68-1387-002 RasGas Specification for Cathodic Protection of Above Ground Storage
Tanks
RGX-S-00-13A0-006 RasGas Specification for Glass Flake Lining
S-EPS35-P-83 RasGas Specification, Application of Thermally Arc Sprayed Metallic
Coatings
RGX-S-00-13A0-012 RasGas Specification for Thermal Arc Sprayed Metallic Coatings
ASTM A123/M Standard Specification for Zinc (Hot Galvanized) Coatings on Iron and
Steel Products.
ISO 1461 Hot-Dip Galvanized Coatings on Fabricated Iron and Steel Articles –
Specifications and Test Methods.
ISO 12944-1-8 Paints and Varnishes – Corrosion Protection of Steel Structures by
Protective Paint Systems.
ISO 14713 Protection against Corrosion of Iron and Steel in Structures – Zinc and
Aluminum Coatings.
BS EN 22063 Metallic and Other Inorganic Coatings - Thermal Spraying.
SSPC Manual Vol. 1. -Good Painting Practice.
Vol. 2. -Systems and Specifications.

Surface Preparation
ASTM D2092 Standard Guide for Preparation of Zinc Coated (Galvanized) Steel
Surfaces for Painting.
ISO 8501-1/ Preparation of Steel Substrates before Application of Paints and Related
Products-
SIS 055900/ Visual Assessment of Surface Cleanliness. Part 1: Rust Grades and
Preparation
BS 7079-A1 Grades of Uncoated Steel Substrates and Steel Substrates after Removal of
and Supp. Previous Coatings.
ISO 8503-1-4 / Preparation of Steel Substrates before Application of Paints and Related
Products-
BS 7079-C1-4 Surface Roughness Characteristics of Blast Cleaned Steel Surfaces.
Products-
BS 7079-D2 Surface Preparation Methods. Part 2: Abrasive Blast Cleaning.
Products-
BS 7079-D3 Surface Preparation Methods. Part 3: Hand and Power Tool Cleaning.
ISO 11124-1-4/ Preparation of Steel Substrates before Application of Paints and Related
Products-
BS 7079-E1-E4 Specifications for Metallic Blast Cleaning Abrasives
ISO 11126-1-10/ Preparation of Steel Substrates before Application of Paints and Related
Products-
BS 7079-F1-F10 Specifications for Non-Metallic Blast Cleaning Abrasives.
SSPC Vis 1 Visual Standard for Blast Cleaned Steel.
SSPC Vis 3 Visual Standard for Power- and Hand-Tool Cleaned Steel
SSPC SP 1-3, 5-8 Steel Structures Painting Council and National Association of Corrosion
10and11 / NACE 1-4 Engineers Joint Surface Preparation Standards.
SSPC SP12/ Surface Preparation and Cleaning of Steel and Other Hard Materials by
High- and
NACE 5 Ultrahigh-Pressure Water Jetting Prior to Recoating.
ISO 8502-6 Preparation of Steel Substrates before Application of Paints and Related
Products – Tests for the Assessment of Surface Cleanliness - Part 6:
Extraction of Soluble Contaminants for Analysis - the Bresle Method
Inspection and Testing

ASTM D610/ Standard Test Method for Evaluating Degree of Rusting on Painted Steel
SSPC Vis 2 Surfaces.
ASTM D1186 Standard Test Methods for Non-Destructive Measurement of Dry Film Thickness
of Non-Magnetic Coatings Applied to a Ferrous Base.
ASTM D1212 Standard Test Methods for Measurement, Wet Film Thickness-Organic Coatings.
ASTM C-136 Standard Test Method for Sieve Analysis of Fine and Coarse Aggregates.
ASTM D3276 Standard Guide for Painting Inspectors (Metal Substrates).

ASTM D3359 Standard Test Methods for Measuring Adhesion by Tape.
ASTM D4228 Standard Practice for Qualification of Coating Applicators for Application of
Coatings to Steel Surfaces.
ASTM D4285 Standard Test Method for Indicating Oil or Water in Compressed Air.
ASTM D4414 Standard Practice for Measurement of Wet Film Thickness by Notch Gages.
ASTM D4417 Standard Test Methods, Field Measurement, Surface Profile-Blast Cleaned Steel.
ASTM D4541 Standard Test Method, Pull-Off Strength, Coatings Using Portable Adhesion
Testers.
ASTM E337 Standard Test Method for Measuring Humidity with a Psychrometer (Wet and
Dry Bulb Temperatures).
ASTM F21 Standard Test Method for Hydrophobic Surface Films by Atomizer Test.
ISO 4628-1-6 / Evaluation of Degradation of Paint Coatings - Designation of Intensity, Quantity
BS3900-H1-4 and Size of Common Defects - Blistering, Rusting, Cracking, Flaking and
Chalking.
ISO 8502-1-10/ Preparation of Steel Substrates Before Application of Paint and
BS7079-B2-10 Related Products – Tests for Assessment of Surface Cleanliness.
SSPC PA 2 Measurement of Dry Paint Thickness with Magnetic Gauges.
NACE RP0188-99 Discontinuity (Holiday) Testing of Protective Coatings.
NACE RP0287 Surface Profile Measurements of Abrasive Blast Cleaned Steel Surfaces Using a
Replica Tape.
ASTM D4258 Standard Practice for Surface Cleaning Concrete for Coating.
ASTM D4259 Standard Practice for Abrading Concrete.
ASTM 4260 Practice for Acid Etching Concrete.
ASTM 4261 Practice for Surface Cleaning Concrete CMU for Coating
ASTM 4262 Test Method for pH of Chemically Cleaned or Etched Concrete Surfaces
ASTM 4263 Test Method for Indicating Moisture in Concrete by the Plastic Sheet Method
ASTM 4940 Test Conductimetric Analysis of Water Soluble Ionic Contamination in Blast
Media
Composite Repair Systems

ISO 14692 Specification and recommended practice for the use of GRP piping in the
petroleum and natural gas industries.
prEN 13121 GRP tanks and vessels for use above ground.
ASME B31.3 Chemical plant and refinery piping.
BS 2782: Part10: Measurement of hardness by means of a Barcol impresser.
Method 1001
ASTM D2583 Standard test method for indentation hardness of rigid plastics by means of a
Barcol impresser.

ISO 868 Plastics and ebonite - Determination of indentation hardness by means of a
durometer (Shore hardness)
ISO 11357 Plastics - Differential scanning calorimetry (DSC).
ISO 8502 Tests for the assessment of steel cleanliness
ISO 8503 Surface roughness characteristics of blast cleaned steel substrates
ISO 8504 Surface preparation methods
NTS-GRP-FJS/01 &NTS GRP guidelines for approval schemes-fitters, joiners, supervisors,
inspectors
NTS-GRP-INSP/01
CSWIP-GRP-1-96As per ISO 8503 (Surface roughness characteristics, blast cleaned steel
substrates)
& CSWIP-GRP-2-96
1.5 Roles & Responsibilities

1.5.1 Operations Technical Manager
The Operation Technical Manager is the owner of this manual.
The owner is responsible for the following:
• Appoint a competent Maintenance Coating Manual owner, typically the Head of Corrosion
Engineering, possessing the following minimum competencies:
- Qualified engineer with significant field experience within the coating discipline
- Suitably trained in the RGEE System 6-6 Facility Integrity Management process
• Review and endorse the contents of any significant changes to the Maintenance Coating Manual.
• Establish clear lines of responsibility, authority, and accountability for the appointed
Maintenance Coating Manual Owner.
1.5.2 Static Equipment Engineering Manager
The Static Equipment Engineering Manager is the administrator of this manual.
The administrator is responsible for the following:
• Coordinate further development and maintenance of the Maintenance Coating Manual.
• Coordinate and participate in implementation, including communicating the requirements and
training of personnel.
• Disseminate information about approved changes to appropriate personnel within RasGas and
ensure that systems are updated as required.
• Maintain the List of Manual Non-conformances to the Maintenance Coating Manual
recommendations.
1.5.3 Head of Corrosion Engineering
The Head of Corrosion Engineering is the appointed owner of the Maintenance Coating Manual and
is responsible for the following:
• Appoint a competent Maintenance Coating Manual custodian, typically the Coating engineer,
possessing the following minimum competencies:
- Qualified engineer or technician with significant field experience within the coating discipline
- Suitably trained in the RGEE System 6-6 Facility Integrity Management process

• Oversee the contents of and any significant changes to the Maintenance Coating Manual.
• Supervise the Maintenance Coating Manual custodian, the Coating engineer, and ensure correct
data entry and review.
• Enforce lines of responsibility, authority, and accountability for the appointed Maintenance
Coating Manual custodian.
• Communicate and report any and all changes to the Maintenance Coating Manual to the Manual
administrators and Manual Owners.
• Communicate requirements and train engineering personnel for related activities.
• Assess the applicability of new technologies for critical facilities.
• Oversee the preparation of detailed procedures for new technology applications.
• Perform internal assessment of Manual with the participation of Maintenance department, and
other end users.
• Participate in external assessments
• Review and endorse the overall contents of the Maintenance Coating Manual.
• Oversee the preparation of MOC documents for review and endorsement of permanent or
temporary changes to the Maintenance Coating Manual.
1.5.4 Coating Engineer
The Coating Engineer is the appointed custodian of the Maintenance Coating Manual and is
responsible for the following:
• Upkeep of the contents of any significant changes to the Maintenance Coating Manual.
• Undertake the correct data entry and review of the Maintenance Coating Manual
• Follow the lines of responsibility, authority, and accountability for the appointed Maintenance
Coating Manual.
• Communicate and report any and all changes to the Maintenance Coating Manual to the Manual
administrators and Manual Owners.
• Communicate requirements and train engineering personnel for related activities.
• Assess the applicability of new technologies for critical facilities.
• Oversee the preparation of detailed procedures for new technology applications.
• Perform internal assessment of Manual with the participation of Maintenance department, and
other end users.
• Participate in external assessments.
• Review and endorse the overall contents of the Maintenance Coating Manual.
• Oversee the preparation of MOC documents for review and endorsement of permanent or
temporary changes to the Maintenance Coating Manual.
• Review and approve requests for deviations from the specifications and coating practices
contained in the Maintenance Coating Manual

1.6 Procedures
1.6.1 Inspection Requirements:
1.6.1.1 General inspection requirements
1.6.1.1.1 All surface preparation, painting work carried out under or to the intent of this specification
shall be subject to systematic inspection at each stage of preparation, surface preparation, painting
and repair by the RasGas Engineer. In addition, the work shall be subject to random inspection as
and when the RasGas Engineer deems it necessary.
1.6.1.1.2 The basic inspection requirements and system shall be detailed in a formal Quality
Inspection and Test Plan and presented by the Contractor as part of the contract documentation for
approval by the RasGas Engineer. A typical Inspection Plan Checklist is shown as Table 12 C. Such
a Plan shall not relieve the Contractor from his responsibility to carry out all work in a safe and
timely manner using skilled personnel and good practices to achieve a high quality product meeting
all other specification requirements.
1.6.1.1.3 All defective or non-conforming work identified at each stage shall be rectified to the
required standard by the Contractor. Any preparatory, painting work carried out to this Specification
that is not systematically inspected and approved by the RasGas Engineer at each stage shall be
deemed not to meet the Specification. The coating shall be removed from all affected areas and they
shall be re-prepared and recoated to the approval of the RasGas Engineer by the Contractor.
1.6.1.1.4 The Contractor shall provide required number of authorized persons who shall be a
qualified Painting Inspector to the minimum standard specified below to coordinate the inspection
work carried out and report the results obtained. The proposed Contractor employees, who may be
Supervisor or Manager, shall also be individually acceptable to the RasGas Engineer. Additionally,
either an appointed RasGas Painting Inspector or an approved qualified Third Party Painting
Inspector shall act on behalf of the RasGas Engineer under the contract, to ensure that the required
inspection work is being carried out in a satisfactory and effective manner to consistently give a
good quality product.
1.6.1.1.5 All proposed Painting Inspectors shall be qualified to at least TWI (ex-ERS) Level 1,
FROSIO or NACE Level 2 and shall have at least five years approved experience of industrial
painting of oil and gas facilities at inspector or supervisor level. The certification and resume of each
Inspector shall be submitted to the RasGas Engineer for approval and they shall be interviewed at the
start of each contract to confirm their technical capability. The Inspectors shall consult the Paint
Manufacturer to obtain the necessary technical support to ensure compliance with product
recommendations.
1.6.1.1.6 The Contractor shall provide a comprehensive range of approved calibrated inspection
equipment at each site of any work that is in progress, to enable all inspection work that is required
under the approved Inspection and Test Plan and Work Specification to be carried out. He shall
provide sufficient “sets” of commonly used inspection equipment to avoid any delays in carrying out
the required inspection at all work sites.
1.6.1.2 Inspection System Requirements
1.6.1.2.1 The proposed inspection system for all preparatory, painting work shall operate via a series
of Hold Points in the work schedule, from which the Contractor shall not proceed until he is given
formal clearance by the RasGas Engineer. This does not mean that these are the only points at which

inspection shall be carried out. It is intended that the Inspection Plan will ensure that relevant
inspection is carried out prior to, during and after each activity in the work schedule.
1.6.1.2.2 The relevant Hold Points, which shall be considered as mandatory under all contracts, are
as follows.
These items are also identified as Hold Points in Table 12 C.
a. Approval of working procedures, safety precautions and QA/QC system.
b. Authorization of Permit to Work.
c. Acceptance of preparatory, painting and inspection tools and equipment type and condition.
d. Acceptance of primary metal/concrete surface or coating condition.
e. Acceptance of the climatic conditions prior to and during all activities.
f. Acceptance of surface preparation standards.
g. Acceptance of primer stripe painting and full primer coat.
h. Acceptance of complete paint coating.
i. Acceptance of remedial coating repairs.
1.6.1.2.3 All Hold Points shall be strictly observed and recorded. Any surface preparation or painting
work undertaken without Hold Point clearance shall be re-worked by the Contractor.
1.6.1.2.4 The RasGas Engineer shall be given at least 48 hours notice of any Hold Point inspections
that require to be carried out. Whilst work is in progress the RasGas Engineer shall be given at least
24 hours notice of any change in the inspection schedule. All parts of the work shall be made
accessible for the inspection in good lighting, with all areas evenly illuminated to a level of not less
than 500 lux daylight or artificial light. In the event of the Contractor wishing to cancel a
prearranged inspection, he is required to give the RasGas Engineer at least one hour’s notice, unless
otherwise formally agreed.
1.6.1.2.5 Full details of the inspection work carried out and the results obtained shall be reported by
the authorized Contractor Painting Inspector on a daily basis in a standard Daily Inspection Report
Form, the format of which shall be approved at the outset by the RasGas Engineer. This Form may
also be used as a daily progress report. A typical Daily Inspection Report format is given in Table 12
D but it shall as a minimum contain the following information.
a. Contractor and client name, project title and reference number and work location.
b. Date.
c. Nature and sizes of items undergoing preparation and painting, areas worked on and
constructional materials involved.
d. Areas not painted and protective measures taken.
e. Original condition of metal substrate or coated surface.
f. General weather conditions, relative humidity, dew point and air and metal temperatures at start
of each shift and every two hours throughout the working day.
g. Preliminary cleaning and degreasing carried out, including solvents used.
h. Method of surface preparation and equipment used, including abrasive type, product brand name,
particle size range and batch number.
i. Standard of surface preparation and cleanliness and surface profile height obtained
j. Manufacturer, product name and number and batch number of all paints applied.

k. Number of coats of each product applied to each area of each item and application method used.
l. Specified dry film thickness (D.F.T.) of each coat of paint and complete paint coating (T.D.F.T.)
and measured wet film thickness (W.F.T.) of each coat and D.F.T. of each coat and complete
paint coating.
m. Locations and sizes of areas of paintwork repaired.
n. Any comments relating to the work that the Contractor feels are relevant.
1.6.1.2.6 These Daily Inspection Report Forms shall be completed, signed and dated by the
authorized Contractor Painting Supervisor/Inspector on a daily basis at least in triplicate. One copy
shall be submitted to the Contractor’s Engineer for review, one copy sent to the Contractor
management and the third copy retained in the site working file. Additionally, the TPI shall submit
(on a weekly basis) a daily photographic record of the work progress to the RasGas Engineer
detailing the “before-after” photos and date of work conducted. This photo record shall become an
integral part of the inspection records.
1.6.1.2.7 The RasGas Engineer shall have the right to request any discontinuity tests he feels are
appropriate on the completed coating system before accepting the completed works. The tests are to
be carried out by the Contractors Painting Supervisor/Inspector - witnessed by the RasGas Engineer.
1.6.1.2.8 For all inspection procedures relating to Composite wrap repair systems, see Section 2.11
for guidelines.
1.6.1.3 Inspection of Equipment, Materials and Access Facilities
1.6.1.3.1 The RasGas Engineer shall have the right to inspect all tools, equipment, plant,
instruments, materials, and access scaffolding and facilities that are used or to be used in the
performance of the preparatory, coating application, and inspection work at the start of and at all
times during the contract. The Contractor shall make all parts of the worksites accessible for these
inspections.
1.6.1.3.2 RasGas reserves the right to reject any tools, equipment, plant, instruments, materials or
access facilities which are considered unsuitable, unserviceable, inadequate or unsafe for the
proposed work or not to fully meet the contract requirements. All rejected items and materials shall
be reported as such and replaced or rectified as instructed by the RasGas Engineer.
1.6.1.3.3 The Contractor shall provide recent calibration certificates for all equipment and
instrumentation used for the contract, where appropriate and as requested by the RasGas Engineer.
Equipment and instrumentation which cannot be calibrated shall be replaced by the Contractor, if
considered to be unserviceable or unsuitable by the RasGas Engineer.
1.6.1.3.4 Upon request, the Contactor shall permit the RasGas Engineer or his Appointed Painting
Inspector to use any item of inspection equipment, to assess its reliability, accuracy and suitability
for the proposed inspection activity. If any item is deemed to be inadequate to carry out an
inspection activity, an alternative item that is acceptable to the RasGas Engineer shall be provided by
the Contractor.
1.6.2 Mandatory Requirements For All Painting Works
1.6.2.1 Mandatory Procedures:
1.6.2.1.1 All paints in the coating system to come from the same manufacturer and manufacturers
application instructions to be followed.

1.6.2.1.2 Compressed air supply to Undergo periodical “blotter test” as per ASTM D 4285 to
determine presence of oil or moisture from supplied air for blasting operations.
1.6.2.1.3 All abrasive for blast cleaning purposes shall be checked for mesh size according to ASTM
C 136, for cleanliness by shaking the abrasive in a clean water vial and observing for oil on surface
and cloudiness/turbidity and pH using litmus paper in the water, before blasting operations
commence and at periodic intervals.
1.6.2.1.4 Testing for Chloride contamination as per operation 1.6.4.1.6 listed below – before blasting
and between each coat.
1.6.2.1.5 Washing of surface to be coated with potable water is required between each coat.
1.6.2.1.6 All Scaffolding to be certified Fit-For-Use as per RasGas standard
1.6.2.1.7 Scaffolding Boards within Tidal zone shall not be fastened to the scaffold and removed at
the end of each work shift
1.6.2.1.8 Finished paint to be subjected to Adhesion test using the HATE gauge (Hydraulic
Adhesion tester) according to ASTM D 4541 after full cure of final coat of paint. At least 1 test to be
conducted on sample plate and periodic tests on finished test plates during the course of the paint
application.
1.6.2.2 Additional Mandatory Procedures for ‘Tidal Zone’ Painting works:
1.6.2.2.1 All paints in the coating system to come from the same manufacturer and manufacturers
application instructions to be followed.
1.6.2.2.2 All painting shall be done after seasonal low tide levels are determined and it is confirmed
to the best assessment of the meteorological department that the sea state throughout the work period
will be favorable
1.6.2.2.3 All painting done on surface wetted by sea waves and splash shall be rejected, re-blasted
and recoated.
1.6.2.2.4 All priming operations shall be done immediately after blasting operations and
establishment of degree of pitting has been carried out, but shall under no circumstances exceed 24
Hours.
1.6.2.2.5 No painting work shall be done during inclement weather, high tide, when the sea is rough
or choppy.
1.6.2.3 Exceptions:
1.6.2.3.1 GRP Gratings, Newly installed Handrails, equipment and Piping systems (As dictated by
RasGas Engineer)
1.6.2.3.2 Equipment or Instrumentation designated to be hand or machine tool cleaned
1.6.2.3.3 All Electrical Wiring, Cables, and cable Trays
1.6.2.3.4 Safety Equipment, Sensors and Alarms
1.6.2.3.5 All piping/equipment operating above 55°C (NOTE: This refers to surface temp during
painting operations, not service temperatures)
1.6.2.3.6 Shock Cell Pads and Wear pads on boat landing
1.6.2.3.7 Fire Proofed Surfaces and Cryogenic Lines (external Surfaces)

1.6.3 Pre- Blasting Operations And Post Blasting Operations
1.6.3.1 Pre-Blasting Operations
1.6.3.1.1 All of the above to be adequately protected to avoid either direct (over blast) damage or
indirect damage by dust accumulation / contamination (equipment / instrumentation)
1.6.3.1.2 All grating panels to be removed to expose supporting structure
1.6.3.1.3 Inspect the surface to be blasted to ensure no weld spatter, slag, slivers, impact damage,
gouges or other sharp protrusions that would be detrimental to the coating are present on the surface.
If found these shall be ground flush prior to blasting operations commencing
1.6.3.2 Post-Blasting operations
1.6.3.2.1 All masking to be removed and mechanical / hand tool cleaning / painting to be carried out
on “exceptions” as required.
1.6.3.2.2 Scaffold contact points and surrounding GRP grating clamp screw points uncoated after
removal of scaffold to be painted to specification standard.
1.6.3.2.3 Verify anchor profile in accordance with ASTM D4417 by using a spring-loaded
micrometer and/or either a coarse or extra coarse replica tape, as required by the anchor profile
depth. (Random-Spot check)
1.6.4 Surface Preparation

(Note: To be read in conjunction with RasGas Offshore Painting Specification ref: EPS 35-B-70,
Section 7 and RasGas Onshore ‘Technical Specification for Painting- General Requirements’ Doc.
Ref: RGX-S-00-13A0-001, Section 5)
1.6.4.1 Surface Preparation Method- Carbon Steel
1.6.4.1.1 The surface to be blasted should be washed down with a RasGas Engineer approved
biodegradable alkali based detergent / degreaser applied as per the manufacturers instructions in
such a manner to remove all surface contamination that would be detrimental to the coating.
1.6.4.1.2 The surface should then be washed with potable water (chloride content to be below
20ppm) at high pressure to remove the contaminated detergent/degreaser before it dries on the
surface.
1.6.4.1.3 Contaminant materials such as *salts (metallic or chloride) can become embedded in the
steel and cannot be removed by abrasive blasting; these contaminants are to be removed by high
pressure potable water washing or potable water blasting. Adequate supply of potable water for these
operations is essential. (*A RasGas approved diluted chloride neutralizing agent may be used)
1.6.4.1.4 The surface shall be abrasive blasted (with a mineral abrasive) to remove loose scale and
heavy corrosion products or hand tool surface prepared as deemed necessary by the RasGas
Engineer. If the loose scale is found to contain deep pitting and a composite repair system is deemed
necessary for application by the RasGas Engineer, then the surface preparation shall be carried out as
laid out in the document contained in Section 9.
1.6.4.1.5 Repeat operation 1.6.4.1.3 above.
1.6.4.1.6 The surface shall then be inspected for the presence of contaminants by means of a RasGas
approved salt contamination meter at equal intervals of 5 tests per 200 m2, any test results showing
salt contamination of 20mg./m2 or more shall require operation 1.6.4.1.3 above repeated until the salt

contamination levels fall below 20mg./m2. Only when acceptable levels of contamination are
achieved abrasive blasting to specification can begin.
1.6.4.1.7 The surface shall then be dry abrasive blast cleaned (with a mineral abrasive) to white
metal as per SSPC SP5 standard while achieving a surface profile within the acceptable range as
stipulated by the Paint manufacturer for his particular product. Where full blast cleaning is deemed
not necessary/appropriate by the RasGas Engineer, sweep blasting shall be carried out to for removal
of all loose paint to the degree specified and to roughen the aged coating. Hand wire brushing, hand
sanding, hand scraping, or other hand impact tools or a combination of these methods to roughen the
surface and provide key for application of the surface tolerant epoxy primer/tie-coat can be done
where blasting operations are not physically/safely possible (with permission from the RasGas
Engineer) and also on previously soundly coated surfaces where blasting is deemed unnecessary.
1.6.4.1.8 The prepared surface shall be tested again for salt contamination – operation 1.6.4.1.6.
above and if found suitable the test locations to be spot blasted to specification, if test results are
unsuitable then operation 1.6.4.1.3 onwards is to be repeated until the prepared surface falls within
acceptable levels.
1.6.4.1.9 The full coating system (as per specification) shall be applied during the same work day if
possible.
1.6.4.1.10 If the full system is not applied during the same day, it will be necessary to wash again
with potable water and retest for chloride contamination, if any rusting is detected re blasting/hand
tool preparation is required, if no rusting is detected then the full coating system is to be applied
before blasting/hand tool preparation operations can resume.
1.6.4.1.11 Significant areas of corrosion pitting or metal loss that are exposed during blasting
operations are to be referred to RasGas for inspection and passed as acceptable prior to any
further coating/wrapping of these areas.
1.6.4.1.12 The primer coat shall be applied within 4 hours of blasting or before any visual
discoloration of the prepared surface. Special attention is to be paid to areas of corrosion pitting
during this time (pittings turning black is an indication of contamination within the pitting).
1.6.4.2 Surface Preparation Method- Stainless Steel, Galvanized Steel, Nickel Alloy
Acceptable surface preparation methods can be varied for this specification dependant on the size
and the access to the item being coated.
• Vessels, cabinets, large bore pipe and valves shall be “Brush –off blast cleaned” to standard
NACE No. 4/SSPC SP 7.
• Small bore piping, valves and instruments may be prepared by hand tool cleaning by “sanding”
to achieve an abraded surface profile to enable adequate coating adhesion.
1.6.4.2.1 Pre-Blasting Operations
• All adjacent coated carbon steel, GRP piping, sight glasses, gauges and instruments to be
adequately protected to avoid either direct (over blast) damage or indirect damage by dust
accumulation / contamination (equipment / instrumentation)
1.6.4.2.2 Abrasive “Brush-off” blasting method
• The surface to be blasted should be washed down with a RasGas approved biodegradable alkali
based detergent /degreaser applied as per the manufacturers instructions in such a manner to
remove all surface contamination that would be detrimental to the coating.

• The surface should then be washed with potable water (chloride content to be below 20ppm) at
high pressure to remove the contaminated detergent/degreaser before it dries on the surface.
• The surface shall then be “Brush –off blast cleaned” to standard NACE No. 4/SSPC SP 7. To
give a surface profile of no more than 25 μm. The purpose of the blast cleaning in this instance is
to give the primer a suitably “roughened “ surface to enable good adhesion while also removing
any minor corrosion products.
• Significant areas of corrosion pitting or metal loss that are exposed during blasting operations are
to be referred to RasGas for inspection and passed as acceptable prior to any further
coating/wrapping of these areas.
1.6.4.2.3 Hand Preparation Methods
• The surface to be prepared should be washed down with a RasGas approved biodegradable alkali
based detergent / degreaser applied as per the manufacturers instructions in such a manner to
remove all surface contamination that would be detrimental to the coating.
• The surface should then be washed with potable water (chloride content to be below 20 ppm) at
high pressure to remove the contaminated detergent/degreaser before it dries on the surface.
• While the surface is still wet using abrasive paper (rating 100 – 120) vigorously ‘rub’ the surface
to achieve a 100% abraded surface suitable for the primer to adhere to.
• Keep the surface wet during the operation (using potable water) and rinse afterwards to ensure
the sanding residue does not dry on the surface to be primed
1.6.5 General Coating Guidelines (For All Surfaces):
1.6.5.1 Application Guidelines
• Manufacturer’s guidelines for storage of coatings shall be applied.

• Manufacturers mixing instructions shall be followed.
• Do not store the coatings in direct sunlight before mixing.
• Do not apply the coating if the surface temperature is within 3°C of the dew point.
• Do not apply the coating if the surface temperature is less than 10°C.
• Do not apply the coating if the steel temperature is outside the manufacturer’s permissible
product application limit, if no limit is given the maximum allowable steel temperature for
coating application shall be 55°C.
• Do not apply the coating if the relative humidity is above 85%.
• Do not apply the coating if local weather conditions are clearly deteriorating and could affect
application or curing.
• Do not apply the primer coating if the specified surface preparation standard has not been
achieved or if the blasted surface has degraded prior to applying the primer coating.
1.6.5.1.1 Over coating
• Coating that has been allowed to cure overnight shall be washed down with potable water and
checked for salt contamination and be completely dry before over coating can begin.
• Coating that has been allowed to cure past the manufacturers permissible over coating period are
to be treated as per the manufacturers over coating instructions.
• Coatings that cannot be re-coated shall be fully removed and re-applied as per this specification

1.6.5.1.2 Coating Repairs
• Coating that becomes damaged are to be repaired as per the manufacturers coating repair
instructions. All repairs shall return the coating to a uniform film.
• Coating repairs shall conform to the specification for surface preparation, application, finish and
dry film thickness.
1.6.5.1.3 Stripe Coating of Primer and subsequent coats
Apply the stripe coat by brush, coating all welds, corrosion pittings, edges, corners, nut/bolt heads,
small bore pipes, brackets, clamps, the interior radius of any cut out sections and any locations
where it is difficult to coat by spray application or spray application will result in excessive
overspray. Stripe coat is to extend at least 50mm. outside of the area being “striped”. Special
attention is to be paid to corrosion pitting during stripe coating – the coating is to be “worked – in”
to the interior of the pitting by employing a circular motion with the brush to ensure the interior of
the pitting is fully coated.
1.6.5.1.4 Exclusions to the Above
If the manufacturers written instructions contradict the above, written permission shall be obtained
from RasGas for any variations within the specification.
Paint manufactures to be consulted for suitability of their products for the below-mentioned
Paint Systems. All Paint Products shall be approved by RasGas

2.0 Coating Systems (Scopes and Specifications)

2.1 Section 1- Uninsulated Carbon Steel Coating System (Non-impact areas), above the splash
zone, operating at Ambient up to +100°C
The following specification shall applied apply to all Primary, Secondary and Tertiary carbon steel
items within those packages Including (but not confined to)Cellar Decks, Mezzanine Deck, Drill
Deck, Production Decks, Top Decks, Heli-Deck, Crane and Pedestal and staircases above the Splash
Zone.
Exceptions
All Primary, Secondary and Tertiary non-carbon steel (or non-ferrous steel) items. All carbon steel
subject to impact and/or high temperature (above +100°C). All carbon steel items, equipment, piping
under insulation. All steel in the Splash Zone.
Specification Ref.: Paint System # RMC-PS-01 (Un-insulated Carbon Steel, above Splash
Zone, operating at ambient upto +100°C)
(For Impact Areas like deck plates/troughs/base plates/ lay down areas, see Section 2.4)
2.1.1 Zinc Rich Primer coat
The primer coat should be a polyamide cured, two component, zinc rich epoxy primer, suitable for
application on blast cleaned surfaces with ability to be applied during high humidity (upto 95%) if
required.
a. Apply the stripe coat.
b. Significant areas of corrosion pitting or metal loss that are exposed during blasting operations are
c. Apply the primer coat by airless or conventional spay method to achieve a minimum dry film
thickness of 50 μm.
d. Remove all masking materials either damaged during blasting operation or containing blasting
media which may dislodge during coating operations.
e. Wash all surfaces with potable water to ensure removal of any accumulated dust and check
surface for contamination as per operation 1.6.4.1.6 (of Surface Preparation) above.
f. Renew all masking of items not to be coated or items which may be affected by overspray during
coating application.
g. Ensure Manufacturers recommended over coating time has not been exceeded before coating
commences.
h. Note that for sweep blasted areas, primer coat needs to be touched up in places where bare metal
has been exposed before application of subsequent coats.

2.1.2 Surface Tolerant Primer coat:

For Hand/Power Tool prepared or sweep blasted Surfaces, or where full blasting operations
safely not possible and/or not suitable
The Primer coat shall be should be a 2-component, surface tolerant polyamide cured epoxy
primer/tie-coat that is capable of being applied to aged coatings with hand tool/power tool
preparation, sweep blasted and sufficiently roughened.
a. Apply stripe coat.
b. Significant areas of corrosion pitting or metal loss that are exposed during blasting operations to
be referred to RasGas for inspection and passed as acceptable prior to any further
c. Apply Primer-coat by airless or conventional spray method to achieve a minimum dry film
thickness of 75 μm (brush or roller may be used for ltd areas where access is difficult to coat by
spray).
f. Renew all masking of items not to be coated or items affected by overspray during coating
application.
g. Ensure Manufacturers recommended over-coat time isn’t exceeded before coating commences.
2.1.3 High Build MIO coat
The mid-coat should be a two component, polyamide cured recoatable High Build MIO (Micaceous
Iron Oxide) pigmented Epoxy Coating that is capable of being applied at high thickness per coat.
The minimum volume solids should be 60%. It should have good impact and abrasion resistance.
The high build coat is to be applied in 2 distinctive coats.
a. Apply stripe coat of 1st. High build Miocoat.
b. Apply 1st. High build coat by airless or conventional spray method (brush or roller may be used
for limited areas where access is difficult to coat by spraying).
c. Wash all surfaces with potable water to ensure removal of any accumulated dust and check
d. Apply stripe coat of 2nd. High build Miocoat.
e. Apply 2nd. High build coat by airless or conventional spray method to achieve a minimum total
dry film thickness of 125 μm dft.
2.1.4 Polyurethane Top coat
The Top Coat for this system should be a two part High Gloss Aliphatic Acrylic Polyurethane finish
that is tough and abrasion resistant. Top coat is to be applied to Handrails, Lifting Beams, piping
systems for Colour coding or aesthetic appearance. The top coat is to be applied at min. 50 μm and
shall be able to completely hide the undercoat at that DFT.
a. Wash all surfaces with potable water to ensure removal of any accumulated dust and check

b. Apply stripe coating of Top coat.
c. Apply Top coat by airless or conventional spray method to achieve a DFT of 50 μm (brush or
roller may be used for limited areas where access is difficult to coat by spraying).
2.1.5 Table 1-Dry Film Coating Thickness for Paint System # RMC-PS-01
Surface Preparation SSPC SP 5 as Described Previously
Coating DFT per Coat

Zinc Rich Epoxy Primer Coat 50 μm
Surface Tolerant Epoxy Primer-Coat 75 μm (only where applicable)
(only where applicable)
1st. - High Build Miocoat 125 μm
2nd.- High Build Miocoat 125 μm
High Gloss Polyurethane Top Coat 50 μm
Total 350 μm dft
For Final Colours, see Appendix F

2.2 Section 2- Uninsulated Carbon Steel Coating System in the Splash Zone, Tidal Zone and Sea
Water Intake structures operating at Ambient upto +100°C
The following specification shall applied apply to all Primary, Secondary and Tertiary carbon steel
items within those packages, including (but not confined to) the spider deck, boat landing, stringers
and staircases in the Splash Zone, Tidal Zone and the sluice gates in sea water intakes onshore.
Exceptions
All carbon steel subject to impact and/or high temperature (above +100°C). All carbon steel items,
equipment, piping under insulation. All steel above the splash Zone, Tidal zone and the sluice gates
at the sea water intakes. All Uninsulated Stainless Steel and Galvanized Steel Coating System within
the Splash Zone (Including CCTV covers and Spot light covers), see Section 3 for this specification.
Specification Ref.: Paint System # RMC-PS-02 (Un-insulated Carbon Steel, in Splash Zone,
operating at ambient upto 100°C)
2.2.1 Corrosion Inhibiting Primer coat
The primer coat should be a polyamide cured, two component, corrosion inhibiting epoxy primer,
compatible to a well designed cathodic protection system and suitable on wet blast cleaned surfaces
(dry or damp) with ability to be applied during high humidity (upto 95%) if required.
a. Apply the primer stripe coat
b. Apply the primer coat by airless or conventional spay method to achieve a minimum dry film
c. Significant areas of corrosion pitting or metal loss that are exposed during blasting operations are
to be referred to RasGas for inspection and passed as acceptable prior to any further coating of
these areas.
surface for contamination as per operation 1.6.4.1.6 (of surface preparation) above.
commences.
2.2.2 Abrasion Resistant Build Coat
The High build/Finish coating should be a two part, Solvent free or High solids, amine cured
Phenolic or Glassflake High Build Epoxy Coating that is capable of being applied at high thickness
per coat and is capable of fully curing in atmosphere or when underwater. The minimum volume
solids should be 85%, preferably 100 %. It should have excellent impact and abrasion resistance.
The high build coat is to be applied in 2 distinctive coats (unless written waiver is obtained by paint
manufacturer to apply in 1 coat).
a. Apply stripe coat of 1st. High build coat.
for limited areas where access is difficult to coat by spraying).

surface for contamination as per operation 1.6.4.1.6(of surface preparation) above.
d. Apply stripe coat of 2nd. High build coat.
e. Apply 2nd. High build coat by airless or conventional spray method to achieve a minimum total
dry film thickness of :
475 μm for Splash Zone Areas without Topcoat
525 μm for Splash Zone Areas with Topcoat
1075 μm for All Tidal Zone Areas and Sluice gates in the sea water intakes
2.2.3 Polyurethane Top coat (Optional) for Splash Zone only
surface for contamination as per operation 1.6.4.1.6. (Of surface preparation) above.
Coating DFT per Coat (Splash Zone) DFT per Coat (Tidal Zone)
Corrosion Inhibiting Primer Coat 75 μm 75 μm
Abrasion Resistant Build Coat 200 μm 500 μm
Abrasion Resistant Build Coat 200 μm 500 μm
Polyurethane Top Coat 50 μm (optional) -
Total 475 or 525 μm as req. 1075 μm
NOTE: Apply Tidal Zone coating thickness for all steel in Tidal Zone and Sluice Gates in Sea
Water intakes
For Final Colours, see Appendix D (applicable for topcoat only)

2.3 Section 3- Uninsulated Stainless/Galvanized Steel, Nickel Alloy Coating System operating at
ambient up to +100°C
Including (but not confined to)Galvanized Handrails, galvanized/SS/Ni Alloy piping, Galvanized
structures and stands, supports, housing, CCTV covers, Spot light covers in all zones requiring
painting (above LAT).
Exceptions
All Instrument tubing, Stainless/galvanized steel surfaces not required to be painted and all Non-
Stainless Steel/Non-Galvanized Steel/ Non- Ni Alloy Surfaces. All stainless/galvanized steel /Ni
Alloy under insulation. All stainless steel /galvanized steel/ Nickel Alloy subject to impact and/or
high temperature (above 100°C).
Specification Ref.: Paint System # RMC-PS-03 (Un-insulated Stainless Steel/Nickel

Alloy/Galvanized Steel operating at ambient upto +100°C)
2.3.1 Non-Ferrous ST Primer Coat
The primer coating should be a polyamine cured, two-component, Non-Ferrous surface tolerant
epoxy primer with good adhesion to Stainless and galvanized steel and does not contain any metallic
or aluminum based pigment.
a. Apply the primer stripe coat. Note : apply Single pack Zinc Rich Epoxy Primer on galvanised
steel, where galvanizing has been damaged or blasted off, before priming with surface tolerant
epoxy primer.
f. Renew all masking of items not to be coated or items which affected by overspray during coat
app.
g. Ensure Manufacturers recommended over coating time isn’t exceeded before coating
commences.
h. Note that for sweep blasted and hand/power tool cleaned areas, primer coat needs to be touched
up in places where bare metal has been exposed before application of subsequent coats.
2.3.2 Polyurethane Top Coat
that is tough and abrasion resistant. It is to be applied at min. 50 μm and shall be able to completely
hide the undercoat at that DFT.

roller may be used for ltd areas where access is difficult to coat by spraying).
Surface Preparation SSPC SP 7 or Hand Abrade

Non-Ferrous ST Epoxy Primer^ 50 μm
Total 100 μm
^ Touchup damaged galvanizing with single pack zinc rich epoxy repair primer before Non-
Ferrous ST Epoxy Primer application
For Final Colours, see Appendix D

2.4 Section 4- Uninsulated Carbon Steel Coating Specification, above splash zone, for Impact
Areas like deck plates/troughs/base plates/ lay down areas/flooring
The following specification shall be applied to all carbon steel surfaces which are subjected to
impact, abrasion and collection of water/salt/grease/oil/mild chemicals/mild acids/mild
alkalis/solvents above the Splash Zone.
Exceptions:
All Primary, Secondary and Tertiary non-carbon steel (or non-ferrous steel) items. All carbon steel
not subjected to impact. All carbon steel items, equipment, piping under insulation. All carbon steel
subject to high temperature (above +100°C)
Specification Ref.: Paint System # RMC-PS-04 (Un-insulated Carbon Steel, above Splash
Zone, subjected to impact and collection of water/salt/grease/oil/mild chemicals/mild
acids/mild alkalis/solvents)
2.4.1 Corrosion Inhibiting Primer coat
The primer coat should be a polyamide cured, two component, corrosion inhibiting epoxy primer,
with ability to be applied during high humidity (upto 95%) if required.
a. Apply the primer stripe coat.
commences.
h. For spot repairs and hand tool/power tool cleaned surfaces, follow the same procedure as laid out
above followed by the subsequent coat(s) of paint.
2.4.2 Abrasion Resistant Build Coat
The High build/Finish coating should be a two part, Solvent free or High solids, amine cured
Phenolic or Glassflake High Build Epoxy Coating that is capable of being applied at high thickness
per coat and is capable of fully curing in atmosphere or when underwater. The minimum volume
solids should be 85%, preferably 100 %. It should have excellent impact and abrasion resistance
with the ability to resist exposure to water/salt/grease/oil/mild chemicals/mild acids/mild
alkalis/solvents. The high build coat is to be applied in 2 distinctive coats.
a. Apply stripe coat of 1st. High build coat.

for limited areas where access is difficult to coat by spraying) to achieve a minimum total dry
film thickness of 300 μm.
c. If and where required, sprinkle, in an even manner, an approved anti-slint/anti-skid powder onto
the tacky surface of the 1st High build coat. Let surface dry and brush off all excess or loose
powder before commencing next operation.
d. Wash all surfaces with potable water to ensure removal of any accumulated dust and check
surface for contamination.
e. Apply stripe coat of Top-coat.
f. Apply Top-coat by airless or conventional spray method to achieve a minimum total dry film
2.4.3 Table 4-Dry Film Coating Thickness for Paint System # RMC-PS- 04
Surface Preparation SSPC SP 5

Corrosion Inhibiting Epoxy Primer 75 μm
Phenolic Solvent free Epoxy 1st. Build Coat 300 μm
Anti-Slint/Anti-Skid Powder (only where required) -
Phenolic Solvent free Epoxy Top Coat 300 μm
Total 675 μm

2.5 Section 5- Uninsulated Carbon Steel, Stainless Steel, Galvanised Steel, Nickel Alloy operating
at +101°C upto +150°C (flex. Upto +200°C)
The following specification shall be applied to all carbon steel, stainless steel, galvanised steel,
Nickel Alloy surfaces which are operating (service temp.) at +101°C upto +150°C, with flex. Upto
+200°C (but not during blasting/painting operations) above the Splash Zone area.
Exceptions:
All Primary, Secondary and Tertiary non-carbon steel (or non-ferrous steel) items operating outside
the abovementioned temperature range. All carbon steel subjected to impact. All carbon, non-carbon
(non-ferrous) steel items, equipment, piping under insulation.
Specification Ref.: Paint System # RMC-PS-05 (Top-sides: Uninsulated Carbon Steel,

Stainless Steel, Galvanised Steel operating at +101°C upto +150°C ,flex. Upto +200°C)
2.5.1 Epoxy MIO Sealer Primer / Midcoat/Topcoat
The primer/mid/top-coat should be a two component, polyamide cured recoatable MIO (Micaceous
Iron Oxide) pigmented Epoxy Sealer coating that is capable of withstanding temperatures upto
150°C. It should have good impact and abrasion resistance. This Epoxy MIO sealer coat is to be
applied in 3 distinctive coats.
a. Apply stripe coat of 1st. Epoxy MIO sealer coat.
c. Remove all masking materials either damaged during blasting operation or containing blasting
d. Apply 1st. Epoxy MIO sealer coat by airless or conventional spray method (brush or roller may
be used for limited areas where access is difficult to coat by spraying) to get a minimum total dft.
of 100 μm.
e. For spot repairs and hand tool/power tool cleaned surfaces, follow the same procedure as laid out
above followed by the subsequent coat(s) of paint
f. Wash all surfaces with potable water to ensure removal of any accumulated dust and check
g. Apply stripe coat of 2nd. Epoxy MIO sealer coat by brush in similar manner to operation 1.
h. Apply 2nd. Epoxy MIO sealer coat by airless or conventional spray method to get a min. total dft
of 100 μm.
i. Apply stripe coat of 3rd Epoxy MIO sealer coat by brush in similar manner to operation 1
j. Apply 3rd Epoxy MIO sealer coat by airless or conventional spray method to achieve a minimum
total dry film thickness of 100 μm dft.


Epoxy MIO Sealer Primer 100 μm
Epoxy MIO Sealer 1st. Build Coat 100 μm
Epoxy MIO Sealer Top Coat 100 μm
Total 300 μm

2.6 Section 6- Uninsulated Carbon Steel, Stainless Steel, Nickel Alloy surfaces operating at +151°C
upto +540°C **
The following specification shall be applied to all carbon steel, stainless steel, and Nickel Alloy
surfaces which are operating (service temp.) at +151°C upto +540°C (but not during
blasting/painting operations) above the Splash Zone area.
Exceptions:
All Primary, Secondary and Tertiary non-carbon steel (or non-ferrous steel) items operating outside
the above-mentioned temperature range. All carbon steel subjected to impact. All carbon, non-
carbon (non-ferrous) steel items, equipment, piping under insulation.
Specification Ref.: Paint System # RMC-PS-06 (Uninsulated Carbon Steel, Stainless Steel,
Nickel Alloy operating at +151°C upto +540°C **)
2.6.1 Inorganic Zinc Silicate Primer coat
The primer coat should be a 2-component Inorganic Moisture Curing Ethyl Zinc Silicate (IZS)
primer
a. Apply the primer stripe coat
thickness of 50μm. Apply by Brush/roller in hard-to-reach areas. Ensure that the relative
humidity is at least 50% during primer application, if not, then spray the touch-dried surface of
primer with clean potable water periodically to facilitate curing.
surface for contamination as per operation 1.6.4.1.6(of Surface Preparation) above.
e. Note to apply mist coat-full coat technique for subsequent coats to prevent pin holes on finished
surface.
g. Ensure Manufacturers recommended over-coating time has not been exceeded before coating
commences.
h. In case adequate moisture is not present (>50%)in the air in order for an IZS to cure properly,
then wet with clean potable water at regular intervals to ensure curing process (refer to
manufacturer’s recommendation on forced curing)
i. For spot-blast repaired surfaces, follow the same procedure as laid out above followed by the
subsequent coat(s) of paint.
2.6.2 HT Silicone Aluminium Midcoat/Topcoat
The mid/top-coat should be a single component, heat resistant silicone aluminum that is capable of
withstanding temperatures upto +540°C and is to be applied in 2 coats
a. Apply stripe coat of 1st. HT Silicone Alum. Coat.
b. Apply 1st. HT Silicone Alum. coat by conventional spray method (brush or roller may be used
for limited areas where access is difficult to coat by spraying) to achieve a min. total dry film

thickness of 25 μm dft. Apply in mist coat fashion to minimize “popping” on IZS primer, rub
down surface with fine emery paper after flash cure if “popping” occurs and apply next coat.
d. Apply stripe coat of 2nd. HT Silicone Alum. Coat.
e. Apply 2nd. HT Silicone Alum. coat by conventional spray method to achieve a min. total dft of
25 μm dft.

Inorganic Zinc Silicate Primer 50 μm
High Temperature Silicone Alum -Mid Coat 25 μm
High Temperature Silicone Alum-Top Coat 25 μm
Total 100 μm
Colour: Aluminum
NOTE: For Stainless Steel Surfaces and Nickel Alloy Surfaces, Aluminum pigmented Heat
Resistant Silicones are not recommended. Please use Graphite pigmented Heat Resistant
Silicone finish.
** Surfaces that operate continuously above +150°C shall be coated with paint system RMC-PS-
06 or shall have a Thermally Sprayed Aluminum Coating (TSA) as manufactured by
Metallisation Ltd. (Or equal and approved) applied and in accordance with RasGas
Specification S-EPS 35-P-83 (For Offshore), or RGX-S-00-13A0-012 (For Onshore).

2.7 Section 7- Insulated Carbon Steel, Stainless Steel, Galvanised Steel operating at ambient below
+120°C
The following specification shall be applied to all insulated carbon steel, stainless steel and
galvanised surfaces which are operating (service temp.) at ambient below +120°C (but not during
blasting/painting operations) above the Splash Zone area.
Exceptions
All Primary, Secondary and Tertiary steel items operating outside the above-mentioned temperature
range (either Insulated or Uninsulated). All steel subjected to impact.
Specification: Paint System # RMC-PS-07 (Insulated Carbon Steel, Stainless Steel, Galvanised
Steel operating below +120°C)
2.7.1 Phenolic Epoxy Primer coat/ Topcoat

The primer coat/top-coat should be a 2-component, high build amine adduct cured phenolic epoxy
primer/coating with the ability to withstand operating temperatures below +120°C.
d. Significant areas of corrosion pitting or metal loss that are exposed during blasting operations are
e. For spot repairs and hand tool/power tool cleaned surfaces, follow the same procedure as laid out
above followed by the subsequent coat(s) of paint
f. Wash all surfaces with potable water to ensure removal of any accumulated dust and check
g. Renew all masking of items not to be coated or items which may be affected by overspray during
h. Apply the top-coat by airless or conventional spay method to achieve a minimum dry film
i. Ensure Manufacturers recommended over coating time has not been exceeded before coating
commences.
2.7.2 Table 7-Dry Film Coating Thickness for Paint System # RMC-PS- 07
High Build Phenolic Epoxy Primer 125 μm
High Build Phenolic Epoxy Top-Coat 125 μm
Total 250 μm
For Final Colours, see Appendix F

2.8 Section 8- Insulated Steel surfaces operating at elevated temperatures (operating at +120°C
and above)
The following specification shall be applied to all steel surfaces which are operating (service temp.)
at +120°C and above (but not during blasting/painting operations) above the Splash Zone area.
Exceptions:
All Primary, Secondary and Tertiary steel items/surfaces operating below the above-mentioned
temperature (Insulated). All carbon steel subjected to impact.
Specification Ref.: Paint System # RMC-PS-08 (Insulated Steel surfaces operating at elevated
temperature, operating at +120°C and above**)
2.8.1 Inorganic Zinc Silicate Primer coat
The primer coat should be a 2-component Inorganic Moisture Curing Ethyl Zinc Silicate (IZS)
primer.
thickness of 50 μm. Apply by Brush/roller in hard-to-reach areas. Ensure that the relative
humidity is at least 50% during primer application, if not, then spray the touch-dried surface of
primer with clean potable water periodically to facilitate curing.
surface for contamination as per operation 1.6.4.1.6. above.
e. Note to apply mist coat-full coat technique for subsequent coats to prevent pin holes on finished
surface.
commences.
h. In case adequate moisture is not present (>50%)in the air in order for an IZS to cure properly,
then wet with clean potable water at regular intervals to ensure curing process (refer to
manufacturer’s recommendation on forced curing)
2.8.2 Heat Resistant Silicone Aluminium Midcoat/Topcoat
The mid/top-coat should be a single component, heat resistant silicone aluminum that is capable of
withstanding temperatures upto +540°C It is to be applied in 2 coats
a. Apply stripe coat of 1st. HT Silicone Alum. Coat.
b. Apply 1st. HT Silicone Alum. coat by conventional spray method (brush or roller may be used
for limited areas where access is difficult to coat by spraying) to achieve a minimum total dry
film thickness of 25 μm dft. Apply in mist coat fashion to minimize “popping” on IZS primer,
rub down surface with fine emery paper after flash cure if “popping” occurs and apply next coat.
surface for contamination as per operation 1.6.4.1.6 (of Surface Preparation) above
d. Apply stripe coat of 2nd. HT Silicone Alum. Coat
e. Apply 2nd. HT Silicone Alum. coat by conventional spray method to achieve a minimum total
dry film thickness of 25 μm dft

Inorganic Zinc Silicate Primer 50 μm
High Temperature Silicone Alum -Mid Coat 25 μm
High Temperature Silicone Alum-Top Coat 25 μm
Total 100 μm
Colour: Aluminum
NOTE: For Stainless Steel Surfaces and Nickel Alloy Surfaces, Aluminum pigmented Heat
Resistant Silicones are not recommended. Please use Graphite pigmented Heat Resistant
Silicone finish.

2.9 Section 9- Uninsulated Carbon Steel Coating System in Internal, Air -conditioned areas
The following specification shall applied apply to all Primary, Secondary and Tertiary steel items
(doors, walls, trims, ceiling) within Internal A/C environment but are not subjected to any impact.
(Follow Section 4 for impact areas)
Exceptions
All Primary, Secondary and Tertiary carbon steel not in the abovementioned exposure condition. All
steel subject to impact and/or high temperature (above ambient).
Specification Ref.: Paint System # RMC-PS-09 (Steel, Interior steel surfaces in an Air
Conditioned environment)
2.9.1 Zinc Rich Primer coat
The primer coat should be a polyamide cured, two component, zinc rich epoxy primer, suitable for
application on blast cleaned surfaces.
c. Apply the primer coat by airless or conventional spay method to achieve a min. dry film
f. Renew all masking of items not to be coated or items affected by overspray during coat
application.
commences.
h. Note that for sweep blasted and hand/power tool cleaned surfaces, primer coat needs to be
touched up in places where bare metal has been exposed before application of subsequent coats.
2.9.2 High Build MIO coat
The mid-coat should be a two component, polyamide cured recoatable High Build MIO (Micaceous
Iron Oxide) pigmented Epoxy Coating that is capable of being applied at high thickness per coat.
The minimum volume solids should be 60%. It should have good impact and abrasion resistance.
a. Apply stripe coat of High build MIO coat.
b. Apply High build coat by airless or conventional spray method (brush or roller may be used for
limited areas where access is difficult to coat by spraying).

2.9.3 Polyurethane Top coat

Zinc Rich Epoxy Primer 50 μm
High Build MIO Coat 50 μm
Total 150 μm
NOTE: Do not apply topcoat for Insulated areas and surfaces under floor tiles/cladding

2.10 Section 10- Insulated/Un-insulated Carbon/Stainless steel subject to cyclic Temperatures of

+5 °C to +300 °C
The following specification shall be applied to all Insulated and Un-insulated carbon steel and
stainless steel surfaces which are subjected to cyclic temperatures of (service temp.) between +5°C
and +300°C (but not during blasting/painting operations) above the Splash Zone area.
Exceptions
All Primary, Secondary and Tertiary carbon steel not in the abovementioned exposure condition or
operating outside the above-mentioned temperature range. All carbon steel subjected to impact or
immersion.
Specification Ref.: Paint System # RMC-PS-10 (Carbon/Stainless steel subject to cyclic

Temperatures of +5 °C to +300 °C)
2.10.1 Option 1: Cold Spray Aluminium
The primer coat should be a 2 component, high build, high temperature resistant, cold sprayed
Aluminium Coating, suitable for application on blast cleaned surfaces at ambient and elevated
temperatures (upto +300°C).
to be referred to RasGas for inspection and passed as acceptable prior to any further coating of
these areas.
c. Apply the primer coat by airless or conventional spay method to achieve a min. dry film
f. Renew all masking of items not to be coated or items affected by overspray during coat
application.
commences.
h. Apply stripe coat of topcoat
i. Apply the top coat by airless or conventional spay method to achieve a min. dry film thickness of
150 µm.
j. Note that for sweep blasted and hand/power tool cleaned surfaces, primer coat needs to be
touched up in places where bare metal has been exposed before application of subsequent coats.

2.10.2 Option 2: Thermal Sprayed Metallic Coating

The Thermal Sprayed Metallic Coating shall consist of a metal combination of 95% Aluminium and
5% Magnesium applied by Arc Spray as per the following RasGas specifications:
Offshore:
S-EPS35-P-83-Application of Thermally Arc Sprayed Metallic Coatings
Onshore:
RGX-S-00-13A0-012, rev. 1- Thermal Arc Sprayed Metallic Coatings

OPTION 1- Cold Spray Aluminium
Cold Spray Aluminium 150 μm
Cold Spray Aluminium 150 μm
Total 300 μm

OPTION 2- Thermal Sprayed Metallic As per RasGas Specification (see reference above)
Coating

2.11 Section 11- COMPOSITE WRAP REPAIR SYSTEM (Protection System # RMC-CR-11)
Guidelines for IMG Composite Repair System or Equal and Approved

The IMG composite repair system or equal and approved shall be applied where deemed necessary
by the RasGas Engineer. This might include areas where deep pitting have been recorded, where
heavy rust scales have been observed or where potential for a pipe leak is highly probable due to
corrosion (e.g. on the weld joints). The repair system shall be applied in accordance with the
guidelines laid out below and any deviations from the same shall be referred to the RasGas Engineer
beforehand and approval sought before any further works are carried out with regards to this. Any
area where the composite repair system is required but application/wrapping is deemed difficult or
impossible by the RasGas Engineer shall be referred back to the RasGas Integrity Engineer for a
solution. Following document contains the guidelines set out by RasGas embracing the various
aspects of a composite repair system:
2.11.1 METHOD STATEMENTS
The repair should be covered by a method statement that addresses each of the main procedures to
be carried out. Input to the method statement should come from the following:
a. RasGas approved Risk Assessment (supplied by wrapping contractor)
b. Working conditions (supplied by RasGas)
c. Applicator training/qualification (supplied by vendor)
d. Design information (supplied by vendor)
e. Plant/Pipe operating conditions, layout, etc (supplied by RasGas)
f. Design of repair (supplied by vendor)
g. Materials information (supplied by vendor).
h. RasGas Work Permit requirements (supplied by RasGas)
Typically a method statement should include the following information:
i. Health and Safety
List of materials to be handled including copies of Manufacturer's Safety Data Sheets (MSDS).
COSHH assessment for process. Details of protective measures to be adopted as per RasGas safety
requirements. List of hazards associated with equipment to be repaired and equipment in the vicinity
of the repair site with protective measures.
ii. Applicator Training
Details of training requirements for applicator.
iii. Repair Design
Details of laminate lay-up including disposition and orientation of individual layers of reinforcement
(this may be presented as a written description or a drawing incorporating standard details, e.g.
overlap and taper information).
iv. Repair Application

• Details of surface preparation procedure, including method of application, equipment to be used
and inspection method.

• Details of in-fill required to achieve a smooth outer profile prior to the application of the
laminate.
• Details of time limitations between stages of the repair, e.g. between surface preparation and
lamination.
• Details of lay-up procedure including if the laminate is to be applied in stages.
• Details of curing procedure including post curing if necessary.
v. Quality Assurance
• Details of hold/inspection points in the repair (see Table 11).
• Details of any materials tests to be carried out (see Point # 2.11.3).
• Details of any systems tests to be carried out (see Point # 2.11.6).
vi. Environmental
Information on disposal of unused material as approved by RasGas SHE dept.
2.11.2 APPLICATOR QUALIFICATIONS
Suppliers of repair methods should have qualified their system for use in specific applications in
complying with the requirements of the design method. Personnel involved in the installation of
composite repairs shall have had appropriate training and be qualified in the repair method to be
undertaken. This shall include the handling of composite materials, surface preparation, lay-up
techniques, quality control procedures, and health and safety procedures (as per RasGas
requirements). It is important that the training given provides sufficient technical background to
allow personnel to obtain a good understanding as to why key operations such as surface
preparation, material handling and lay-up technique are so important.
This also applies to the use of material in the pre-packaged form. Selection of these materials does
not reduce the need for ensuring personnel are suitably trained.
Ideally training should include practical demonstration through the pressure testing of demonstration
samples.
Note that training in one repair option does not necessarily qualify personnel for alternative methods.
Installation personnel should be the subject of a continuing review of competency with a log kept of
experience in the application of repairs. This is important as the levels of competence and experience
achieved by an individual applicator should also consider in the context of repair activities. For
example, working in confined spaces or applying material around complicated geometries can pose
additional difficulties that should be taken in to account.
Supervisory personnel shall also be trained in the relevant technique and should have had a period
during which they were engaged in the application of repairs. Supervisors shall also be the subject of
a continuing review of competency. Guidance on the content of a suitable training programme may
be obtained from ISO 14692 where the training requirements for the installation of composite (GRP)
pipe are given. Full details of pipe jointing approval schemes are also given in related NTS
(Norway) and CSWIP (UK) documents.

2.11.3 INSTALLATION GUIDANCE

Suppliers of repair material shall provide full installation instructions for their repair systems.
The guidance given in the following sections is intended to complement that given by suppliers and
to emphasize the key operations necessary for a successful repair. In the event of conflict the
supplier should be contacted for clarification.
For certain repair methods it is intended that the remedial work is carried out by specialist
contractors and it would be expected that these personnel would be well versed in repair techniques.
In these circumstances the guidance proved below would be of value to RasGas as background
information and to appraise them of the facilities they need to provide.
Full instructions for each repair situation shall be given in the method statement prepared in each
instance.
a. Surface Preparation
Surface preparation is single most important operation in the achievement of a successful repair.
The surface preparation should extend over the whole surface onto which the composite laminate is
to be applied.
There are a number of surface pre-treatments, but they normally entail cleaning/degreasing and
surface abrasion. This may (or may not) be accompanied a subsequent chemical treatment stage. For
repairs to carbon steel pipe a durable bonded connection can be achieved with cleaning to remove
debris and corrosion products followed by mechanical abrasion as the sole surface preparation
activity. In these circumstances it is important that the nature of the abrasion technique is fully
specified. This shall include the grade and duration of shot blasting, the grade of any abrasive paper
or other equipment that is used. Surface roughness gauges or other measurement technique shall be
used to check that the prepared surface is as required by the specification. All paint, tape, corrosion,
dust or other loosely attached debris shall be removed.
The surface preparation issues that govern the performance of a repair material are analogous to
those that are considered to be important in the application of painting systems and other protective
coatings. These are generally listed as: the presence of rust and mill scale, the presence of surface
contaminants and the profile of the surface following preparation. Thus the surface preparation
methods mentioned in the earlier part of this document shall prevail, depending on the surface
condition, as decided by the RasGas Engineer.
The steel surface shall be blast cleaned to an SSPC SP5 (where blasting possible) using a clean
mineral abrasive as defined earlier on in this document (See 1.6.4.1-Surface Preparation Section for
details). These parameters can be changed, depending on the site limitations & as decided by the
RasGas Engineer.
The repair of other metallic pipe such as alloyed steel is likely to require a chemical treatment for a
satisfactory repair (follow wrapping manufacturer’s recommendation).
The surface preparation of GRP pipe requires mechanical abrasion only. The bonding of material
onto phenolic GRP pipe can be problematical and the pipe vendor shall be contacted in each
instance.
Any chemicals used for surface preparation shall be within the recommended shelf life, freshly
mixed (where appropriate) and applied strictly in accordance with the supplier's instructions.

The time period between the completion of surface preparation and the application of the composite
laminate is an important factor in the achievement of a good adhesion. The time period between
surface preparation and laminate application shall not exceed 4 hours.
Apply repair material as soon as possible after the surface has been treated since water absorption
onto a freshly prepared surface can be rapid as can the reaction of the surface with air and both of
these factors can impair the achievement of a good joint. The surface preparation of a number of
repair sites before any laminate material has been applied would not be recommended practice. The
minimum and maximum allowable time between surface preparation and bonding shall be specified
in the method statement.
It is important that prepared surfaces are protected from contamination prior to the application of the
repair laminate. Any sign of deterioration of the prepared surface through handling, the presence of
water or other influence should be cause for rejection and the surface preparation procedure
repeated.
A quality check shall be introduced into the repair schedule specifically identifying surface
preparation as a key stage and a hold point in the process. Where a chemical treatment is applied it
can be advantageous to incorporate a small amount of pigment in the solution to be applied. This
allows the operator, or the inspector supervising the work, to visibly check that it has been applied
correctly.
To check that the surface treatment has effectively promoted bonding, carry out a 'stipple' test. This
is be done by applying an amount of adhesive or resin to the prepared surface with a pallet knife and
then removing the knife with a lever action. It is recommended that the application is performed at
the 6 o'clock position. If the adhesive or resin material remains on the pipe it demonstrates that it has
properly wetted the surface.
Alternative method of demonstrating good bonding is to show that the adhesive bond is stronger
than the shear strength of the composite material. This shall be done by applying a small amount of
material to the steel surface along side the actual repair and then mechanically removing it. The test
would entail the bonding of a strip of material onto the prepared surface coincidentally with the
repair itself. A typical sample would allow a bonded area of 50 mm x 50 mm with a tab of un-
bonded material to allow the material to be pulled off. The presence of remaining composite
laminate over at least 30% of the bonded surface of the steel is evidence of a satisfactory bond. A
test area of 50 mm by 50 mm will be sufficient. The specified technique cannot be replaced by
another without explicit guidance from the supplier who will need to have qualified the alternative as
part of a revised design. The means by which the quality of a prepared surface is measured is not
straightforward. There are some potential techniques, but these are very specific to the chemistry of
the substrate and the surface preparation process. Measurement of surface tension (the wetting
behaviour of a droplet on the surface) is a recommended method.
b. Laminate Lay-up
The details of the lay-up procedure shall be fully specified by the supplier (vary according to the
repair method to be used).
Material variants include pre-packaged material supplied as a pre-pregnated roll or reinforcement
and resin supplied separately requiring cutting and metering on a bespoke basis. Both of these
alternatives should be applied using contact moulding. Another variant is for reinforcement to be
supplied pre-cut and then applied at the site of the repair using a resin infusion process. Other
proprietary systems, for example, the bonding of fully cured composite material onto a repair site
can be utilized as well, subject to prior approval from RasGas Corrosion Engg. Department.

For all options it is necessary that materials and tools are prepared and brought together at the repair
location prior to the work commencing. Where material needs to be pre-heated to achieve an
elevated temperature this should be done in a controlled manner. Any material that has been pre-
heated and then subsequently not used should be discarded even if it has not been mixed with other
material.
Reinforcement should be pre-cut away from the immediate vicinity of repair in an area where
dimensions can be properly measured and material bagged ready for use after preparation. The
requisite amounts of
resin, catalyst/hardener and any other ingredient or permitted filler shall be accurately measured and
thoroughly mixed. Dual volume syringes can be used as a means of achieving this for two part
systems.
For certain repair methods it is necessary to use proprietary in-fill compounds to make good local
surface imperfections, e.g. external corrosion damage. The final geometry of the surface should be
measured and shall comply with the specified tolerances. The external surface of the filler shall be
prepared according to manufacturer’s instructions.
Where separate adhesive material is required to achieve a bond between individual laminate layers
attention needs to be given ensuring the adhesive is applied uniformly and that bond line thickness is
in accordance with design.
Individual layers should be applied to the repair site in a sequential manner in the order specified viz
method statement. Particular care should be taken with directional reinforcement where the fiber
alignment needs to be controlled according to the requirements of the design. The overlaps between
individual layers will be dependent on the nature of the reinforcement and these should be defined as
part of the laminating procedure. Overlaps should be staggered around the geometry of the repair
area. Consolidation of the layers of reinforcement and resin can be accomplished through the use of
simple hand tools such as rollers. This needs to be carried out thoroughly to ensure adhesion
between individual layers and to remove air inclusions, but excessive pressure should be avoided to
prevent damage or undesired reorientation of fibers. The geometry and orientation of the pipe being
repaired can have an influence on the quality of the repair. Small diameters and regions of rapidly
changing curvature, e.g. a tee intersection, can be difficult to laminate due to the resistance in the
reinforcement to drape. The use of lighter weight fabrics or directional reinforcement to 'tie' the
laminate into difficult areas can be useful. On vertical surfaces drainage of resin prior to cure may
cause difficulties and the addition of thixotropic additives may be required.
The minimum thickness for the repair laminate shall be 5 mm. The extent of the laminate over the
surface should be specified within the design. This should normally be the larger of 100 mm or
2(D.t)0.5 in all directions beyond the damaged region, where ‘D’ and ‘t’ are the external diameter and
thickness of the pipe respectively. Care should be taken to ensure that there are no significant
discontinuities in laminate thickness at the edge of the repair. Typically thickness should be tapered
to give a minimum slope of 6:1. In the event of excessive heat generation in resin containers,
evidence of premature gelation, or a significant increase in viscosity, the material should be
discarded and a further batch of material prepared.
Where the external finish of a repair laminate is important as it is intended to carry a bearing load,
e.g. within a support, the surface can be moulded flat by applying a former prior to final cure. Any
spillage, drips or runs, which may later flake off, should be removed. The outer surface should have
a smooth contour.
For major repairs there may be a need for material to be applied in stages with cure occurring
between them. In these circumstances it may be necessary to lightly abrade the cured surface to
ensure good secondary bonding. Repairs should be carried out above the dew point. However, it is
allowed (upon seeking permission from RasGas Engineer) to proceed in conditions of low ambient
temperatures with suitable local protection to the repair area. This may involve the use of temporary
covers or housings. The material supplier should be contacted for confirmation that resin curing will
continue to be satisfactory. Similar considerations should be taken in regions of high ambient
humidity. Where condensation is possible, e.g. repair onto a cold pipe, this should be considered at
the outset of material selection and design.
Repairs should not be applied when the temperature of the surface is less than 3 °C above the dew
point of the surrounding air or when the relative humidity of the air is greater than 85% unless local
conditions dictate otherwise. Guidance on the estimation of the probability of condensation can be
found in ISO 8502-4. Also, the pipe surface temperature, ideally, should always be more than 5 °C.
Since it isn’t possible to determine properties of the actual repair laminate, the contractor shall
prepare a sample laminate alongside repair using the same materials. This sample is to be submitted
to RasGas for measuring parameters such as fiber content and mechanical characteristics.
c. Cure
The cure of a repair laminate is strongly influenced by temperature and the correct mixing of resin
constituents prior to lamination. It is important that the prevailing temperature conditions are
considered when, for example, resin catalyst levels are being assessed. On no account, however,
should the limits set by suppliers be exceeded without recourse to further information. It should be
noted that for curing in extreme ambient conditions there may be special resin formulations that may
be more suitable.
Cure can be assisted by keeping the repair laminate covered with a plastic film during installation.
This protects the laminate from mechanical abuse and water, retains heat and excludes air that can
inhibit the cure in certain resin systems. This is especially important for thin repair laminates where
there may be insufficient material to retain heat generated due to cure.
Where elevated temperatures are required for cure it is recommended that these are achieved through
the use of heating blankets that fully cover the repair laminate. Heating blankets should extend
beyond the repaired region by at least 50 mm. A protective film should be positioned between the
blanket and the laminate to prevent material being bonded to the blanket. The temperature should be
monitored throughout the curing process.
The use of heated air guns directed to the surface of a curing laminate to accelerate the process is not
allowed due to the likely evaporation of reactants from the surface.
The time for full cure is dependent on the type of resin used in the repair and ambient conditions.
The extent of cure may be measured using Barcol or Shore hardness or DSC (Differential Scanning
Calorimetry). Acceptance values shall be obtained from the supplier for each repair method. Details
of the test methods are given in BS 2782: Part10: Method 1001, ISO 868 and ISO 11357
respectively. Typical Barcol hardness values for styrenated resins are in the region 35 to 40 (Shore
hardness approximately 60), but in any case should be at least 80% of the value obtained from cast
resin specimens.
The extent of cure achieved during installation shall be the same as that in the design.
The repaired pipe may be returned to service after full cure has been achieved, assuming the pipe
service has been reduced prior to repair application. Guidance for the repairs of live pipes are given
in Section 2.11.4.

A Barcol or Shore hardness impresser is a simple hand held tool that can give an immediate
indication of the degree of cure. DSC is a laboratory base technique requiring a small sample of
resin. It gives an accurate measure of the degree of cure. Other methods are available to assess cure
such a residual styrene content (BS 2782: Part4: Method432A) and the acetone test (assessment of
surface tact after exposure to acetone).
d. Key Hold Points
The key hold points to be observed during a repair are summarised in Table 11.
Table 11: Hold Points during Manufacture
Hold Point Checked by

Method Statement Applicator
Materials Preparation
1. reinforcement Applicator
2. resin
Surface Preparation
1. inspection Contractor Supervisor
2. mechanical test Contractor Supervisor
Filler Profile Applicator
Stage Check on Applicator
Reinforcement
Tests on Repair Laminate
1. Cure Contractor Supervisor
2. Thickness
3. Dimensions
4. External Inspection
Pressure Test Inspection Authority (If and where
applicable)
The stipple test is to be included as an extra key hold point during surface preparation.
e. Documentation
On completion the repair shall be permanently marked with its reference number. A logbook opened
for each repair and retained for its service life. The records that should be provided with each repair
should include:
i. Material Records
• Record of resin type and quantity
• Record of reinforcement type and quantity
• Record of personnel on the fabrication
• Record of layers and orientation of reinforcement
• Record of surface preparation procedure
• Record of cure system
• Record of post cure
ii. Quality Control Records
• Repair reference number

• Visual inspection report
• Thickness measurement
• Repair dimensions
• Barcol or Shore hardness measurement (if carried out - dependent on resin system)
• DSC measurement (if carried out - dependent on resin system)
• Bond strength measurement (if carried out)
• Laminate strength measurement (if carried out)
• NDT results (if carried out)
iii. Independent Inspection
Report (if carried out)
iv. Service Inspection
Details of service inspection intervals
2.11.4 Live Repairs
Repairs to live pipe systems are permissible provided that the associated hazards are fully considered
in the risk assessment for the operation. This shall include any hazards to surrounding live
equipment in addition to that being repaired. Live repairs will be carried out with some reduction in
line pressure.
Where the pipe to repair is leaking, the effect of this on the likely success of the repair should be
considered beforehand. Reference should be made to the material supplier & approvals sought by all
concerned parties. Whilst there are resin systems for which it is possible to achieve an acceptable
bonded connection when surfaces are wet, a dry situation is preferable. A distinction should be made
between surfaces that are wet and those where there is flowing water. In case of the latter, the leak
should be plugged prior to the repair being applied. The plugging method should be considered as
integral part of the repair and the total arrangement should have been demonstrated to be satisfactory
by the supplier through qualification.
In the event of the repair being carried out under reduced pressure conditions the repaired pipe shall
be returned to full service after full cure has been achieved. Repairs that are plugged to stem flowing
liquid/gas should have been treated as leaking pipes for the purposes of design qualification and
should have been subject to the appropriate tests.
2.11.5 Repair Of Clamps, Piping Components, Tanks Or Vessels

The design of composite repairs of clamps, piping components, tanks or vessels, shall be carried out
using the procedures as per the manufacturer’s recommendation. Prior to applying the composite,
repair ‘in-fill’ materials shall be used to provide a smooth external contour.
The details of repairs to clamps, piping components, tanks or vessels including the final geometrical
form prior to the application of the composite repair shall be provided by the supplier. The
arrangements at the edges of the repair are particularly important. The supplier shall demonstrate the
suitability of these details through prototype pressure testing.
Prototype testing is recommended for these types of repairs. The effects of local variations in
geometry are not easily amenable to calculation and testing should confirm that these features do not
adversely affect the performance of the repair.

2.11.6 System Testing
If required system pressure tests should be specified by RasGas. For most repairs process control as
described in Point # 2.11.3 is a satisfactory means of assuring fitness for purpose. This will also
require the performance of a bond test as described above.
All repairs should be cured in accordance with the Repair System Supplier instructions before
pressure testing. Where required, hydrotesting shall take the form of a service test at 1.1 times the
operating pressure for a period of at least 60 minutes over which any changes in pressure and
temperature should be recorded. Any signs of leakage from the repair should be cause for rejection
of the repair. The repaired system should be flushed with an appropriate medium prior to testing. All
supports and anchors should be in place prior to pressure testing. Temporary supports or restraints
can be added if necessary.
If the test pressure exceeds the pressure for which the repair has been designed then this higher
pressure should be considered as a separate design case. For the purposes of the calculation the test
condition may be treated as an occasional load.
In circumstances where it is considered necessary to carry out a hydrotest to 1.5 times design
pressure (e.g. piping systems) to the maximum allowable operating pressure (MAOP) of the pipeline
special consideration should be given to ensure that the test pressure does not cause additional
damage to other parts of the system. Where a 1.5 or MAOP hydrotest is specified the test pressure
should be regarded as separate design case. For the purposes of the calculation the test condition
may be treated as an occasional load and the design strains/design factors specified for Class 1
repair, design lifetime 1 year, may be used. The repaired system should be flushed with an
appropriate medium prior to testing. Hydrotesting will usually only be carried out where the repair
has been to a leaking pipe.
Where a repair is undertaken on damaged pipe where the residual wall thickness is still above the
design code minimum there is little value in conducting a hydrotest. The use of a service test to
confirm fitness for purpose is as a result of concerns that retesting to 1.5 times design pressure or to
the MAOP of the pipeline may cause additional damage to a pipe system that has been the subject of
deterioration. The use of process control will only be satisfactory if the procedures described in this
guideline are observed.
When considering test requirements it should be noted that the failure modes of composite
components under sustained pressure are benign. This will also likely to be the case where the repair
is for a leaking pipe where any failure will be through delamination at the steel/repair interface.
2.11.7 Fire Service
The requirements for fire performance should be identified in the risk assessment. Flame spread and
smoke generation should also be considered in the assessment. Due account shall be taken of the
response of the complete system (original pipe and the repair).
Strategies for achieving fire performance include the following:
a. Application of additional composite material such that enough basic composite will remain intact
for the duration of the fire event;
b. Application of intumescent external coatings;
c. Application of intumescent and other energy absorbent materials within the laminate;
d. Use of resin formulations with specific fire retardant properties.

Further guidance on the design and testing of composites for fire performance may be obtained from
ISO14692.
2.11.8 Electrical Conductivity
For repairs to steel or other metallic pipework, the properties of underlying pipe will satisfy
electrical conductivity requirements. Where the pipe to be repaired is insulating (e.g. GRP) and
electrical conductivity requirements are specified, the properties of the repaired arrangement shall be
measured to ensure that the original characteristics of the system are restored. Guidance on how
these measurements can be taken are given in ISO 14692.
2.11.9 Inspection
Composite repairs will be subject to visual inspection & any sign of delamination/fluid ingress
between the composite laminate and steel pipe will be rejected. Additional inspection criteria shall
be furnished by the manufacturer.
2.11.10 Health and Safety
Health and safety issues shall be fully addressed in the risk assessment and repair method statements.
In the majority of cases the hazards associated with composite repair methods can be catered for
using simple protective equipment. Reference should be made to supplier’s instructions, local
regulations and any permit to work procedures.
Manufacturer's Materials Safety Data Sheets should be read and understood before a repair is started.
This may entail a COSHH assessment for the process. Resins and associated chemicals, surface
preparation agents and adhesives should have quoted TLV limits for short and long term exposures.
In addition to TLV limits the ALARP (as low as reasonably possible) principle is applicable. This
can be accommodated by adopting simple safety procedures that will limit operator exposure. For
example, directing personnel to stand such that prevailing airflows draw fumes away from the
breathing area and the use of covers on containers can be very effective.
Where repairs are carried out in enclosed spaces or if overhead working is necessary further
consideration are required.
If forced ventilation is deemed to be necessary experience has shown that relatively slow, but
constant air velocities are the most effective. Strong and local extraction in the immediate vicinity of
a composite surface can have an adverse effect by removing material through evaporation. It should
be noted that when considering ventilation strategies many of the chemical species of concern are
heavier than air. Styrene (a component of polyester and vinyl ester resins) is an example where a
downwards extraction away from the operator is the most effective.
The quantity of many chemical species in the atmosphere may be estimated using Draeger tubes and
measured values compared with allowable limits (If required by the RasGas Engineer). Where repair
material is to be machined, for example, drilling for bolt holes, grinding for surface preparation,
secondary bonding or material removal, precautions need to be taken to contain the dust hazard
where & if required.
Such operations should be carried out in the open air with operators wearing the recommended
protective clothing. If the amount of material to be removed is large, extraction local to the repair
site should be provided.
2.11.11 Environmental Considerations
All repair materials shall be designed to allow for satisfactory disposal according to prevailing Qatari
environmental regulations. In addition to any specific requirements the BATNEEC (Best Available
Technique Not Entailing Excessive Cost) principle is applicable which requires the environmental
impact of any activity to be minimised.

Special attention shall be given to the disposal of unused chemicals and resins that may be left after a
repair operation. Incineration in the open air should not be carried out. The BATNEEC principle
should be regarded in the same way as ALARP.
2.11.12 Future Modifications
Existing repairs may be modified, but this would only be after a design assessment and specific
design approval of the new repair by the manufacturer. For example, the upgrade of the pressure
rating of a repair may be achieved by the application of further material. Reference should be made
to the manufacture for such activities.
In the event of the failure of a repair, the course of action should be to remove the original material
first. The repair of a leaking laminate through the simple application of additional thickness,
particularly if the leak is caused by a delamination at the laminate/pipe interface, is unlikely to be
successful & is not to be followed as recourse. A repair denoted as temporary cannot be
subsequently changed to permanent through the later addition of further material unless it can be
demonstrated that the permanent design does not rely on the original temporary material to
contribute to repair integrity. Different repair systems should not be mixed at the same repair site
without reference to the manufacturers concerned.
2.11.13 Decommissioning
Reference shall be made to the risk assessment prior to decommissioning. If necessary, a separate
risk assessment shall be carried out to cover this activity. The removal of repair material may be
achieved by mechanical means, although it should be noted that a well bonded repair would require
a significant amount of effort for removal.
Procedures should be put in place to contain any dust that may be generated. Care should be taken to
avoid damage to adjacent equipment that is to remain in service and this should be protected if
necessary.
Components should be disposed of in an appropriate manner (see Point # 2.11.10).
2.11.14 Storage Conditions
Storage of material shall comply with the manufacturer’s instructions. Manufacturer's Materials
Safety Data Sheets shall be retained for reference. It should be noted that the materials used will
need to be stored and controlled according to COSHH (or similar) regulations.
Attention also needs to be given as to how combinations of chemicals are to be stored. These issues
will need to be addressed in the risk assessment for the chemical store.
Accelerators and catalysts for styrenated resins shall not be kept adjacent to one another, since if
inadvertently spilled and mixed they may cause an explosive hazard
All materials should be clearly labeled with relevant Health and Safety data, batch number, expiry
date and any other relevant technical information.
Control of the temperature during storage is important. Extreme temperatures should be avoided
(store near ambient).
Reinforcements should also be carefully stored to ensure that condensation either due to storage of
material below the dew point or on movement between areas at different temperatures cannot occur.
Shelf lives quotes by the supplier’s should be observed.
Resin systems deteriorate over time, especially in high ambient temperatures, and catalysts can lose
their activity. Material should be disposed of at any time where there is any evidence of changes in
colour, smell, viscosity or tack.
Disposal of time expired material shall be carried out the in required manner and according to
supplier’s instructions. Generally, chemicals should not be mixed prior to disposal, although resin
may be converted to solid form though the addition of curing agents. This operation must be done
with care as curing reactions are exothermic and the heat generated from hardening resin in bulk can
cause high temperatures.
3.0 Training and Support -

All the relevant Operations and Maintenance need to be familiar with this procedure. The Static
Equipment Engineering Section- OTD will conduct the required training and refresher training on
this manual.
4.0 Verification and Measurement -

Verification for the use of this manual is addressed through the review and spot check of the
approval process during Maintenance Coating Refurbishment Programs.
5.0 Feedback and Continual Improvement -

The owner of this procedure will, at least once every two years, coordinate the review with the
appointed owner and custodian of this manual, and solicit feedback from the end users and other
related engineers for continuous improvement to the manual to cope with the changing operational
conditions.

6.0 APPENDICES
6.1 Appendix A
Appendix A- 1. Tables Table 12A- Corresponding Degrees of Paint Rusting Standards
Appendix A- 2. Table 12B- Corresponding Surface Preparation Standards
Appendix A- 3. Table 12C-Typical Painting and Wrapping Quality Inspection and Test
Plan Checklist
Appendix A- 4. Table 12D- Painting- Daily Inspection Report
6.2 Appendix B- Approved Paint Vendors and Products
6.3 Appendix C- Warranty Requirements
6.4 Appendix D- Specific RasGas Offshore Painting- Finish Colour Designation
6.5 Appendix E- Specific RasGas Painting Safety Guides
6.6 Appendix F- Coating System Index

APPENDIX A.-Tables
a. The following Tables should be read in conjunction with sections of text and Schedules to which
they relate.
b. The International Standards referenced in the Tables should also be consulted, where further
clarification of the Table contents is required.
c. Particular attention should be paid to the Notes accompanying many of the Tables.
TABLE 12 A. Corresponding Degrees Of Paint Rusting Standards
BASIC DESCRIPTION ISO 4628-3 EURO SCALE ASTM D610
No visible rusting of coating Ri 0 Re 0 No. 10
Localised rusting of 0.05% of coated surface area Ri 1 Re 1 No. 8*
Marked localised rusting of 1% of surface area Ri 3 Re 3 No. 6
Widespread localised rusting of 10% surface area Ri 4** Re 5 No. 4
Extensive rusting of up to 50% of surface area Ri 5 Re 7 No. 1
NOTES: 1. European Scale of Rusting is the same as SIS 18 51 11

2. ASTM D610 Standards have been adopted by SSPC as Visual Standard No. 2
3. *No.8 Standard actually specifies less than 0.1% of coated surface area rusted
4. **Ri 4 Standard actually specifies 8% of coated surface area rusted
TABLE 12 B. Corresponding Surface Preparation Standards

BASIC DESCRIPTION ISO 8501-1 SSPC NACE
Solvent cleaning SP 1
Thorough hand and power tool cleaning St 2 SP 2
Very thorough power tool cleaning St 3 SP 3/11
Light or brush-off blast cleaning Sa 1 SP 7 No. 4
Thorough or commercial blast cleaning Sa 2 SP 6 No. 3
Very thorough or near white metal blast cleaning Sa 2.5 SP 10 No. 2
Visually clean or white metal blast cleaning Sa 3 SP 5 No. 1
Pickling to white metal SP 8
NOTES: 1. ISO 8501 Part 1 is the same as BS 7079 Part A1 and SIS 05 59 00
2. SSPC and NACE Standards are given in Steel Structures Painting Manual, Volume 2

TABLE 12 C.-Typical Painting And Wrapping Quality Inspection And Test Plan Checklist
(SUB) CONTRACTOR COATING SCHEDULE

WORK LOCATION DOCUMENT REF. NO.
PROJECT TITLE EQUIPMENT
CONTRACT NO. DATE
INSPECTION
ITM. DESCRIPTION OF ITEM ACTIONS BY REMARKS
REQ’D
RG
T.P.I.
OPCO
A THROUGHOUT WORKING DAY
1 Safety/condition of equipment/machinery Visual inspection H H H
2 Correct PPE is worn by all personnel Visual inspection H H H
3 Atmospheric relative humidity/dew point Psychrometer and Tables I W R/H
4 Metal surface temperature Contact thermometer I W R/H
B BEFORE PREPARATORY CLEANING
1 Work methods/QC system/safety measures Record inspection I H H
2 Permit to work in order and authorised Record inspection H H H
3 Control/inspection instruments calibrated Visual/record inspection H H H
4 Presence of surface-breaking defects Visual inspection I R R
5 Defects found are satisfactorily removed Visual inspection I R R
6 Presence of gross surface contamination Visual inspection I R R
7 Rust grade/degree of coating breakdown Visual inspection I H H
8 Type of water/brand of degreasing agent Visual inspection I R R
9 Presence of residual oil or grease Water spray test I R R
10 Presence of residual salts* Salt test I R R
11 Type, brand and grade of abrasive used Visual inspection I R R
12 Acceptance of power/hand tool cleaning Visual inspection I W W/H
C DURING PREPARATORY CLEANING
1 Batch number and date of abrasive used Visual inspection I R R
2 Presence of oil/water in compressed air Blotting paper at exhaust I R R
3 Air pressure used for blast cleaning Hypodermic needle gage. I W W
4 Blast cleaning surface cleaning standard Visual inspection v. Std. I W/H W/H
5 Profile height of blast cleaned surfaces Replica tape/comparator I W/H W/H
6 Residual dust and matter on surfaces Tape/pocket microscope I W W
7 Type/condition of power/hand tools used Visual inspection I R R
8 Standard of power/hand tool cleanliness Visual inspection I W/H W/H
9 Presence of residual millscale *(only if Copper sulphate test I R R
applicable)
10 Presence of salts* Salt Test I R R

TABLE 12 C. Typical Painting And Wrapping Quality Inspection And TestPlan Checklist
(Continued)
INSPECTION
ITM. DESCRIPTION OF ITEM ACTIONS BY REMARKS
REQ’D
RG
T.P.I. OPCO
D DURING PAINT OR COMPOSITE TAPE WRAP APPLICATION
1 Types, brands, dates, condition of paints Visual inspection I R R
2 Paint storage conditions Visual inspection I R R
3 Paint mixing procedure and control Visual inspection I W W
4 Rust present on blast cleaned surfaces Visual inspection I R R
5 Time between blast cleaning and priming Record inspection I R R
6 Paint/Wrap application technique and Visual inspection I W W
quality
7 Stripe priming of edges, corners, crevices Visual inspection I R R
8 Full primer coat thickness Wet/dry film tkns. Check I H H
9 Primer profile and appearance Visual inspection I H H
10 Time between primer and first midcoat Record inspection I R R
11 First midcoat and stripe thickness Wet/dry film tkns. Check I W W
12 First midcoat and stripe profile/appearance Visual inspection I W W
13 Time between first and second midcoat Record inspection I R R
(only if applicable)
14 Second midcoat and stripe thickness (only if Wet/dry film thickness. I W W
applicable) Check
15 Second midcoat /stripe Visual inspection I W W
profile/appearance(only if applicable)
16 Time between second midcoat and topcoat Record inspection I R R
17 Complete paint coating/wrapping thickness Wet/dry film thickness. I H H
check
18 Complete paint coating profile/appearance Visual inspection I H H
19 Final curing time for coating system Record inspection I R R
20 Presence of holidays in coating (where Low or high voltage test I H H
applicable)
21 Adhesion of coating (where applicable) Dolly pull-off test I W W
22 Identification of areas for repair Use of indelible marker I W W
23 Coating/wrapping appearance after repair Visual inspection I H H
24 Complete QIT form and associated docs. Record inspection I H H
KEY: * Subsidiary inspection test to be carried out at discretion of RASGAS Engineer

I Inspection item to be carried out where operation involved forms part of Contract work scope
R Inspection reports and records to be fully reviewed and approved
W Inspection activity to be witnessed and approved
H Mandatory Hold Point in schedule beyond which work shall not proceed without formal approval
CONTRACTOR T.P.I. ( If Applicable) R.G. (OP CO)

Signature
Name
Position
Date

Table 12 D (Painting- Daily Inspection Report –Template Below)
PAINTING - DAILY INSPECTION REPORT
Do not leave empty boxes. If Not Applicable please enter N/A
CONTRACTOR COATING SYSTEM NO.
WORK LOCATION REPORT REF. NO.
PROJECT/ITEM TITLE ITEMS COATED
CONTRACT NO. DATE
WEATHER CONDITIONS
Time / Date
Rel. Humidity (%)
Dewpoint ( C)
Metal Temp. ( C)
SURFACE CONDITION AND DEGREASING (Circle/Highlight as necessary)

Original Status Coated Wrapped Bare
Metal Condition Defect-free Laminated/Pitted Ground Rejected
Metal Rust Grade ^^ A B C D
Coating Breakdown ## Ri 0 / 10 Ri 3 / 6 Ri 4 / 4 Ri 5 / 1
Contamination Heavy Light
Degreasing Agent ……………………. Swabbed Sprayed Water Tested
SURFACE PREPARATION (Circle/Highlight as necessary) *= ISO 8501-1

Method Dry Blasting Sweep Blasting Wet Blasting Power Tool Hand Tool
Abrasive Used Type………………. Brand………………. Batch No…………... Size Range………..
Prep. Standard SSPC SP 5/*Sa 3 SSPC SP 10/*Sa 2.5 SSPC SP 7/*Sa 1 SSPC SP 3/*St 3 Other………….
Profile Ht. (um) 35-50 50-75 75-100 Range………... Using………….
Other Tests Salts…..…. Yes/No
PAINT APPLICATION (Circle/Highlight as necessary)

Method Airless Spray Air Spray Brush Trowel Other………….
When Priming Time Since Cleaning………………….. Visible Surface Rusting…..……….Yes/No
Product Details Product Base Batch Additive Thinner # and Overcoating WFT Range DFT Range
No. Batch No. percentage Period (um) (um)
Stripe Coat
Primer
First Midcoat
Second Midcoat
Topcoat
FINAL TESTING AND REPAIR (Circle/Highlight as necessary)

Thickness/Appearance DFT - Accept/Reject Appearance - Accept/Reject
Holiday Detection Test LV/HV Tester ………… Test Voltage…………….. Pass/Fail
Coating Adhesion Test Adhesion Tester……… Pull Off Stress…………… Accept/Reject
Repaired Areas % of Total Area……….. Primary Locations………. Rejected Because……….
GENERAL COMMENTS:
CONTRACTOR T.P.I. ( If Applicable) R.G. (OP CO)
Signature
Name
Position
Date
## CORRESPONDING DEGREES OF PAINT RUSTING STANDARDS(ISO 4628-3 / SSPC Vis. 2):
Ri 0/10- No visible rusting of coating; Ri 3/6- Marked localised rusting of 1% of surface area;
Ri 4/4- Widespread localised rusting of 10% surface area (8% for Ri.4); Ri 5/1- Extensive rusting of up to 50% of surface area
^^ Bare Metal Rust Grade standard according to Visual Standard SSPC-Vis 3

APPENDIX B: APPROVED PAINT VENDORS AND PRODUCTS
APPENDIX B: Approved Paint Vendors and Products
Product
Description
Paint Vendors
AMERON CARBOLINE HEMPEL INTERNATIONAL JOTUN SIGMA
Zinc Rich Amercoat Carboline Hempadur

Interzinc 52 Barrier SigmaZinc 102
Epoxy Primer 68A 858 1536
Surface
Amercoat Rustbond Hempadur Interseal 670 Jotomastic Sigmacover
Tolerant
Epoxy Primer 185 8HB 45880 HS 87 280/630
High Build Amerlock Carboline Hempadur Intergard Penguard Sigmacover

Miocoat 400 MIO 893 MIO 45881 475HS MIO HB MIO 435
High Gloss
Amercoat Carbothane Hempathane Sigmadur
Polyurethane Interthane 990 Jotathane
Topcoat 450 S 834 55100 Gloss 7528
Corrosion
Carboguard Hempadur Penguard Sigmacover
Inhibiting Amercoat 71 Interseal 414
Primer Coat E19 15590 ZP AO 280
Hempadur
Abrasion
Amerlock Carboguard Multi- SigmaShield
Resistant Interzone 954 Jotazone
Build Coat 400 GFA 1209 strength 1200
35530
Non-Ferrous
Amercoat 71 Carboguard Hempadur Penguard Sigmacover
Surf Tolerant Intergard 269
Primer TC 893 15552 Primer 630
Epoxy Mio Amerlock Carboline Hempadur Intergard Penguard Sigmacover

Sealer t 400 MIO 893 MIO 45881 475HS MIO HB MIO 522
Inorganic Hempel's
Zinc Silicate Dimetcote 9 Carbozinc 11 Galvosil Interzinc 12 Resist GT SigmaZinc 158
Primer 15700
Hempel's
HT Silicone Amercoat Carboline Silicone Sigmatherm
Aluminium Intertherm 50 Solvalitt
878 4631 Aluminum 540
56910
Sovachem
Phenolic Amercoat 90 Phenoline Hempadur Interline 850 Sigma
Tank lining
Epoxy HS 187 15500 Intertherm 228 Phenguard
Sp8 series
Cold Spray
N/A N/A N/A Intertherm 751 N/A N/A
Aluminium

APPENDIX C: Warranty Requirements
Terms and Type of Liability and Coverage

The contractor and paint manufacturer shall jointly provide RasGas with a Product
performance and Application warranty based on the “European Scale of Degree of Rusting for
Anti-Corrosive Paints” of the ‘European Committee of Paint and Printing Ink Manufacturers’
Association’. The warranty shall be for a minimal duration of 5 (five) years whereby the
severity of corrosion shall not exceed a Re 3 on the abovementioned scale. The degree of
compensation coverage shall be on a diminishing scale of 10% coverage starting from 100%
till the end of the first years, 90% till the end of the second year and so on. When the defective
areas exceed more than 5% of the total area in the first 2 years and 10% in the next 3 years, the
warranty shall automatically be invoked and the necessary remedial action taken. The warranty
shall cover coating material, cost of scaffolding, cost of labour to do the repairs and cost of
supervision. The guarantee can be based on a reference area within the plant/platform, in
accordance with ISO 12944 sections: 7 and 8, with easy to access for future inspection, the
area shall clearly be identified, accepted and passed by all concerned parties.
RasGas shall at no times be liable to arbitrate in case a dispute arises between the
contractor and the paint manufacturer as to responsibility of a defect. An independently
appointed TPI by the paint manufacturer and contractor shall arbitrate in case a dispute arises,
without compromising on the coverage provided to the affected area.
The warranty does not cover mechanical damage by boats/barges or heavy/sharp objects. It
does not cover any alterations done to the painted area after the painting process is completed.
It does not cover any natural/man-made disasters like fire, explosion, radiation, collision or
other accident, acts of God, wars (whether declared or not), vandalism, riot, civil commotion or
other malicious damage (like industrial action) and Any corrosion penetration from the internal
surface of the supporting structure/piping.
Under these circumstances, the contractor is allowed to invite the paint manufacturer to
advise/provide inspection to cover liability on their part. The paint manufacturer is also
allowed routine inspection provided that it is done in the presence of a RasGas inspector.
In case of conflict between a warranty document issued to RasGas by the paint
manufacture and/or contractor and this document, this document shall take precedence.

APPENDIX D: Specific RasGas Offshore/Onshore Painting- Finish Colour Designation (ignore

Table No. below)
OFFSHORE:
Offshore Structures Exterior Exposure – Epoxy System
Surfaces Finish Coat Color Remarks

Designation
(Note 1)
Platform
Frame 40-F-38 Beige
Deck 40-F-2 Charcoal Refer to Section 8.14
Helipad: Deck 40-F-38 Beige
Helipad: Border 40-F-41 Seal Gray Target “O” shall be 75-R-403, Century Blue. I.D.
marking Numbers, if required, shall be 84-J-5,
Black. Refer to Section 4.1.4.
Safety Nets and Supports Galvanize
Stairs, Ladders, Handrails, Galvanize Includes all exterior exposure stairs, ladders, etc.,
Catwalks regardless of location.
Cranes and Derricks 40-Y-21 Lemon Includes drilling derrick, lifting cranes, etc.
Yellow (Note 2)
Life Rafts or Lifeboats 40-Y-3 Inter- Color must conform to regulations of controlling
national Orange authority. Refer to Section 4.14.
Misc. Structural Steel 40-F-38 Beige
Buildings Exteriors: Refer to Table 3 for Interior Surfaces
Walls 40-W-9 White
Doors 40-F-38 Beige
Window Trim 40-W-9 White
Roofs 40-W-9 White
Tanks 40-F-38-Beige
Piping 40-F-38-Beige Includes valves, fittings, scraper traps, etc.
Applies only to uninsulated surfaces.
Heat Exchangers 40-F-38-Beige Includes air coolers, steam reboilers, etc. Applies
only to uninsulated surfaces.
Pressure Vessels 40-F-38-Beige Includes all uninsulated pressure vessels, such
as receivers, scrubbers, separators, surge drums,
pulsation dampers, contractors, etc.
Machinery 40-F-38-Beige Includes compressors, pumps, motors, engines,
etc. Refer to Sections 4.8 and 4.8.1.

Offshore Structures Exterior Exposure – Epoxy System (Contd.)
Surfaces Finish Coat Color Remarks

Designation
Drilling and Producing Equipment
Machinery Moving Parts 40-Y-3-Orange Applies to parts that could cause injury, such as
shaft couplings, flywheels, fans, sprockets, etc.
Boilers 11-A-30-Aluminum
Stacks, Vents, and Flues 40-J-5-Black
Instrument and Electrical 40-F-38-Beige Includes product meters, control panels,
Equipment enclosures, transformers, etc. Paint switches and
emergency stop buttons “safety” red. Surface
where shock hazard exists, use “safety” orange.
Equipment Foundations 40-J-5-Black Includes machinery bases, pedestals, etc.
Gas Meters and Regulators 40-J-5-Black
Notes to Table 2
1. When maintenance painting is required, top coat with 89-Y-21, Lemon Yellow.

Offshore Structures Interior Exposure – Conditioned Air
System Surfaces No. of Finish Coat Color Remarks

No. Finish Designation
Coats
Personnel Facilities Living Quarters Factory finished architectural
components (paneling, ceiling, floor
tile, etc.) shall not be painted.
5 Walls 1 44-F-39-Pale Grey Other available colors (20 series, 31
series, or 44 series) may be
substituted.
5 Ceilings 1 44-F-109-White
5 Doors, Trim 1 44-F-39-Pale Grey Other available colors (20 series, 31
substituted.
6 Deck 2 58-F-2-Charcoal Refer to Section 8.14
— Miscellaneous Same as adjacent area. Includes grills, radiators, pipes,
Steel exposed steel framing, etc.
Galley, Mess, Laundry, Toilers and Shower Rooms
5 Walls 2 44-W-109-White
5 Ceilings 2 44-W-109-White
5 Doors, Trim 2 44-F-39-Pale Grey Other available colors (20 series, 31
substituted.
5 Deck 2 58-F-2-Charcoal Refer to Section 8.14
— Miscellaneous Same as adjacent area. Includes grills, radiators, pipes,
Steel exposed steel framing, etc.
Storerooms, rec. Same as Living Quarters
rooms, corridors,
etc.
Equipment
7 Piping 1 20-F-38-Beige Includes valves, fittings, etc.
7 Machinery 1 20-F-38-Beige Manufacturer’s standard finish may be
substituted. Refer to Section 4.8 and
4.8.1.
7 Machinery Moving 1 20-Y-15-Orange Applies to parts that could cause injury
Parts – See table for rest.

Offshore Structures Interior Exposure – Conditioned Air(Contd.)
System Surfaces No. of Finish Coat Color Remarks

No. Finish Designation
Coats
Equipment (Continued)
7 Heat Exchangers 1 20-F-38-Beige Includes air coolers, steam
reboilers, etc.
7 Pressure Vessels 1 20-F-38-Beige Includes all uninsulated vessels,
such as separators, sumps,
surge drums, contractors, etc.
12 Boilers 1 11-A-30-Aluminum
7 Stacks, Vents, 1 20-J-5-Black
Flues
7 Instrument and 1 20-F-38-Beige Include product meters, control
Electrical panels, enclosures, etc. Paint
Equipment switches and emergency stop
buttons “safety” red. Use
“safety” orange for surfaces
where shock hazards exist.
7 Tanks 1 20-F-38-Beige Includes exterior surfaces of all
small tanks such as diesel, lube
oil, glycol, etc.
7 Equipment 1 20-J-5-Black Includes machinery bases,
Foundations pedestals, etc.
7 Gas Meters and 1 20-J-5-Black
Regulators
ONSHORE:
Refer to color references in RGX-S-00-13A0-004 for Onshore topcoat colors.

APPENDIX E: Specific RasGas Painting Safety Guides
10. HEALTH AND SAFETY CONSIDERATIONS

10.1 Blast cleaning with grit or synthetic abrasives should be used in lieu of sandblasting.
10.2 A protective hood with a positive fresh-air supply shall be used during blast-cleaning operations.
10.3 A filter-type dust mask shall be used during hand tool or power tool cleaning operations in
enclosed areas or in other situations where excessive concentrations of dust are produced.
10.4 Protective clothing such as gloves, goggles, and aprons should be worn during solvent cleaning
operations. Hands should be cleaned with a waterless hand cleaner after exposure to solvents.
Clothing or protective equipment that is wet with solvents or paint should be promptly removed
and laundered before reuse.
10.5 Protective clothing such as gloves, goggles, and aprons shall be worn during pickling
operations. Hands should be cleaned with a waterless hand cleaner after exposure to pickling
solutions. Eye protection shall be required during all surface preparation procedures.
10.6 Prior to the start of daily work, the contractor shall ascertain that all necessary tests have been
made for toxic gases, chemicals, or explosive mixtures (see API Publ 2015). The safety
conditions covered by OSHA and/or the local jurisdiction, as well as those the contractor may
deem necessary, shall be met.
10.7 Particular care must be exercised when working in close or confined spaces, especially when
spraying. The contractor shall ascertain that all necessary tests have been made for oxygen
sufficiency and hydrogen sulfide. The threshold limit value (TLV) prescribed by OSHA for the
particular solvent vapor in the air shall not be exceeded unless fresh-air masks, as approved by
the National Institute of Occupational Safety and Health (NIOSH), are supplied to workmen.
When volatile solvents are flammable, the concentration in the air shall be kept to one-quarter or
less of the lower explosive limit (LEL) by adequate exhaust or ventilation facilities. All blast-
cleaning equipment shall be maintained in good working order and shall be inspected regularly
by RasGas safety personnel.
10.8 Removal of lead-based products should be done in accordance with all appropriate laws and
regulations. For minor repairs to a red lead/alkyd system, spot blasting and priming with a
compatible non lead-based primer should be conducted. Removal of the entire lead-based
system should be considered.
10.9 All operatives shall have received adequate training and be fully competent in the use of
equipment for surface preparation, as well as airless spray application devices, before being
allowed to operate such equipment.
10.10 All painting, including disposed of hazardous materials, shall be accomplished in accordance
with local governmental regulations. All applicable VOC regulations shall be strictly observed.
Knowledge of these laws will be necessary to ensure that all such work is conducted in a safe,
legal manner.




APPENDIX F: COATING SYSTEM INDEX
Uninsulated Carbon Steel (Non-impact areas), atmospheric exposure, operating at Ambient upto to +100 oC
Surface DFT
System
Preparation
Product µm
Comments
Primer Zinc Rich Epoxy 50
Dry Grit Blast
Intermediate Epoxy MIO 125
SSPC- SP5 / Large Area Repairs
ISO 8501-1 SA 3 Intermediate Epoxy MIO 125
Top Polyurethane 50
Primer Surface Tolerant Epoxy 75
Mechanical Prep
RMC-PS-01 Intermediate Epoxy MIO 125 Small Repairs &
SSPC-SP3 /
Intermediate Epoxy MIO 125 Touch-up
ISO 8501-1 ST 3
Top Polyurethane 50
Sweep Blast Intermediate Epoxy MIO 125
Large Area Repairs
Only Intermediate Epoxy MIO 125
Top Polyurethane 50
Carbon Steel in the Splash Zone, Tidal Zone and Sea Water Intake Structures-Ambient upto to +100 oC
Surface DFT
System
Preparation
Product µm
Comments
Primer Universal Epoxy Primer 75
Dry Grit Blast
Intermediate High Build Epoxy 200
Intermediate High Build Epoxy 200
ISO 8501-1 SA 3
Top-optional Polyurethane-optional (50)
Primer Universal Epoxy Primer 75
Mechanical Prep
RMC-PS-02 SSPC-SP3 /
Intermediate High Build Epoxy 200 Small Repairs &
Intermediate High Build Epoxy 200 Touch-up
ISO 8501-1 ST 3
Top-optional Polyurethane-optional (50)
Dry/Wet Blast Primer Universal Epoxy Primer 75
Tidal Zone/Sluice Gates
SSPC- SP5 / Intermediate High Build Epoxy 500
Only
ISO 8501-1 SA 3 Top High Build Epoxy 500
Uninsulated Stainless Steel/Galvanised Steel, Nickel Alloy-Ambient upto to +100 oC

Surface DFT
System
Preparation
Product µm
Comments
Sweep Blast Primer^ Surface Tolerant Epoxy 50

Large Area Repairs
/Brush-Blast
Top Polyurethane 50
RMC-PS-03 Mechanical Prep
Primer^ Surface Tolerant Epoxy 50 Small Repairs &
SSPC-SP3 /
ISO 8501-1 ST 3 Top Polyurethane 50 Touch-up
^ Touchup damaged galvanizing with single pack zinc rich epoxy repair primer before ST Epoxy
Carbon Steel, Areas subject to Impact, abrasion, collection of water/mild chemicals (above splash zone)
DFT
System Surface Preparation Product µm
Comments
Dry Grit Blast

Primer Epoxy Primer 75
SSPC- SP5 / Intermediate High Build Epoxy 300 Large Area Repairs
ISO 8501-1 SA 3
Top High Build Epoxy 300
RMC-PS-04 Primer Epoxy Primer 75
Mechanical Prep
Intermediate High Build Epoxy 300 Small Repairs &
SSPC-SP3 /
ISO 8501-1 ST 3
Touch-up
Top High Build Epoxy 300

COATING SYSTEM INDEX (CONTD.)
Uninsulated Carbon/Stainless/Galvanised Steel, Nickel Alloy +101 oC upto to +150 oC (flex +200 oC)
Surface DFT
System
Preparation
Product µm
Comments
Dry Grit Blast Primer Epoxy MIO 100

SSPC- SP5 / Intermediate Epoxy MIO 100 Large Area Repairs
ISO 8501-1 SA 3
Top Epoxy MIO 100
RMC-PS-05
Primer Epoxy MIO 100
Mechanical Prep
Small Repairs &
SSPC-SP3 / Intermediate Epoxy MIO 100
Touch-up
ISO 8501-1 ST 3
Top Epoxy MIO 100
Uninsulated Carbon/Stainless Steel, Nickel Alloy +151 oC upto to +540 oC

Surface DFT
System
Preparation
Product µm
Comments
Dry Grit Blast Primer Inorganic Zinc Silicate 50

SSPC- SP5 / Intermediate Silicone Aluminum** 25 Large Area Repairs
ISO 8501-1 SA 3
Top Silicone Aluminum** 25
RMC-PS-06
Mechanical Prep Primer Inorganic Zinc Silicate 50
Small Repairs &
SSPC-SP3 / Intermediate Silicone Aluminum** 25
Touch-up
ISO 8501-1 ST 3
** Use Silicone Graphite instead of Silicone Aluminum for Stainless Steel, Ni Alloy
Insulated Carbon/Stainless/Galvanised Steel-Below +120 oC

Surface DFT
System
Preparation
Product µm
Comments
Dry Grit Blast
Primer Phenolic Epoxy 125
ISO 8501-1 SA 3 Top Phenolic Epoxy 125
RMC-PS-07 Mechanical Prep Primer Phenolic Epoxy 125
Small Repairs &
SSPC-SP3 /
Touch-up
ISO 8501-1 ST 3 Top Phenolic Epoxy 125
Insulated Steel +120 oC and Above

Surface DFT
System
Preparation
Product µm
Comments
Dry Grit Blast Primer Inorganic Zinc Silicate 50

SSPC- SP5 / Intermediate Silicone Aluminum** 25 Large Area Repairs
ISO 8501-1 SA 3
RMC-PS-08 Primer Inorganic Zinc Silicate 50
Mechanical Prep
Intermediate Silicone Aluminum** 25 Small Repairs &
SSPC-SP3 /
Touch-up
ISO 8501-1 ST 3

COATING SYSTEM INDEX (CONTD.)
Uninsulated Carbon Steel-Internal, Air -conditioned areas

Surface DFT
System
Preparation
Product µm
Comments
Primer Zinc Rich Epoxy 50
Dry Grit Blast
SSPC- SP5 / Intermediate Epoxy MIO 50 Large Area Repairs
ISO 8501-1 SA 3
Top Polyurethane 50
RMC-PS-09
Mechanical Prep
Small Repairs &
SSPC-SP3 / Intermediate Epoxy MIO 50
Touch-up
ISO 8501-1 ST 3
Top Polyurethane 50
Insulated/Un-insulated Carbon/Stainless steel subject to cyclic Temperatures of +5 °C to +300 °C

OPTION 1: 2 Component, High Build, High Temperature Resistant, Cold Sprayed Aluminium
Surface DFT
System
Preparation
Product µm
Comments
Dry Grit Blast Primer Cold Sprayed Aluminium 150

ISO 8501-1 SA 3 Top Cold Sprayed Aluminium 150
RMC-PS-10 Mechanical Prep Primer Cold Sprayed Aluminium 150

Small Repairs &
SSPC-SP3 /
Touch-up
ISO 8501-1 ST 3 Top Cold Sprayed Aluminium 150
OPTION 2: Thermal Sprayed Metallic Coating

Dry Grit Blast See RasGas Specification ref: S-EPS35-P-83 For Offshore
RMC-PS-10 SSPC- SP5 /
ISO 8501-1 SA 3 See RasGas Specification ref: RGX-S-00-13A0-012 For Onshore
Composite Wrap Repair System

Surface DFT
System
Preparation
Product µm
Comments
Dry Grit Blast 50
Primer Zinc Rich Epoxy
SSPC- SP5 /
Large Area Repairs
ISO 8501-1 SA 3 Composite
Composite Wrap As Reqd.
Wrap
RMC-CR-11 Mechanical Prep 50
Primer Surface Tolerant Epoxy
SSPC-SP3 / Small Repairs &
Composite Touch-up
ISO 8501-1 ST 3 Composite Wrap As Reqd.
Wrap


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RasGas Company Limited

Maintenance Coating Manual

Custodian of this Manual: Coating Engineer

Owner of this Manual: Operations Technical Manager

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Signature Page and Revision History

Verified SIGNED 21-Sep-08

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Procedure User Job Title

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Scope of Work and Paint Specification

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Glossary of Terms and Abbreviations

ALARP As Low as Reasonably Practicable (http://www.hse.gov.uk/risk/theory/alarp.htm)

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Reference Standards and Codes

Painting and Coating - General

RGX-S-0013A0-001 RasGas Specification for Painting -General Requirements

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Inspection and Testing

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Composite Repair Systems

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1.5 Roles & Responsibilities

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1.6.4 Surface Preparation

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• Manufacturer’s guidelines for storage of coatings shall be applied.

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2.0 Coating Systems (Scopes and Specifications)

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2.1.2 Surface Tolerant Primer coat:

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Surface Preparation SSPC SP 5 as Described Previously

Coating DFT per Coat

For Final Colours, see Appendix F

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For Final Colours, see Appendix D (applicable for topcoat only)

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Specification Ref.: Paint System # RMC-PS-03 (Un-insulated Stainless Steel/Nickel

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Surface Preparation SSPC SP 7 or Hand Abrade

Coating DFT per Coat

For Final Colours, see Appendix D

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Surface Preparation SSPC SP 5

Coating DFT per Coat

For Final Colours, see Appendix D

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Specification Ref.: Paint System # RMC-PS-05 (Top-sides: Uninsulated Carbon Steel,

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Surface Preparation SSPC SP 5

Coating DFT per Coat

For Final Colours, see Appendix D