PIPE RACK AND PIPING

PAINTING PROJECT.

Document No. Doc. Type Discipline Job No.

W467-NOCPL-JP-SPP-01 PROCEDURE MECHANICAL W467

CLEANING AND PAINTING

PROCEDURE
FOR PIPING AND
STRUCTURAL STEEL

Revision
Remarks Issued Date Return Date
No.
00 ISSUE FOR REVIEW 18.03.2021
01 Revised Job Procedure 25.03.2021

RANJAN KUMAR PAUL D’SOUZA

Prepared By Checked By Approved By ILIN Issued By ILIN
IMPORTANT:

No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form, or by
means of electronic, mechanical, photocopying, recording, or otherwise, without the written permission of NOCPL.
 PIPE RACK AND PIPING
PAINTING PROJECT.

Revision History

Revision Revision date Page Scope of Revision

00 18.03.2021 13 ISSUE FOR REVIEW

01 25.03.2021 14 ISSUE FOR REVIEW

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BLASTING AND PAINTING PROCEDURE
NOCPL-SPP-JP-01 Rev.00
FOR PIPING & STRUCTURAL STEEL
 PIPE RACK AND PIPING
PAINTING PROJECT.

TABLE OF CONTENTS

1 SCOPE 4

2 REFERENCE 4

3 DEFINITIONS 4

4 PERSONNEL QUALIFICATION 4

5 GENERAL 5

6 RECEIVING, STORING AND HANDLING OF PAINTING MATERIALS 5

7 SURFACE PREPARATION 6

8 PREPARATION AND APPLICATION OF PAINTING MATERIAL 8

9 INSPECTION AND ACCEPTANCE 11

10 REPAIR OF DEFECTS OR DAMAGES 13

11 COLOUR SCHEDULE 13

12 HEALTH, SAFETY & ENVIRONMENT 13

13 RECORD 14

14 ATTACHMENTS 14

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BLASTING AND PAINTING PROCEDURE
NOCPL-SPP-JP-01 Rev.00
FOR PIPING & STRUCTURAL STEEL
 PIPE RACK AND PIPING
PAINTING PROJECT.

1. SCOPE
This procedure defines the minimum technical requirements of Cleaning & Painting for Steel
Structures and piping which is required paintings in order to meet Project specification, Paint
Manufacturer recommendations, Reference code and standards in Pipe Rack & Piping
Painting Project.

The existing plant structures and piping were inspected and found heavily corroded &
coating failure observed due to prolong exposure to environment & heavy rainfall as per ISO
12944-2 classification of environments, location of ILIN shall be classified under-C4-
Corrosivity Category.

Corrosivity Mass loss per unit Thickness loss Examples of typical environments
category surface in a temperate climate
C-4 Low-carbon steel Thickness Industrial areas with High humidity
Mass loss >650to Loss>80to200µ & Aggressive environment and
1500gm/m2 coastal areas with high salinity.

2. REFERENCE
STEEL STRUCTURAL PAINTNG COUNCIL (SSPC) MANUAL:

SSPC-PA-2 SSPC Method of Measurement of Dry Paint Thickness

with Magnetic Gages

SSPC-SP-1 Solvent Cleaning

SSPC-SP-2 Hand Tool Cleaning

SSPC-SP-3 Power Tool Cleaning

SSPC-SP-5 White Metal Blast Cleaning

SSPC-SP-10 Near White Metal Blast Cleaning

---- Paint Manufacturer’s Technical Data Sheet

3. DEFINITIONS
COMPANY – Idemitsu Lube India Pvt. Ltd., Patalganga, Maharashtra
CONTRACTOR – Narmada Offshore Constructions Pvt. Ltd.

4. PERSONNEL QUALIFICATION
4.1.1 All operation shall be performed by skilled workmen
4.1.2 All Painting Engineer shall have experience of similar job.

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BLASTING AND PAINTING PROCEDURE
NOCPL-SPP-JP-01 Rev.00
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 PIPE RACK AND PIPING
PAINTING PROJECT.

4.1.3 Experience certificate of operators handling Water Jetting Pump shall be

submitted to ILIN for review & approval.

5. GENERAL
Approved Procedure for Painting application and Clients Painting Specification for Steel
structure and piping shall be followed to indentify the followings:
 Surface to be Painted
 Method of surface preparation
 Required anchor profile
 Required Painting system
 Selection of painting materials

6. RECEIVING, STORING AND HANDLING OF PAINTING MATERIALS

 All Painting materials shall be delivered to shop by the Paint Manufacturer’s in unopened
original containers, good state and correctly labeled as per requirements. The same shall
be ensured and verified by CONTRACTOR Engineer.

 Technical data sheet shall be supplied, clearly indicating all the features and
requirements of the products (i.e. max/min over painting times for the specified DFT,
max/min DFT, max temperature resistance etc.).

 Paints and Thinners shall be stored in well-ventilated building or shelter. Shelter storage
temperature shall not exceed 35°C unless stated otherwise in Paint Data Sheet.

 All paint material must be used within the manufacturer specified period. Paint shall be
used in strict rotation according to batch number and shelf life.

 Paints which have exceeded the shelf life shall be set aside and removed from painting
storage area. Expired paint shall not be used.

 The paint materials shall be stored in optimal conditions for their best conservation.

 Temporary storage of paint materials covered with canvas or tarpaulins.

 Paint container showing signs of leakage shall be discarded.

 Abrasives shall be stored in dry and clean area.

7. SURFACE PREPARATION

7.1 General

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BLASTING AND PAINTING PROCEDURE
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 PIPE RACK AND PIPING
PAINTING PROJECT.

Any surface that has to be St2 manual tool cleaned followed by water cleaning or water
mopping on existing coating (for non-rusted portion) whereas St3 Power tool cleaning
followed by water washing or water mopping on rusted or bare metal (for rusted portion).
All surface to be painted shall be removed of all the contaminants such as oil, greases,
chemicals or soil shall be removed prior to water jet cleaning by the use of suitable
broom brush. During cleaning, all weld areas and attachments shall be given special
attention to ensure all welding flux and spatter is removed by the use of files scrapers,
chipping, hammers, power or hand brushes or grinders fitted with flexible grinding discs.

Surface preparation shall be done as per the following method (any one as applicable):
 Solvent Cleaning to remove oil stains (only if required).
 St2- Manual tool cleaning followed by water washing or water mopping on
existing coating.
 St3- Power tool cleaning followed by water washing or water mopping on
rusted or bare metal.
7.2 List of Instruments required for doing painting works:
 Sling Hygrometer
 Dew Point Calculator
 Digital Temperature Gauge
 Coating Thickness Gauge (DFT).
 Wet Film Thickness Gauge
 Measuring beaker.

7.3 Water Jet Cleaning Equipment

7.3.1 All water jet cleaning equipment shall have current Inspection
Certificate from an independent third party and the same will be
ensured by the CONTRACTOR Painting engineer prior to using the
equipment.
7.3.2 Prior to mobilization of manpower at site Medical Fitness Certificate
(Form-6) shall be submitted to ILIN.
7.3.3 Low pressure water cleaning (2000-5000 PSI) shall be done for
removal of dust and foreign contamination before surface preparation
and water mopping shall be done wherever water wash is not possible.
7.3.4 The pressure and volume of the compressed water supply for water jet
cleaning shall be fulfill the requirements of water jetting pump’s
manufacturer and suitable for the surface to be clean.
7.3.5 Prior to starting the water jet cleaning, quality of water shall be
checked it shall be free from foreign contaminations.
7.3.6 Proper PPE’s such as PVC Suits, Nose Mask, Safety Helmet, Face
Shield/ Safety Googles, Metal Toe Guard Gum boot etc. shall be used
by workers operating water jetting pump.
7.3.7 Calibration certificate for PRV, Hose Certificates & Pump fitness
certificate shall be submitted to ILIN for review.
7.3.8 Area barrication shall be done prior to starting water jetting activities
with proper display board.

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BLASTING AND PAINTING PROCEDURE
NOCPL-SPP-JP-01 Rev.00
FOR PIPING & STRUCTURAL STEEL
 PIPE RACK AND PIPING
PAINTING PROJECT.

7.3.9 All cables shall be covered with GI sheet before starting water jetting
operation. GI sheets shall be fixed properly prior to starting the work.
7.3.10 Prior to starting works on height scaffolding shall be inspected by
NOCPL & ILIN HSE officer and only after getting scaffolding approval
(green tag) the height work shall be started. Workers shall wear Safety
Harness while working on height.
7.3.11 Usage of mobile phones while working at height or doing water jetting
shall be strictly prohibited.
7.3.12 Only authorized operator shall operate the water jetting pump or spray
gun.
7.3.13 Housekeeping shall be done on day to day basis, debris falling from
pipe rack shall be removed after completion of day work.

7.4 Protection of surfaces not to be coated

7.4.1 When using water jet cleaning method: All the surfaces which are not
coated shall be protected from damage and from paint products by
adequate temporary coverings during all operations of surface
preparations and painting.

7.4.2 Stainless steel and non-ferrous surfaces shall be protected from

overspray and coatings intended for carbon steel. The
CONTRACTOR painting supervisor shall ensure protection of all
equipment that is not to be painting or liable to be affected by the
presence of paint. Special attention shall be given to avoid splashes
of zinc-based paint on equipment of austenitic steel to prevent high
temperature cracking corrosion.

7.5 Weld area and sharp edges

7.5.1 All weld seams, sharp edges and surface irregularities shall be
contoured and surface irregularities ground smooth prior to blasting.

7.6 Inspection
7.6.1 After completion of surface preparation, the CONTRACTOR Engineer
shall carry out the inspection activities.

8 PREPARATION AND APPLICATION OF PAINTING MATERIAL

8.3 General
8.3.1 The Selection of Painting systems & Painting materials shall be strictly
followed as per Clients/manufacturer Painting Specification for Steel

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 PIPE RACK AND PIPING
PAINTING PROJECT.

structural/piping and the same shall be ensured by the CONTRACTOR

Engineer.

8.3.2 CONTRACTOR Engineer shall strictly follow the instructions and

recommendations as prescribed by the Painting Manufacturers for the
preparation and application of all Painting materials.

8.4 Painting Equipment

8.4.1 All Painting equipment shall have current inspection certificate from an
independent third party and the same will ensure by the Contractor
Engineer prior to use the equipment.

8.5 Weather Conditions

 The CONTRACTOR Engineer shall measure and recorded the local
conditions of temperature and humidity during cleaning, painting and curing.

 Painting shall only be applied when suitable weather conditions prevail and
the same will be ensured by CONTRACTOR Engineer.

 All inspection and first coat primer application shall be completed in daylight.
Outdoor painting is not allowed in night time as per ASTM D3276.

 Painting shall not be applied under the following conditions or when such
conditions are likely to prevail before the coating is cured:

a. At temperatures below 10°C for (or according to Painting Manufacturer

recommendation) or when the temperature is likely to fall below this figure
before the surface film is dry or on surfaces registering low temperatures.

b. When the relative humidity of the atmosphere exceeds 85%

c. The steel temperature is less than 3°C above the dew point

d. During foggy or misty conditions

e. Before dew or moisture has evaporated

f. When it is raining, or rain is imminent

 CONTRACTOR Engineer shall be responsible for scheduling his activities

under consideration of suitable weather and other atmospheric conditions.

8.6 Painting Material Preparation

8.6.1 Painting for two-pack or multiple packs painting system shall be mixed
in the proportions and under the conditions recommended by the
Manufacturer.
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BLASTING AND PAINTING PROCEDURE
NOCPL-SPP-JP-01 Rev.00
FOR PIPING & STRUCTURAL STEEL
 PIPE RACK AND PIPING
PAINTING PROJECT.

8.6.2 The mixed Painting shall be used within the regulated pot life and shall
not be used on expiry of its “pot life”.
8.6.3 Painting components shall be properly stirred to obtain a homogenous
consistency.
8.6.4 The mixed painting shall match with other prepared products of the
same coat.
8.6.5 Paint mixing ratio shall be 4:1 & only T-91 or T-92 thinner shall be
used with primer.
8.6.6 Pot life shall be considered as 1 Hr at 30◦C.
8.6.7 Painting shall be done according to the application instruction of the
Painting Manufacturer and shall be performed by skilled and
experienced staff with suitable Personal Protection Equipment (PPE).
8.6.8 The priming coat shall be applied as soon as possible after the surface
preparation has been carried out and before any contamination of the
cleaned surface.
8.6.9 Angles, corners, sharp edges, bolt or rivet heads, weld seams and
other surface irregularities shall be stripe-coated by brush. This coat
shall be the same product as the primer.
8.6.10 After completion of Primer coat, CONTRACTOR Engineer shall
perform the inspection as per Section 10 in this procedure.

Painting shall be done as per below mentioned specification:

8.6.11 Painting may be applied by the following two methods as approved or

specified by the painting Manufacturer.

Brush and Roller Application (Primer Application):

i. Brush application may be used under the following
circumstances:

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 PIPE RACK AND PIPING
PAINTING PROJECT.

ii. When area cannot be coated properly by roller application

for any reason, such as space or material or environmental
considerations.
iii. For the initial coat of paint to corners, edges, crevices,
holes, weld or irregular surfaces prior to roller application.
iv. For “touch up” to localized damaged areas.
v. Brush or rollers used shall be of a suitable size and shape
and shall be kept clean by use of Paint Manufacturer’s
recommended solvents.
vi. Where rollers are used, the nap shall be of sufficient length
to work the coating well in the surface.
vii. Roller application shall be in accordance with the paint
Manufacturer’s instructions.
viii. The specified coating thickness shall be achieved at all
protrusions, corners and crevices. Edges, cracks, bolt
heads, etc. may require the coating to be evened by lying
off with a brush after roller application.
ix. To ensure correct film thickness, WFT shall be used to
measure the wet film thickness continuously during
application. WFT shall be calculated and maintained at the
time of application to achieve specified DFT 125-
150microns. Over coating shall be 1 hr at 30◦C.

Intermediate coat
x. When the structure or piping painting works are completed,
the surface shall be checked by CONTRACTOR Engineer
and the damaged areas shall be repaired with the same
primer or Manufacturers’ recommended coatings.
xi. Emery paper of grade 120 shall used to remove overspray,
foreign particles, and contaminants.
xii. After abrading surface with emery paper cleaning the
prepared surface shall be cleaned to remove residue of
abraded coatings and contaminants and shall be inspected
for contamination as per ISO 8502-3.
xiii. Wet film thickness shall be checked during coating by
painter to ensure that the full coating thickness will be
achieved in the specified number of coats (as
recommended by the Coating Manufacturer).
xiv. A final coat shall be applied in accordance with the
undercoat over coating time recommended by the Coating
Manufacturer.
xv. The final coat shall provide a smooth, even finished coating
surface, where gloss finish coats are applied, the surface

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BLASTING AND PAINTING PROCEDURE
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 PIPE RACK AND PIPING
PAINTING PROJECT.

shall be a smooth gloss finish with no breaks in the

surface.
xvi. Relative humidity shall be less than 85% while application
surface temperature should be above 3 deg. Of dew point.
xvii. Paint mixing ratio shall be 4:1 & only T-91 or T-92 thinner
shall be used with intermediate coat paint.
xviii. Stirrer shall be used for continuous agitation of paints.

Final Coat
xix. Abrade previously coated surface with emery paper grade
120 to remove overspray, foreign particles & contaminants.
xx. After abrading surface with emery paper cleaning the
prepared surface shall be cleaned to remove the residue of
abraded coatings and contaminants and shall be inspected
as per ISO 8502-3.
xxi. Relative humidity shall be less than 85% while application
and surface temperature shall be above 3◦C above dew
point.
xxii. Mixing ration shall be 5:1 and only T-21 or T-06 thinner
shall be used.
xxiii. Pot life of paint shall be considered as 3Hrs at 30◦C.
xxiv. To ensure correct film thickness, WFT shall be used to
measure the wet film thickness continuously during
application. WFT shall be calculated and maintained at the
time of application to achieve specified DFT 102 microns.
Over coating shall be 5 hr at 30◦C.

Drying times
Each coat shall be allowed to cure thoroughly in accordance with the Paint Manufacturer’s
instruction for over coating before the next coat is applied. Curing times are highly
dependent on local conditions.

 Coated items shall be handled with equipment such as wide belt slings, web belts, and
wide padded skids selected to prevent damage to the coating.

 Handling equipment likely to cause damage to the coating shall not be used.

 Items such as chains, cables, hooks, tongs, metal bars and narrow skids shall not be
permitted to come in contact with the coating.

 Dragging or skidding in coated items shall not be permitted.

9 INSPECTION AND ACCEPTANCE

9.1 General

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BLASTING AND PAINTING PROCEDURE
NOCPL-SPP-JP-01 Rev.00
FOR PIPING & STRUCTURAL STEEL
 PIPE RACK AND PIPING
PAINTING PROJECT.

 All Inspection activity shall be carried out as per the approved Inspection Test
Plan in the various phases of execution and inspection.
 Request for Inspection (RFI) shall be raised to COMPANY for inspection as
per the approved Painting ITP for Steel structural and Piping Painting Works.

9.2 Inspection of Surface Preparation

CONTRACTOR Engineer shall check the surface of the Water jet cleaned
materials as per required surface preparation and ensure the clean surface must
be free from mill scale, oil, grease, soil, cement, salt, acids, or another corrosive
chemical, which are harmful for painting.

9.3 Inspection of Coating application

The following inspection and testing shall be performed during the application coating
system:
 Checking on raw materials (integrity of packing, expiry dates etc.)

 Checking of paints documentations (Technical Data Sheet, MTC etc.)

 Checking of meteorological and environmental conditions.

Thickness Check
Coating film thickness shall be measured for the following items:

INSPECTION INSPECTION
S.No. INSPECTION ITEM
FREQUENCY IMPLEMENTATION
One point / 5 -20 m² Wet Film Thickness
1 Wet Film Thickness
(Min. 10 Points / Day) gauge
One point / 3 – 5 m² Dry Film Thickness
2 Dry Film Thickness
(Min. 6 Points/Day) gauge
3 Corners 100% Inspection mirror

Measurement of wet film thickness (WFT) has to be done only for reference and
shall not be recorded.

 Thickness gauges to be used for measurement of paint films shall be

calibrated.
 Measurement of film thickness is less than 80% of the nominal dry film
thickness (DFT) is not acceptable.
 If the dry film thickness does not meet the specified value, additional coats
shall be applied.

Drying / Curing

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BLASTING AND PAINTING PROCEDURE
NOCPL-SPP-JP-01 Rev.00
FOR PIPING & STRUCTURAL STEEL
 PIPE RACK AND PIPING
PAINTING PROJECT.

For each coat, the Drying/Curing shall be checked as per the Manufacturers’
Product Data Sheet and the same shall be ensured by the CONTRACTOR
Engineer.

Porosity check
 Film continuity shall be checked as follows,
 Visual Inspection for holidays, pinholes, and excessive overspray shall be
done by CONTRACTOR Engineer for every subsequent coat and after
completion of Final coat.
 Areas found to have been improperly coated shall be reapplied.

10 REPAIR OF DEFECTS OR DAMAGES

 Any defect or damage that may occur shall be repaired before the application
of further coats.

 Areas which are to be over coated shall be thoroughly cleaned free from
grease, oil and other contaminants and shall be dry.

 The surfaces shall then be prepared to the standard as specified.

 Damaged surface shall be touchup with the coating as per the client’s
technical specification or Coating Manufacturers’ Recommended paints shall
be used. The repair coat shall overlap sound coating.

11 COLOUR SCHEDULE
11.1 The coating colour shall be strictly followed as per the COMPANY approved Painting
Specification for Steel structural or Piping.

12 HEALTH, SAFETY & ENVIRONMENT

12.1 All work shall strictly comply with Project Health, Safety & Environmental Plan and
Shop Safety Rules & Regulations.

12.2 Safety shields, helmets, goggles, respirators, ear protection and protective clothing
shall be use or worn then and where necessary during all operations.

12.3 Material Safety Data Sheet shall be always available at coating area for ready
reference.

12.4 Only competent personnel are permitted to operate the equipment and such persons
shall be tested by a competent person.

12.5 To prevent uncontrolled and reduce water/air emissions, the works shall be
conducted in a controlled environment.

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BLASTING AND PAINTING PROCEDURE
NOCPL-SPP-JP-01 Rev.00
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 PIPE RACK AND PIPING
PAINTING PROJECT.

12.6 Waste generated such as paint containers, other waste shall be properly stored prior
to removal from site/warehouse.

13 RECORD
13.1 The entire process shall be assured by Contractor Painting Supervisor/Engineer by
recording all the variables in the Painting Report.

14 ATTACHMENTS:
14.1 Painting Inspection Report.
14.2 Inspection Test Plan.
14.3 Quality Assurance Plan.
14.4 Painting Checklist.

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BLASTING AND PAINTING PROCEDURE
NOCPL-SPP-JP-01 Rev.00
FOR PIPING & STRUCTURAL STEEL