‘Normative docum (It is a document that provides rules, guidelines or characteristics for activities of or results. Standard: It isa document established by consensus and approved by a recognized body that provides for (G_Vmmon and repeated use rules, guidelines or characteris for activites or thei results Code of practice: Code consists of laws having legal status. It will always be considered mandatory. It is a document that recommends practices or procedures for the design, manufacture, installation, maintenance or utilization of equipment, structure or products. A code of practice may be a standard, a part of standard or independent of a standard. ‘Specification: It is a document that prescribes the requirements with which the product or service has to conform. Procedure: Iisa written description ofall essential parameters and precautions to be observed when applying the technique to a specfie test, following an established standard, code or specification. Instruction: I is a written description ofthe precise steps to be followed in testing to an established standard, code, specification or procedure. Various stapes of inspection: General: the specification. Get to know the plant. ' Get to know the personnel. Ensure all concerned understand the specification, Make written reports at an agreed frequency. At the beginning of the day: ‘Cheek the equipment. ' (Cheek the materials. Check the enviror During the day: eck the equipment. ' Check the material usage, Check the environment. Check the operators work Check the standards. ( Ensure that the system meets the specification requirement. Check for any application faults. Af Chock . ck the visual appea Check the house keeping, Make the final check on the integrity of the work ‘Complete inspeetion reports Equipment for inspection purpose: Whirling hygrometer with dew point calculator. Surface profile gauge. Testex tape with micrometer. Surface profile or compa Steel temperature got Hypodermie needle ga ator kit7. Zero plate for calibration purpose. 8. Wet film comb gauge. 9. Coating thickness gauge. 10. Inspection mirror 11. Stanley knife. C121 Portable holiday detector. Painting inspectors du 1. Toassess the condition of substrate prior to treatment. 2. To inspect surface preparation in accordance with BS 7079 / SIS 05 5900 3. To measure surface profile and record it. 4, To ensure materials used at site conforms to client specification requirement. 5. To ensure that the equipment used are calibrated and in working condition. 6. To-ensure that the personnel employed for the task to be performed are qualified to the client's specification/standards 7. Check environment conditions like RH%, dew point, ambient temperature, steel temperature. 8. Check WET and DFT 9. Witness application of each coat and inspect completed paint system. 1 0. Fill out the inspection format.ae ‘s / RUST GRADES. 1. Grade ‘A’ is usually equivalent to the state of the steel surface shortly after having been rolled. Grade ‘B’ is usually equivalent to the condition of the steel surface after being exposed to and unprotected fiom ust in a comparatively aggressive atmosphere. 3. Grade ‘C’ is equivalent to the condition of the surface after being exposed, under aggressive conditions for approximately one year. 4. Grade ‘D” is same as Grade °C’ but for approximately three yeats. BLOTTER TEST: Attach a piece of blotter or absorbent paper to a clipboard, then hold it approximately at a distance of 45 ~ 60 CM in front of the blast nozzle during air flow only, with a hozzle pressure of 388 Kpa (50 PSI) for approximately one minute. Satisfactory results shall be no water or oil contamination on the blotter. The blast system shall be operated for atleast 5 minutes under actual field conditions at the specified pressure prior to carrying out the test GENERAL CHECKS 1. SAMSS approved materials 2. Saudi Aramco qualified blasters and painters. 3. Check surface cleanliness. 4. Sweep blast by air to remove any dust particles settled on the materials 5. Mixing of paint by mechanical stirrer 6. Ensure environment conditions are conducive. 7. 8 9 1 Check wind velocity. Dew Point Relative humidity percentage. 9, Equipment operating conditions Elcometer ~ Calculator usage to get Dew point and R.H.% readings, For Dew point: 1. Set Dry bulb temperature reading to Wet bulb temperature reading on outer scale 2. Note down Dew point temperature in the window above opposite to wet bulb temperature Eg, Dry bulb temperature - 20 Deg.C, Wet bulb temperature ~ 15 Deg C, then Dew point is 11 Deg.C For Relative humidity 1. Set Dry bulb temperature to Dew point temperature on outer scale and read Relative Humidity percentage in the window below. E g., Dry bulb temperature ~ 20 Deg.C, Dew point reading ~ 11 Deg C, then RH % is 58Use of Whirling Hygrometer: Fill cistern with distilled water and ensure that wick is clean. Whirl psychrometer rapidly for approximately 20 seconds and record wet and dry bulb temperatures immediately. An average of three readings should be taken to ensure accuracy. The difference between the wet and dry bulb temperatures gives depression value. From the chart read off percentage humidity. To achieve an accurate measurement of wet bulb / dry bulb temperature, 1. Keep the wick clean, tight fitted and fully over the thermometer and saturated with distilled water. 2. Evaporate maximum amount of water from the wet bulb by whirling the hygrometer at a minimum speed of 180 revolutions/minute 3. Minimise the effect of your body by holding the hygrometer in front of you and towards the wind Ona still day, walk forwards while whirling Whirling should not be done in direct sunlight or near heat sources, ‘As soon as whirling is stopped, wet bulb temperatures should be first noted down immediately. ‘Thermometer should not be touched while noting down the readings. Only use values when consecutive readings achieved are same. In correct use of the hygrometer will result in the wet bulb temperature and consequently RH % and dew point being too high ao Operating the hygrometer: 1. Fill the reservoir with distilled water. 2. Check that the wick covers the bulb of the wet thermometer fully and is saturated with water. 3. Hold the handle of the hygrometer and whirl { for 30 to 40 seconds. 4. Quickly read the thermometer and whirl the hygrometer. 5. Repeat steps 3 and 4 until consecutive readings are the same, 6. Calculate the wet bulb depression i.e, the difference between the dry and wet bulb temperatures. 7. Use the table to find relative humidity percentage and dew point. E.g, Dry bulb ~ 20 Deg.C, Wet bulb ~ 15 Deg.C, then Depression (20 ~ 15) ~ 5 Deg. C Relative Humidity: 59% Using chart, values achieved at intersection of dry bulb column and depression of low. Dew Point: 11 Deg C On dry bulb readings scale move down the wet bulb readings to the RH, which is closest to the % current value From the chart, Read depression Dew point = Wet bulb depression in %RH * 61%, Depression -4 Deg.C So dew point 15-4 = 11 Deg.C Note: If at temperatures below freezing, ice forms on the wet bulb extra whirling is necessary to give true wet bulb reading, Check the thermometer both wet and dry for their condition i. if they are broken etc,] | Use of Testex tape: 1. Locate the surface area on which measurements have to be taken. 2. Select appropriate grade of Press-O-film e.g., 0.8 to 2 mils ~ Use Coarse, 1.5 to 4.5 mils — Use X - Coarse 3. Prepare snap gauge. Clean anvils, adjust gauge dial to read a minus 2 mils (8 mils when anvils are shut). This is the back-off distance to account for Mylar backing on tape. 4. Peel Press-O-film, from paper, leave ‘bv'ls eye’ on release paper. 5. Check unexposed film with gauge. Film may vary in thickness and maximum limits of profiles cannot exceed thickness of the film coating, Release snap gauge gently when making measurement 6, Apply film on blasted surface. 7. Rub with a burnishing tool over the round, cut out portion of Press-O-film, using moderate pressure. Press-O-film will become darker when surface is replicated! Make sure that the entire circular area has uniformly darkened 8, Remove replica and place between anvils of snap gauge, making sure replica is centered between anvils, Gauge reading is the maximum peak to valley height of the blasted surface (when snap gauge is adjusted as in step 3) Note: For profiles higher than 4.5 X-Coarse grade can be used with the following additional step. Follow. steps 1 to 5 as above, noting the unrusted tape thickness. Tapes that measure atleast 6 mils can be used to measure profiles upto 5.5 mils. Continue “ith steps 6 through 8 ‘Metal surface cleanliness grades: SSPC SPI Solvent cleaning, SSPC SP2 (S12) Hand tool cleaning SSPC SP3_ (St3)_ Power tool cleaning SSPC SP7 (Sal) Brush off blast cleaning SSPC SP6 — (Sa2)_ Commercial blast cleaning SSPC SP10 (Sa2.5)Near white blast cleaning SSPC SPS (Sa3)_ White metal blast cleaning Nozzle pressure: Hypodermic needle gauge is used to measure nozzle pressure. This simple tool consists of a needle mounted on a pressure gauge. The gauge on the compressor shows the air pressure at the compressor only. It does not indicate blasting pressure. Hoses, air filters, blast machines and other components between the compressor and the nozzle all contribute to friction and pressure losses. Use of hypodermi Put the needle on the tip of the gauge, with the level of the needle towards the front of the gauge. Insert the needle into the blast hose at a 45 Deg angle, at about six inches behind the nozzle with the tip of the needle pointing towards the nozzle. Inserting the needle towards the nozzle and with the level up will prevent abrasive from entering the gauge causing a false reading or damage. The needle should penetrate enough to position the tip into the center of the air stream. The sister the actual pressure al the nozzle ge willFor example blasting on structural steel usually demands nozzle pressures between 100 and 110 psi (7 ar/698 Kpa ~ 7.6 bar/758 Kpa). In normal field practice contractors accept anything between 90 & 100 psi (6.2 & 7 bar, 620 & 689 Kpa) - Ina blast system with 50 feet length of blast hose and air hose a pressure drop of 10 to 15 psi is expected. Nozzle pressure below 85 psi indicates something wrong in the system. Check the air compressor pressure setting, then check for restrictions at all hoses and fittings, moisture separators and other system components Also check the nozzle orifice for excessive wear. Always store the needles and gauges in their respective cases in dry dust free area, ‘As a safety precaution insert the hypodermic needle gauge while the compressor is in the off condition Also remove the gauge when the machine is switched off. Inserting the needle gauge when the machine is switched on may some times blow off the needle. i Rust Grades A. Steel surface largely covered with adhering mill scale but little, any, rust B. Steel surface, which has begun to rust and from which the mill scale has begun to flake C. Steel surface on which mill scale has rusted away or from which it can be scraped but with slight pitting visible under normal vision. D. Steel surfaces on which the mill scale has rusted away and on which general pitting is visible under normal vi Blast Cleaning: Sal Light blast cleaning Sa2 Thorough blast cleaning Sa2.5 Very thorough blast cleaning Sa3 Blast cleaning to visually clean steel St2 Thorough hand and power tool cleaning St3__ Very thorough hand and power tooi cleaning Painting equipment / instruments which are needed for a painting job. Hypodermic needle gauge (0-160 PSI/0-L1Kg.sq cm) ~ To measure blast pressure in the nozzle. Surface prpfi/e_needle gauge ~ To measure surface profile of blasted material (0.002 mm ~ I Div) Magnetic Thermometer (0-120 Deg. C) ~ To measure surface temperature of steel. Surface comparators - To compare the surface preparation of blasting grades Pictorial surface standards ~ To refer to visual standards of prepared surface to BS 7070, ISO 8501 VIS 1-89, SSPC VIS-3 6. Testex tape ~ To have a permanent record of surface profiles, 7. Micrometer ~ To measure the profiles in microns of the Testex (Press-O-film) tape. 8 Whirling hygrometer and Dew point calculator ~ To measure Relative humidity and Dew point 9. Wet film comb gauge ~ To measure wet filia thickness of paint, while the paint is in wet and in applied condition 10, Dry film thickness gauge (Electronic coatit Non-Ferrous metal substrates. (small shims) ~ Used to do calibration of eloometer against the selected range of waune ing thickness gauges) ~ To measure coating on Ferrous and i ity measurement meter ~ To assess the velocity of prevailing wind condition in the almosphere (Km/Hr, miles/sec)_/7B. SIS = 05 = 5900 (Swedish standards) — To compare the rust grades, blasting grades of the prepared surfaces 14, Protective coatings inspection manual ~ Illustrations / techniques of painting technology, useful guide for paint inspections. 15, Portable holiday detector ~ To assess pinholes / holidays on a coating, Voltage settings are relative to the coating thickness. For a range of selection determining coating thickness is a pre-requisite prior to testing for pinholes and porosity Quality control activities — QC checks and inspection stages: I Before application: To be familiar with specifications, coating systems and painting materials identification Check paint certificates, paint manufacture product data sheet Go through paint manufacturer instructions, method statement, inspection and test plan for painting Check quality control equipment kit, equipment calibrations, personnel qualifications and material conservation status. IL Surface Condition: Check the condition of the surface, if any special treatment like solvent cleaning is needed etc., IIL Pre blast check: Work periuit obtained, equipment condition, safety precautions adhered to or not. Check the environment conditions like ambient temperature, weather condition (wind), dew point, relative humidity and steel temperature, IV. Affer blasting: Check for visual appearance, surface roughness, measure profile V, Paint application: Check for atmospheric conditions, substrate temperature, dew point, relative humidity, siripe coat requirement for odd locations, welds, bolts, suts etc, Carry out wet film thickness, dry film thickness readings, adhere strictly to recoating intervals +r painting: Visual inspection of finished coatings. Should be free of suns, sags, drips, dry spray, foreign matter or other paint defects and shall have a uniform appearance. Carry out holiday detection if requiredGeneral painting procedure: 1. Abrasives shall be kept dry and clean, 2. Hypodermic needle gauge should be used to determine blasting pressure, 3. Blotter test shall be carried out to determine the purty of air supply from the compressor. 4. Surface shall be free from detrimental contaminants such as oil or grease. 5. Rough welds and cut offs should be ground to a small radius and all weld spatters shall be removed. 6. Blasting shall be carried out only if the steel temperature is 3 Deg. C above the dew point temperature. 7. Substrate temperature, relative humidity, dew point temperature shall be carried out minimum twice aday 8. Recoating intervals shall be in accordance with the specifications. 9. The maximum size of the paintbrush shall be 125 mm. 7 10. Paints to be sprayed shall be filtered through a 60-mesh screen 11. DFT measurements shall be in accordance with SSPC — PA2 requirements and a calibrated gauge shall be used Paint storage: All paints and thinners shall be stored in well-ventilated buildings. Tarpaulins can be used to cover paints in site conditions upto 14 days Each paint container shall be clearly marked in accordance with 09-SAMSS-060. Paint cans showing signs of leaking shall not be used. Paints that have exceeded the shelf life shal! not be used. Paint preparation: All paints used in a coating system shall be from the same manufacturer. A power stirrer shall be used to mix the paint Paint that gelled shall be discarded, Paint skinning which has formed shall be removed. Contaminated paint cans shall be discarded Paint application Paints shall not be applied if one or more of the following conditions exist unless the paint is formulated for that condition 1. The substrate temperature is less than 10 Deg. C 2. The substrate temperature is less than 3 Deg, C from the dew point temperature 3. The relative humidity is above 85% 4, The substrate is contaminated 5. Adverse weather conditions such as rain, mist or strong winds exist. 6. Ambient temperature, substrate temperature, relative humidity, dew point ~ all these checks should be carried out twice a day or more. 7. Primer, intermediate and topcoats shall be of contrasting colours 8. If more than one application is required to achieve the minimum specified dry film thickness for the primer, intermediate or topcoats then those coats shall also be of the same colour 9. Welds, edges, bolts and rivets shall be stripe coated, 6Einished coating appearance: Finished coating shall be free of runs, sags, drips, dry spray, foreign matter or other paint defects and shall be uniform in appearance. Adhesion shall not be less than that required in the appropriate specifications, ‘Areas that are blistered, cracked, porous or below minimum dry film thickness as give specifications shall be repaired the applicable Repairs: Clean defective area by a suitable solvent. For areas less than 0.1 sq.m grind to a rough metal surface using atleast a 80 grit disc sander. Alternatively sweep blast to bare steel. Feather edge the coating dtleast upto 50 mm beyond bare metal, For areas greater than 0.1 sq.m blast clean to obtain the metal surface to the level of pre-treatment onginaily specified, Feather edge the coating to atleast SO mm beyond the bare metal Remove dust and debris by brush or vacuum, Apply coating by brush for areas less than 0.1 sq.m and by spray method for areas greater than 0.1 sq.m to the original specification requirements except that the first coat of a multi coat system shall be thinned by 15%. ‘The coating shall be holiday tested when fully cured. Any defects shall be repaired and re-inspected, Precautions whilk airless) Gun pressure should be moderate not very high. Gun should be held perpendicular to the surface Distance of the gun from the work should be between 6” and 8” Spray gun should not be weaved or oscillated. Gun and hand movement should be perpendicular and in tandem. Banding: to build up uniform film thickness, paint application for every stroke should overlap the previous one. Check the WET while the area is wet Check the banding / stroking Do not build up very thick coats. While applying second coat, do sanding with emery paper to get good adhesion. This is required to get a key for the next coat. 10, Weld areas / comners/ odd locations shall be stripe coated woaeRe eens ard) SIS = 05 ~ 5900 (Swedish su Blast cleaning preparation grades A~ASa2%, ASa3 B-B Sa 1, BSa2,BSa2%,BSa3 C-C $a 1, C $a 2,C$a2%, C S23 D-D Sal, DSa2,DSa2%4,DSa3 Hand and power tool cleaning: BSi2,BS1 3 Csi2,€813 D812, DSt3