COE10813, Maintenance Paint and Protective Coating Surveys

Engineering Encyclopedia
Saudi Aramco DeskTop Standards
Maintenance Paint and

Protective Coating Surveys
Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi
Aramco and is intended for the exclusive use of Saudi Aramco’s
employees. Any material contained in this document which is not
already in the public domain may not be copied, reproduced, sold, given,
or disclosed to third parties, or otherwise used in whole, or in part,
without the written permission of the Vice President, Engineering
Services, Saudi Aramco.
Chapter : Paints & Coatings For additional information on this subject, contact
File Reference: COE10813 A.A. Al-Madhlouh on 873-8540
Engineering Encyclopedia Paints & Coatings
Maintenance Paints and Protective Coating Surveys
CONTENTS PAGES
Management Philosophy ...................................................................................................1

Survey Sheets and Methodology..........................................................................2
Who Should Carry Out Surveys and Evaluations?...............................................3
Results of a Maintenance Paint Program ...........................................................................4
Corrosion Occurring at Specific Units ...............................................................................4
Common Problems...............................................................................................5
Alkyd Paint Systems Suitable for Use by Saudi Aramco .....................................5
A Complete Survey - Problem Solving..............................................................................5
Conclusions .......................................................................................................................8
Saudi Aramco DeskTop Standards

Management Philosophy
It is necessary to determine local Saudi Aramco management goals for maintenance painting prior to
undertaking detailed surveys and inspections. In general, refineries and petrochemical plants are painted to
achieve four goals:
• Corrosion Prevention.
• Aesthetics and Appearance.
• Safety and Housekeeping.
• Minimum Environmental Impact.
Of these, corrosion prevention is the predominant goal, but in actual fact, much painting is undertaken for
appearance. As discussed previously, many of Saudi Aramco's facilities are located in dry desert environments
where there would be little significant metal loss (see COE 108.02).
Through the use of planning sessions, Saudi Aramco management has the opportunity to establish their basic
philosophy in advance of an actual survey. This step was reviewed in COE 108.02 in detail. One example
might include philosophy statements such as the following:
• Atmospheric corrosion occurring on units, tanks, or structures shall be prevented.
• The selection of maintenance paint coating systems shall be based on sound economic policies.
• Maintenance painting of all equipment shall be based on the extent of rust film breakdown. [This standard
is often established as being an ASTM D-610 (SSPC-Vis 2) rating of 8 to 6, but at times has been as low as
an ASTM D-610 rating of 4.]
• Safety painting of hand rails, ladders, safety equipment, and signs has a high priority.
• Painting of storage tanks shall be done to reduce losses from hydrocarbon evaporation and minimize
atmospheric contamination.
• Maintenance painting shall not be undertaken as a remedy for dirt accumulation, rust staining, fading,
chalking, color change, or oil or water spills.
• Color dynamics are the responsibility of management, not the survey team.
Saudi Aramco DeskTop Standards 1

It is only after such guidelines are established that a maintenance paint survey can be accomplished. A policy
statement establishes the guidelines set by the plant owner and not by the surveyor. Once these parameters are
established, they should not be changed. For example, a change in policy from emphasizing corrosion
protection to appearance could cause an increase in painting costs.
Survey Sheets and Methodology
Figures 1, 2, and 3, located in the figure sheets, show the data sheets developed for executing maintenance paint
surveys. Figure 1 covers a process or process block area; Figure 2, tankage; and Figure 3, pipe bands. These
data sheets require the surveyor to inspect painted steel surfaces, as well as to evaluate thermal insulation,
fireproofing, concrete, and other nonmetallic physical plant systems. The most difficult of these to survey is the
process block area.
A process block is a complex network of structures, piping, and vessels sometimes as high as a 15 story building
(Figure 4). Operating temperatures range from ambient temperature to ~1000°F. Atmospheric conditions are
usually clean, but may be contaminated with live steam or cooling tower drift. There may also be bare carbon
steel equipment that sweats, because it operates below the atmospheric dew point. A surveyor should learn to
divide the process or process block area into manageable sections that can be painted in an economical fashion.
The surveyor inspects the specific process block areas, usually climbing the structures from top to bottom and
rating individual pieces of equipment, structures, piping, and vessels. At the end of this survey, he compares
his rating to parameters established during the evaluation of painting philosophy and schedules repainting of
the unit.
Upon completing inspection, the surveyor must be able to refer to the painting history of the process unit, pipe,
or tankage. It is only by knowing past performance that an economically effective selection of a repainting
system can be made. The ability to determine a paint system's durability is the key element in effective
maintenance.
Economics are a prime consideration for scheduling maintenance painting. In a well-defined process block area
there usually are equipment, piping, and structures having little or no paint. At some locations, rotating
machinery may be painted, and at others, painting may not be required. When the bulk of the equipment is in
good condition however, the process block is scheduled for repainting at a future date; the rusting equipment
and structures are not scheduled sooner because of economics.

A large storage tank or sphere (Figure 5) is much easier though more physically demanding to survey than
process unit areas. It is inspected by circling it at ground level and establishing an overall performance rating
of the paint film and its degree of breakdown, usually by rusting. The shell rating may vary depending on
exposure and prevailing wind conditions. After shell evaluation, the surveyor climbs the tank and closely
inspects the paint film on the accessible shell. Depending upon local safety regulations, the surveyor may or
may not be able to climb on the tank roof to evaluate its condition. Touch-up of an existing paint system is
seldom if ever recommended. It is extremely important to evaluate the roof and wind girders of a storage tank
since these parts of the tank corrode at a substantial rate due to paint failure caused by water accumulation.
Tankage, roofs, and shells should normally be scheduled for repainting at the same time. Because the roof is
continually exposed to sunlight and often to standing water, paint systems may deteriorate rapidly, and the roof
may require repainting before the shell. Even when completely rusted, piping within the tankage fire banks
should not be repainted separately from the tank for economic reasons.
Evaluation of piping within a refinery or petrochemical plant is accomplished by observing the overall
condition of maintenance paints on above-ground pipe racks or in pipe trenches along roads. Congested
conditions (Figure 6) make it impractical to mobilize a crew to paint selected pipelines. All piping in a specific
pipe rack or trench is scheduled for repainting at the same time. Particular care must be given to sweating
pipelines.
Who Should Carry Out Surveys and Evaluations?
Plant surveys can be conducted a number of ways. The interpretation and evaluation of the results, however,
should always be carried out by trained Saudi Aramco personnel. For example, findings made by Saudi
Aramco onsite inspectors may be incorporated into a survey. Inspectors from paint contractors can be hired and
trained to carry out large refinery, petrochemical plant, or offshore structure inspections. In the case of smaller
plants, corrosion prevention personnel from Dhahran can make evaluations and recommendations for future
action. Experience has shown results have been questionable when "outsiders" have been used to interpret
survey results and plan future action. Trained surveyors are available from the Corrosion Control Division in
Dhahran.

Results of a Maintenance Paint Program
The actual maintenance paint survey can take a few days to well over 30, depending upon the size of the facility
and the composition of the survey team. Surveys have ranged from a one-man effort for a small petrochemical
plant or marketing terminal to a large program involving a number of surveyors at a refinery with a
maintenance paint budget of one to two million dollars per year. A major benefit of these surveys is a
structured maintenance paint schedule.
The scheduled painting of units, piping, and tankage is based upon an order of priority determined by the owner
and established by his maintenance paint philosophy. The paint program can be scheduled as far as ten years in
advance. A detailed survey should be repeated every year and not more than every three years in order to
accomplish the following:
• Confirmation or reordering of the existing painting schedule priorities for the next few years.
• Review the existing plan and its quality and results.
• Determination of the success of newly instituted maintenance paint management techniques.
• Update the technology base for dealing with severe corrosion problems.
An excerpt from a refinery maintenance paint schedule is shown in Figure 7.
Corrosion Occurring at Specific Units
As stated previously, atmospheric corrosion in many facilities is usually not a determining factor. In certain
plants, however, microclimates, usually man-made, can cause rapid failure of oil or alkyd-based paint systems.
A partial listing of these conditions includes:
• Salt water piers or structures.

• Sulfur plants.
• Amine treating units.
• Equipment downwind of cooling towers.
• Cold, sweating insulation.
• Chemical treating units.
• Water treatment plants.
• Waste water treatment facilities.
• Alkylation units.
• Coking units.
• Wet gas scrubbing units.
• Sweating pipelines.

Where these situations exist, paint systems must be designed to withstand the corrosive environment. In the case of
cooling tower drift, for example, whether dealing with fresh or salt water, an inorganic, zinc-rich coating can be
specified. In a sulfur plant location, however, a chemically resistant epoxy coating system resistant to SO 2 and SO3
should be specified.
Common Problems
There are two recurring problems encountered with maintenance paint surveys: lack of direct program
management and incomplete records. Based on past experience, a single individual should be made responsible
for total program administration and execution, with management's support in seeking the stated objective. The
second recommendation is that this individual also be responsible for maintaining all painting activity records.
The most important section on the paint survey sheet is the box entitled "Painting History". If a painting
history does not exist, or if it is ignored, future maintenance paint systems recommendations may be less cost
effective. Maintenance paint records in many locations are incomplete or depend on the memory of
individuals, which is often inaccurate.
Alkyd Paint Systems Suitable for Use by Saudi Aramco
In most locations, alkyd maintenance paint systems are considered the most cost effective choice for general
use for a number of reasons, including service life. Composite performance curves for process units and
tankage at two different locations are shown in Figures 8 and 9. As previously stated, owners in nearly all
locations base repainting needs on the degree of rusting and film breakdown as evaluated by ASTM D-610.
The two curves show equipment and tankage evaluated using this criteria. These plants are located in highly
industrialized atmospheric environments, experiencing rain of 40-50 in. per year and 70-80% annual average
relative humidity. It is reasonable to expect alkyd paint systems to be the system of choice in the Kingdom,
especially in desert areas where the "Time-of-Wetness" would be appreciably lower than the example above. In
both locations, alkyd paint systems have proven highly cost effective.
A Complete Survey - Problem Solving
A complete refinery or petrochemical plant survey considers not only paints, coatings, and linings, but other
areas of corrosion prevention and abatement as well. Examples of these are discussed below:
• Improved Contractor Performance - Frequently the surveyor is called upon to evaluate contractor
performance. During surveys it may be necessary to recommend changes in abrasive, different
application techniques, use of QA/QC techniques, and with approval, complete shutdown where the
contractor's performance could be improved only by major changes in equipment or performance.

• Coatings on Nonmetallic Surfaces - In refineries and petrochemical plants, organic coatings and linings are
frequently applied to nonmetallic substrates. The surveyor must be able to recommend remedial action for
coating failure. Figure 10 shows the failure of a polyurethane foam overcoated with a synthetic elastomeric
coating. This system had been applied to a large, heated storage tank. In order to preserve the insulating
foam plastic and to prevent corrosion under the insulation, the external barrier coating system must be
maintained. The surveyor must be able to evaluate its condition, and recommend the correct surface
preparation and maintenance paint system.
Figure 11 shows the failure of a fiber reinforced plastic lining in a below-grade, reinforced concrete water
neutralization sump. In this particular application, the water is extremely aggressive and the concrete is
suffering severe degradation. It must be repaired prior to relining the sump. The type of fiber glass-
reinforced polyester (FRP) lining used was specified in error and had to be replaced with a more
chemically resistant FRP lining material.
• Under Insulation Corrosion and Fireproofing - Of great concern to Saudi Aramco and within the
petroleum/petrochemical industry in general is corrosion that occurs under concrete fireproofing and
thermal insulation. When this condition is encountered, the surveyor must be able to develop
recommendations and remedial measures. One example is shown in Figure 12. In this instance, the
concrete fireproofing had to be removed from the structural steel, which was then abrasive blasted and
coated with a phenolic epoxy coating. Coating of the concrete was recommended for the new concrete
fireproofing to prevent water penetration and subsequent deterioration.
• Equipment Rust Staining - At one refinery, newly applied maintenance paint rapidly deteriorated due to
rust staining that occurred almost immediately after painting. There were two reasons for this. The paint
contractor painted only the underside of the steel platform plate used at each level of the process unit
structure so that when it rained, water on the bare rusted top of the plate cascaded down the unit, staining
it badly. The galvanized weather jacketing for the thermal insulation systems on a vacuum tower had
completely rusted (see Figure 13). Rainwater washed down this tower and carried with it sufficient rust
to stain painted equipment and structures.
• Corroded Safety Valve Springs - In another location safety valve springs were corroding badly because
of door casing design. Rainwater and airborne debris were able to enter the case and surround the
horizontal coil spring. The recommended solution was that the case be internally cleaned of debris and
scale and then filled with a petrolatum-based rust preventive heavily pigmented with zinc dust. In
addition, more drain holes were recommended for the six o'clock position of the spring case to allow
rainwater to drain more rapidly.

• Cone Roof Tanks - During an evaluation of paint systems applied to cone roof tanks, it was found that
rain shields had been erected around the perimeter of the tank roofs (Figure 14). Rainwater collection
has caused complete immersion of that portion of the roof adjacent to the shield, as shown in Figure 14.
It was recommended that the rain shields be taken down.
• Lifting and Delamination - Lifting and delamination of coatings is the most frequently encountered type
of paint failure after rust breakdown and is seen frequently within Saudi Aramco facilities; examples are
shown in Figures 15 and 16. The first shows massive cracking and lifting of white tank paint applied
over what apparently is an inorganic zinc-rich coating. The second is on a rather small vertical pressure
vessel in a process block area. The suspected reason for failure in this particular case was the use of a
synthetic resin, red lead primer under an oil-based topcoat. Most cracking, lifting, and delamination is
caused by primer incompatibility, over-curing of catalyzed primers, or the topcoat lifting from inorganic
zinc-rich primers.
• Piers, Decks, and Buoys - Often during maintenance paint surveys, engineers are called upon to make
recommendations for new pile coatings, to repair systems for marine pilings, and to improve the
efficiency of cathodic protection systems in minimizing underwater corrosion. Replacement coatings for
pilings above and below the water can take many forms. Figure 17 shows an FRP jacket, petrolatum
based system used to repair coal tar epoxy coatings over steel piling. After ten years of service, the
system has deteriorated. These FRP jacket systems are proving to be economical and have, in specific
locations, saved up to 50 percent of the cost of other forms of protection, such as epoxy cladding or
Monel jacketing. Splash zone coatings require extensive surface preparation and are difficult to apply
correctly.
• Inorganic Zinc-Rich Coating Maintenance - A single coat of an inorganic zinc-rich system has been used
to protect an entire refinery located in extremely corrosive atmospheric conditions. It has done an
excellent job for over 15 years as shown in Figure 18. Another IZRC was used to repair the original
system. This repair is now 5-6 years old. An inorganic zinc-rich coating was specified in this location
because three-coat alkyd paints broke down completely in approximately two to three years.
• Temperature Indicating (T.I.) Paint - Silicone-acrylic T.I. paint is designed for use as a process indicator,
rather than for corrosion prevention or aesthetics. It turns from blue to white when the shell of a carbon
steel vessel overheats because of a failure in its refractory lining or an upset process. This is shown in
Figure 19. When it turns white, it must be repaired. This usually is done when the system is on-stream
and at temperature. The paint is reduced with 50% solvent and spray applied.
• Corrosion at Pipe Supports - This is a common problem worldwide. One method of preventing such
corrosion is by bonding a wear pad with an epoxy adhesive to the pipeline. This is pictured in Figure 20.

Conclusions
There are a number of conclusions that can be made concerning maintenance painting and maintenance paint
surveys in Saudi Aramco facilities:
• Prior to a refinery or petrochemical plant survey, a statement concerning maintenance painting policy
reflecting the management goals must be prepared.
• The survey should be performed or supervised by Saudi Aramco. Outside evaluations of painting
histories or performance should not be relied upon. Past painting records are critical to the success of the
survey.
• After the survey, a detailed schedule of units to be painted should be prepared. Specific units or
structures located in a corrosive atmosphere should be identified. Paint systems should be developed for
use in each area.
• Additional surveys should be undertaken after the initial survey to set additional painting priorities and to
determine the success of the first survey.
• There should be one person in each plant responsible for the management and execution of the paint
program.
• During the survey, the surveyor should be prepared to resolve questions concerning materials and
corrosion prevention in all areas.
The implementation of these guidelines can provide beneficial cost effective results, not only in maintenance
painting, but in cost management and critical corrosion prevention.

Figure 1. Data Sheet - Paints/Protective Coatings - Process Block Area.

Figure 2. Data Sheet - Paints/Protective Coatings - Tankage.

Figure 3. Data Sheet - Paints/Protective Coatings - Pipe Bands.

Figure 4. A Typical Petroleum Refining Process Complex. In order to undertake a

maintenance paint survey, it is necessary to reduce it to its component parts. This facilitates
needed repainting.
Figure 5. Large Storage Tank Requirements. Large storage tanks require surveys of the
shell, roof, attachments, and surrounding piping. Corrosion occurs most rapidly on roofs
and wind girders requiring special attention to those areas.

Figure 6. Offsite Piping. Offsite piping usually is not painted as regularly as process units
or tankage. For this reason, corrosion frequently occurs at pipe supports, under insulation,
and on sweating pipelines. The surveyor must be particularly aware of these critical
situations.
Tankage 8 Shells Only

4 Complete Tanks
2 Roofs Only
Process 2 Chemical Treating

2 Water Treatment Cooling
Tower Areas
2 Process Units
2 Utility Areas
Piping Various
Figure 7. Maintenance Plant Survey - First Year Schedule.

Years of Service
Figure 8. Process Units - Maintenance Painting. Alkyd maintenance paint systems

applied to process units. Since painting occurs after an ASTM rust breakdown evaluation
of 6-8, the average life of such a system would be about 10 years.

Figure 9. Tankage Maintenance Painting. Alkyd maintenance paint systems can easily
be applied to tankage because of their simpler structure.

Figure 10. Large Heated Storage Tank Insulated with Polyurethane Foam with an
Elastomer Topcoat. The topcoat must be repaired to avoid deterioration of the
polyurethane and possibly severe corrosion of the tank.
Figure 11. Failed FRP Lining. A failed FRP lining. It was applied to a below-grade
water neutralization sump constructed from reinforced concrete.

Figure 12. Concrete Fireproofing. A fireproof concrete coating applied to the supporting
structure of an insulated condenser. Corrosion is occurring under the concrete making
removal necessary.
Figure 13. Rusted Galvanized Coating. A galvanized coating completely rusted when
used as a weather jacket over thermal insulation applied to a vacuum tower. Rust carried by
rainwater completely stained the newly painted equipment.

Figure 14. Rain Shields. Rain shields erected around the perimeter of a cone roof tank
allows rainwater to collect causing rapid paint failure and corrosion to occur. This is clearly
shown at the tank roof perimeter.
Figure 15. Lifting Topcoat. Topcoat lifting from an IZRC primer, probably due to
incompatibility.

Figure 16. Topcoat Peeling on a Drum. Topcoat peeling on a drum. This is due to either
overcuring of the primecoat or incompatibility between the coats.

Figure 17. Plastic Jacket/Petrolatum Tape System. Plastic jacket/ Petrolatum tape
system applied to dock piling as a maintenance coating to prevent marine splash zone
corrosion.
Figure 18. 15 Year Old Single-Coat System. After 15 years of service, a single-coat
system or water-based, self-cured IZRC is in need of repair. The tank was repainted with
another coat of the same material. The recoated tank has been protected for a number of
years from corrosion.

Figure 19. Temperature Indicating Paint. A blue temperature indicating paint turned
white at a vessel mid-section indicating overheating. It must be repaired after the tower's
internals are inspected for damage.

Figure 20. Wear Pads. Because of corrosion at pipe supports, wear pads bonded to the
pipeline are recommended. This wear pad was approximately 10 years old when this
photograph was taken.

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Engineering Encyclopedia

Saudi Aramco DeskTop Standards

Maintenance Paint and

Management Philosophy ...................................................................................................1

Saudi Aramco DeskTop Standards

• Aesthetics and Appearance.

• Safety and Housekeeping.

• Minimum Environmental Impact.

• Atmospheric corrosion occurring on units, tanks, or structures shall be prevented.

Saudi Aramco DeskTop Standards 1

Survey Sheets and Methodology

Saudi Aramco DeskTop Standards 2

Who Should Carry Out Surveys and Evaluations?

Saudi Aramco DeskTop Standards 3

Results of a Maintenance Paint Program

• Review the existing plan and its quality and results.

• Determination of the success of newly instituted maintenance paint management techniques.

An excerpt from a refinery maintenance paint schedule is shown in Figure 7.

Corrosion Occurring at Specific Units

• Salt water piers or structures.

Saudi Aramco DeskTop Standards 4

Alkyd Paint Systems Suitable for Use by Saudi Aramco

A Complete Survey - Problem Solving

Saudi Aramco DeskTop Standards 5

Saudi Aramco DeskTop Standards 6

Saudi Aramco DeskTop Standards 7

Saudi Aramco DeskTop Standards 8

Figure 1. Data Sheet - Paints/Protective Coatings - Process Block Area.

Saudi Aramco DeskTop Standards 9

Figure 2. Data Sheet - Paints/Protective Coatings - Tankage.

Saudi Aramco DeskTop Standards 10

Figure 3. Data Sheet - Paints/Protective Coatings - Pipe Bands.

Saudi Aramco DeskTop Standards 11

Figure 4. A Typical Petroleum Refining Process Complex. In order to undertake a

Saudi Aramco DeskTop Standards 12

Tankage 8 Shells Only

Process 2 Chemical Treating

Figure 7. Maintenance Plant Survey - First Year Schedule.

Saudi Aramco DeskTop Standards 13

Figure 8. Process Units - Maintenance Painting. Alkyd maintenance paint systems

Saudi Aramco DeskTop Standards 14

Saudi Aramco DeskTop Standards 15

Saudi Aramco DeskTop Standards 16

Saudi Aramco DeskTop Standards 17

Saudi Aramco DeskTop Standards 18

Saudi Aramco DeskTop Standards 19

Saudi Aramco DeskTop Standards 20

Saudi Aramco DeskTop Standards 21

Saudi Aramco DeskTop Standards 22

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