Professional Documents
Culture Documents
1.0 GENERAL
Painting is the most commonly used application for corrosion prevention – both for external
corrosion as well as internal corrosion.
HPCL, Mumbai Refinery has a customized painting specification for all its equipment, piping and
structural. This painting specification is periodically reviewed by Inspection Division of the
Refinery to take care of the latest developments and requirements.
As part of the periodical review of the specification, a study was conducted during Jul-Aug,
2011 to review the existing practices vis-à-vis current industrial practices and to study the
available products with reputed painting manufacturers for more effectiveness and durability of
the painting systems used in the Refinery.
Based on the study findings, a detailed presentation was made in the Refinery weekly PRM
meeting dated 11/08/2011 prior to formal revision of the existing specification.
Basis the study results and the discussions during the presentation in PRM, the following
revised painting specification is being released for implementation at HPCL, Mumbai Refinery.
2.0 SCOPE
This specification is applicable only on metallic surfaces within HPCL, Mumbai Refinery.
Scope of work covered in this specification shall include, but not limited to the following:
1. Surface preparation
2. Selection and application of painting on:
A) Equipment
B) Piping
C) Steel structures
D) Storage Tanks
E) High temperature surfaces (Furnace Casings, Stacks, etc.)
The following surfaces and materials shall not be painted unless otherwise specified by
Inspection through specific recommendation:
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3.0 CODES AND STANDARDS
This specification is prepared basis the following standards. However, the Inspector may
consult other codes and standards, if required.
For all cases, manufacturer guidelines shall be followed. Following restrictions are given as
recommended practices:
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coatingoperations commencing and at least every 4 hours while coating application
is ongoing.
7) Coatings shall not be applied before the surface has been inspected and the
preparatory work approved.
8) All sharp projections shall be ground to minimum 2 mm radius and a thick stripe
coat shall be applied at sharp edges.
A. SURFACE PREPARATION
c. Blast cleaning
2) Mill scale, rust, rust scale and foreign matter shall be removed fully to ensure that a
clean and duty and dry surface is obtained. The minimum acceptable standard in case
of manual or hand tool cleaning shall be St.2 or equivalent, in case of mechanical or
power tool cleaning it shall be St.3 or equivalent, in case of blast cleaning it shall be
Sa2½ or equivalent as per Swedish Standard SIS-055900-1967 / ISO-8501-1-1988.
Where highly corrosive conditions exist, and then blast cleaning shall be Sa3 as per
Swedish Standard.
Remove all other contaminants, oil, grease etc. by use of an aromatic solvent prior to
surface cleaning.
3) Blast cleaning shall not be performed where dust can contaminate surfaces undergoing
such cleaning or during humid weather conditions having humidity exceeding 85%.
4) Irrespective of the method of surface preparation, the first coat of primer must be
applied on dry surface. This should be done immediately and in any case within 4 hours
of cleaning of surface. However, at times of unfavorable weather conditions, the
Engineer-in-charge shall have the liberty to control the time period, at his sole discretion
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and/or to insist on re-cleaning, as may be required, before primer application is taken
up. In general, during unfavorable weather conditions, blasting and painting shall be
avoided as far as practicable.
5) Mechanical or Power tool cleaning: Power tool cleaning shall be done by mechanical
striking tools, chipping hammers, grinding wheels or rotating steel wire-brushes.
Excessive burnish of surface shall be avoided as it can reduce paint adhesion. On
completion of cleaning, the detached rust mill scale etc. shall be removed by clean rags
and/or washed by water or steam and thoroughly dried with compressed air jet before
application of paint.
6) Manual or Hand tool cleaning: Manual or hand tool cleaning is used only where safety
problems limit the application of other surface preparation procedure and hence does
not appear in the specifications of paint systems.
6) Water cleaning: Water blasting shouldbe used for surface preparation method where
water is available in sufficient quantity. The water used shall be inhibited with Sodium
chromate/phosphate.
7) Water mopping: Fresh water mopping (maximum chloride content 50 ppm) shall be
carried out on Salt Water spray areas, before application of primer, to remove the salts
deposited on metal surface. Mopping can be repeated before application of other
coats to remove salts deposited on previous coats, if such deposits are suspected.
B. COATING APPLICATION
1) Surface shall not be coated in rain, wind or in environment where injurious airborne
elements exists, when the Steel surface temperature is less than 5oF above dew point,
when the relative humidity is greater than 85% or when the temperature is below 40oF.
2) Blast cleaned surface shall be coated with one complete application of primer as soon as
practicable but in no case later than 4 hourson the same day.
5) When the successive coat of the same color have been specified, alternate coat shall be
tinted, when practical, sufficiently to produce enough contrast to indicate complete
coverage of the surface. The tinting material shall be compatible with the material and
not detrimental to its service life.
7) Airless spray application shall be in accordance with the following procedure: As per
Steel structure Paint Manual Vol.1 & Vol.2 by SSPC, USA, Airless spray relies on hydraulic
pressure rather than air atomization to produce the desired spray. An Air Compressor
or Electric Motor is used to operate a Pump to produce pressure of 1,000 to 6,000 psi.
Paint is delivered to the Spray Gun at this pressure through a single hose within the Gun,
a single paint stream is divided into separate streams, which are forced through a small
orifice resulting in atomization of paint without the use of air. This results in more rapid
coverage with less overspray. Airless spray usually is faster, cleaner, more economical
and easier to use than conventional air spray.
8) Guidelines for painting Color Bands: Color Bands shall be applied at following locations:
c. Other points such as midway of each piping way, near valves, junction points of
service appliances, walls, and on either side of Pipe Culverts
f. Flow directions shall be indicated by an Arrow in the flow direction. Colors of Arrows
shall be Black or White and in contract to the color on which they are superimposed.
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Above 12” OD 100 mm
1) Painting material shall be procured from HPCL approved Manufacturers as given below:
2) All paint materials shall be accompanied by Manufacturer Test Certificate. All Zinc based
paints shall have minimum 85% ± 5% of metallic Zinc by weight of total solids on dry
film. Glass flake Epoxies shall have minimum 20% ofGlass flake pigments in dry film by
weight of total pigments.
A. Surface preparation
B. Primer application
C. Each coat of paint
5) All defects noticed during stages of inspection, shall be rectified free of cost by the
Contractor. All related records shall be kept by the Contractor.
6) Wet film thickness shall be checked to ensure application of extra coat during wet stage.
7) Dry film thickness shall be taken on each coat after drying and curing of the coat.
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8) DFT Meter used shall be calibrated before each inspection and shall be witnessed by the
Inspector. It is the duty of the Inspector to satisfy himself with the performance of the
DFT Meter.
During the study conducted during July-Aug, 2011, the existing technical specifications were
found to be in line with industry practices.
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HEAT RESISTANT STACK BLACK THREE BRUSH/ROLLER 40 x 3 = 120
(capable of resisting 200oC)
SYSTEM 4: FOR CARBON STEEL MATERIAL FACING SALT WATER SPRAY (UP TO 100oC)
Note: Salt water spray areas will requirefresh water blasting or fresh water mopping prior
to paint application or subsequent coat application to remove salts deposited on the
surface as per 5.A.7. This system shall be applied for surfaces up to 100oC. Beyond
this temperature, surface shall be insulated.
(F-12 Heat resistant Si-Al paint & F-15 Phenolic Epoxy coating)
SYSTEM 6: FOR NEWLY FABRICATED HOT LINES/VESSEL & EQUIPMENT SURFACES WHICH
ARE TO BE INSULATED AND HAVING SURFACE TEMPERATURES UP TO 150oC
HIGH-BUILD TWO-PACK POLYAMIDE CURED EPOXY TWO Airless Spray 2 X 100 = 200
(MID COAT)
SYSTEM 8: FOR PAINTING OF TANK INTERNAL,i.e.Shell, Roof underside, Roof Trusses& Supports,
Bottom, etc.) below 80oC
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TOTAL 1 COAT 400
SYSTEM 11:FOR EXTERNAL SURFACE OF VESSEL, PIPING, AND ALL STRUCTURAL UP TO 90oC
HIGH-BUILD TWO-PACK POLYAMIDE CURED EPOXY (MID TWO BRUSH/ROLLER 125 x 2 =250
COAT)
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TOTAL 4 COATS 158
HIGH-BUILD TWO-PACK POLYAMIDE CURED EPOXY (MID TWO BRUSH/ROLLER 120 x 2 =240
COAT)
TWO-PACK POLYAMIDE & EPOXY RESIN BASED COAL ONE BRUSH/ROLLER 100
TAR EPOXY BLACK (FINISH COAT)
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6. FIRE WATER PORED
B. OTHER EQUIPMENT:
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Note: If any service or equipment class is not mentioned in the above list, then the color code
will be decided by the Inspector in consultation with Field Operations.
Common types of defects that shall be repaired during paint maintenance are:
• Mechanical damage
• Welding damage
• Scaffolding erection damage
• Peel off
• Blistering
• Wrinkle marks
• Adhesion failure
• Discoloration
• Edge separation
• Edge fracture
• Weathering
Any other damage considered serious for performance of the paint system by the
Inspector shall be considered.
Partial or complete removal and repair of damaged section shall be done in consultation
with the Manufacturer.
Within the guarantee period, for any failure/damage of painting system, Paint
Applicator/Manufacturer should carry out repair painting of paint damage area free of
cost.
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It shall be 2-pack Epoxy, pigmented with Al
It shall be a 2-pack PU
It should be re-coatable.
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% of Epoxy Resin by weight in mixed Resin Coal Tar blend shall be
between 35- 45%
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