IMS

Doc Name: SOP for Metal spray coating

Doc Code : IMS / BM-I / DP-05

Issue No: 01 , Rev0 Date:

SURFACE PREPARATION AND HVOF COATING PROCEDURE FOR BOILER TUBE COATING

1. SCOPE:
This procedure is for surface preparation and HVOF (High Velocity Oxy Fuel) coating for
prevention of Erosion and corrosion on boiler tube.

2. FEED STOCK:
Feed stock shall be in form of Chromium carbide based powder (Cr2C3+ 25 NiCr).
Recommended Powder Manufacturer: FUJIMI INCORPORATED- JAPAN or H C Starck –
Germany

Chemical Composition (Weight %)

C Ni Fe Cr
9.2 to 18 to 22 0.3 Max Balance
10.8

3. PRE – INSPECTION:
Pre inspection of the Tube shall be carried out by ATS & CUSTOMER.
If any major defect is found on area which is to be coated, ATS will inform to rectify the
same. Surface irregularities such as rough weld capping, slag, buckshot, burs, undercuts or
sharp non radius edges should be repaired by CUSTOMER prior to abrasive blasting and
coating.

4. WORKMEN SAFETY:
4.1 Operator shall be provided with forced air respirators (Coating Helmet with air
connection) so that dust is not inhaled during coating.
4.2 Dark goggles to be worn during coating for protection of eyes from UV ray damage.
4.3 Ear plugs should be worn during coating and blasting to protect from Noise.
4.4 Proper clothing to be used which is resistant to fire.(Boiler Suit)
4.5 Blasting work should be carried out by wearing a blasting hood with suitable
arrangement for forced air inlet for Breathing.
4.6 All Safety PPE’S to be worn during the Thermal spray application.

5. WORK PLACE:

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 IMS
Doc Name: SOP for Metal spray coating

Doc Code : IMS / BM-I / DP-05

Issue No: 01 , Rev0 Date:

5.1 Blasting and coating work should be carried out in a closed area with proper
arrangement for extraction of dust and fumes created during blasting and coating.
5.2 The place should have proper illumination. Localized halogens can be used by blaster
and operator if required.
5.3 Blasting and coating work cannot be carried on if Humidity level rises above 85%. No
blasting and coating work to be done when it is raining.
5.4 Environment conditions can be controlled with the deployment of Dehumidifiers to
lower the humidity and increase the holding time between blasting and coating.
5.5 Proper access to the job should be provided by means of scaffolding so that the surface
to be coated is easily accessible. Scaffolding should be safe and inspected so that workers
can move easily.

6. MASKING:
Uncoated portion shall be masked by masking tape.

7. CLEANING PRIOR TO BLASTING:

7.1 Prior to abrasive blasting all the surfaces have to be decontaminated to remove
hydrocarbon and fabrication residues, by using cleaning media.
7.2 Visible oil and grease contaminated surface shall be solvent cleaned prior to abrasive
blast cleaning.
7.3 Surface irregularities such as rough weld capping, slag, buckshot, burs, or sharp non
radius edges to be repaired prior to abrasive blasting. If any of these are rediscovered after
blasting they shall be removed and blasting of only those areas to be done again.

8. BLAST CLEANING:
8.1 Blasting to be carried out with air pressure 6 to 7 Kg.
8.2 The abrasives shall be free from oil, grease, moisture, chloride contamination, etc.
Blasting abrasive can be Aluminum Oxide of Mesh size of G 16, G 24 .
8.3 Compressed Air shall be free from absence of oil and contaminants. The air discharge
temperature shall not increase 1000C.
8.4 Blast cleaning shall not be performed when the surface to be blasted is less than 30C
above dew point temperature or when relative humidity in the vicinity of work is greater
than 85%.

9. INSPECTION OF BLAST CLEANED SURFACE:

9.1 Visual inspection should be carried out and surface roughness to be checked by Surface
roughness meter. If on any localized area, roughness found is less than 10 microns Ra then
blasting should be carried out on the area.

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 IMS
Doc Name: SOP for Metal spray coating

Doc Code : IMS / BM-I / DP-05

Issue No: 01 , Rev0 Date:

9.2 Blasted surface profile should be more than 60 microns.

9.3 Interval between blasting and application of first coat of Thermal Spray coating should
not exceed more than 4 hours. (If humidity level is less than 60%, 6 hrs. holding time is
permitted)
9.4 In low-humidity environments or in controlled environments with enclosed structures
using industrial dehumidification equipment, it may be possible to retard the oxidation of
the steel and hold the surface finish for more than six hours

10. THERMAL SPRAY COATING:

10.1 Coating work should start only after obtaining clearance for the blasted area and within
4 hours after blasting.
10.2 Thickness of each crossing pass shall be kept at minimum so that the thermal stresses
are reduced.
10.3 Gun distance from surface shall be in the range of 6 to 8 inches.
10.4 HVOF technique will be used for carrying out this Job.
10.5 The required thickness will be achieved in multiple passes.
10.6 Coating thickness should be measured by stage inspection by Digital thickness gauge.
10.7 Coating thickness shall be achieved between 250 to 350 microns.
10.8 Oxygen, nitrogen and petroleum gas (LPG/Propane) are required to run an HVOF
system.
10.9 As per the procedure or requirement, test samples will be coated at same time within
same conditions as the HVOF Coating.

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