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Bader Al Mulla & Bros. Co. W.L.L. Trading & Manufacturing Group DOC. NO.: BMB/ PRO/9/PT-213 Rev.01

SURFACE PREPARATION AND PAINTING PROCEDURE

1.0 PURPOSE This procedure establishes the minimum requirement for the surface preparation, coating application for shop fabricated Pressure Vessels and Inspection of painted / coated surface of the same (Internal & External) 2.0 SCOPE This Specification is applicable for Surface Preparation and Painting / Coating of Knock Out Drum manufacturing for Action Consultancy Bureau and the end user is Joint Operations, Wafra, Kuwait. 3.0 REFERENCE 3.1) 3.2) 3.3) 3.4) 3.5)

Approved Drawings Hempel data sheets. JO Specification: JOS-02-05 Rev.0 JO Specification: JO-MP932-V-113 Rev.B KOC-P-001 Rev.3

3.6) 3.7) 3.8) 3.9) 3.10) 3.11)

BMB QAP for Coating Inspection No. QP-30014442-002 SSPC-SP6 Near White Blast Cleaning. ISO 8501-1 – Visual assessment of surface cleanliness. ISO 8502-6 – Extraction of soluble contaminants for analysis — The Bresle method ISO 8502-9 - Field method for the conductometric determination of water- soluble salts NACE RP 0188 – Discontinuity (Holiday) Testing of New Protective Coating on Conductive Substrates.

4.0 RESPONSIBILITY:

4.1)

Qualified or Experienced personnel shall be arranged for painting / coating.

4.2)

Production Manager is responsible for adherence to the requirements set out in the fore going procedure.

4.3)

Quality Control Inspector is responsible to ensure that all procedure requirements have been complied with.

5.0 EQUIPEMENTS / INSTRUMENTS 5.1) 5.2) 5.3)

Complete Shot Blasting System with de-moisturizers & Oil filters Airless Spray Painting System DFT Gauge

5.4) 5.6) 5.7)

WET Gauge Dew Point meter Pin hole detector

6.0 GENERAL REQUIREMENTS 6.1.1) The blasting shall be carried out after completion of Pressure Tests and complete draining of water. 6.1.2) Surface to be painted shall be inspected and approved by QC inspector prior to each coating being applied. Prior to commencement of blasting all the surfaces that could be damaged by the abrasive material including flange serrated faces and other machined areas shall be adequately protected against mechanical damage. 6.1.3) The surface preparation and application of paint system shall be conducted only by trained or experienced operators/

operators. 6.1.4) Blasting and Painting shall not be carried out i) when the relative humidity is (RH) 85% or higher ii) when the air temperature is below 5°C 6.1.5) The metal surface shall be dry, clean and the metal temperature shall be at least 3°C above the dew point. 6.1.6) Blasting and Painting shall not be carried out under adverse weather conditions, e.g.Rain, fog, sandstorm, high wind velocity (56 km/hr. or higher), high ambient temperature (>50°C) or when such conditions are likely to occur prior to completion of the work.

6.1.7) The manufacturer instructions regarding over coating time intervals between coats shall be strictly observed.

7.0 BLASTING PROCEDURE: Revision No: 01

Date: 08-04-2015

Page 1 of 6

Bader Al Mulla & Bros. Co. W.L.L. Trading & Manufacturing Group DOC. NO.: BMB/ PRO/9/PT-213 Rev.01 7.1)

7.2)

SURFACE PREPARATION AND PAINTING PROCEDURE

Abrasive material shall meet the requirements of sub-clauses of 8.5 of KOC-P-001 Rev.3. and JO Spec. No. JOS-02-05 Rev.0

Abrasive material shall be Garnet or Grit or Shots.

7.3) All abrasive material shall be kept dry and covered when not in use. 7.4)

Neither sand nor contaminated recycled abrasive shall be used under any circumstances for blasting.

7.5) Pre cleaning: a) All surface imperfections such as weld spatters, slags, sharp subjects etc., shall be removed by wire brushing, cosmetic grinding or filling as applicable prior to blasting. b) Oil and grease shall be removed by solvent cleaning in accordance with SSPC-SP1 or high pressure washing or detergent cleaning. The washed surface shall be dry and free from trace contaminants. 7.6)

All external and internal surfaces of Knock Out Drum shall be blasted to specification SA 2 ½ near white metal. The surface profile shall comply with the requirement of relevant data sheet.

7.7)

Operating pressure for shot blasting will be 100 psi. Shots shall be covered properly and it shall be free from contamination.

7.8) Laps like surface defects and other surface defects revealed by blast cleaning shall be dressed and shall be re blasted. 7.9) All blasting equipments shall be fitted with efficient oil and water traps. Dead man mandle shall be fixed as close as practical to the blast nozzle. Blasting equipment, hose and nozzle to be earthed. 7.10) All surfaces shall be inspected for contamination free test prior to any coating. 8.0 STORAGE OF PAINTS: 8.1)

All painting materials shall be stored in sealed dry area container under cover in accordance with safety regulations and as per manufactures recommendations in the painting area. The paint shall be protected from direct sun

light, open flames. If required paint materials shall be stored in air conditioned room. 8.2) The paint materials shall be in their original sealed containers, with manufacturers labels, with batch nos, date of manufacturer and date of expiry. 8.3) Stock of paints and thinners shall be related regarding to ensure that only fresh materials are issued. The paint materials, first in shall be first out. 9.0 PAINTING PROCEDURE: 9.1 GENERAL REQUIREMENTS

9.1.1) Clean paint nettles shall be used at all times. The use of miscellaneous tins shall not be permitted. 9.1.2) All remnant abrasives shall be removed from surface by air before priming. 9.1.3) Application of all paints shall be spray technique and roller or brush for critical areas and fittings unless otherwise specified. The coating material shall be mixed and applied in accordance with manufacture’s data sheets. 9.1.4) Each coat shall be free from pin holes, blisters detrimental runs, sags inadequate film build & foreign inclusions. Painting shall be done as per coating schedule to the required thickness as mentioned in this procedure. 9.1.5) All painting appliances shall be cleaned simultaneously after use with cleaner recommended by painting manufacturer. 9.1.6) Painting material shall be procured from Hempel or other equivalent manufacturers. Data sheets of proposed paints from the manufactures shall be submitted to the Client for their review. 9.1.7) All bevelled edges ( if any) to be covered with masking tape of 4 inch wide before application of primer.

Revision No: 01

Date: 08-04-2015

Page 2 of 6

Bader Al Mulla & Bros. Co. W.L.L. Trading & Manufacturing Group DOC. NO.: BMB/ PRO/9/PT-213 Rev.01

SURFACE PREPARATION AND PAINTING PROCEDURE

9.2 PRIMER 9.2.1) The blasted surfaces shall be cleaned before priming by higher-pressure air. All the surfaces shall be visually inspected and approved by QC Inspector prior to the primer being applied.

9.2.2) No abrasive blasting operation shall be carried out to the detriment of painting work in progress or freshly applied coating which has not dried thoroughly. 9.2.3) Blasted surface shall be coated within four hours to avoid oxidation/flash running. The primer paint shall be thoroughly stirred to a homogeneous state using mechanical means. Apply paint up to but not within four inches of joints to be field welded (if any).

9.2.4) Paint that exceeds its pot life shall not be used and shall be discarded. When thinning is required in order to achieve the correct viscosity of the paint, only thinners recommended by manufacturer’s shall be used. 9.2.5) At welds and at intricate locations, painting shall be patted on with the side of brush to ensure that a full coating is obtained. 9.2.6) After drying the inspection has been carried out. Surface texture shall be visually examined for defects like sagging, runs, missing, over sprays, foreign contamination, air pockets, drips, pin holes and the DFT shall be measured and recorded. 9.3) INTERMEDIATE COAT:

9.3.1) In multi coating painting system, all intermediate coats will be of contrasting colour to differentiate between coats. 9.3.2) Check the primer coat drying time and recoating interval as per data sheet. 9.3.3) The intermediate coat shall be applied after cleaning the primer coated surface thoroughly. The cleaning shall be done as per the method specified in the paint manufacturer data sheets.

9.3.4)

WFT measurement shall be in accordance to ASTM D1212. Frequent monitoring of WFT will be carried out during application of the paint to maintain the required DFT. DFT measurement shall be made with magnetic thickness gauge after proper drying of each coat and tolerance as per SSPC Pa2.

9.3.5) After drying the inspection has been carried out. Surface texture shall be visually examined for defects like sagging, runs, missing, over sprays, foreign contamination, air pockets, drips, pin holes and the DFT shall be measured and recorded. 9.4) TOP COAT: 9.4.1)

Check the intermediate coat drying time and recoating interval as per data sheet.

9.4.2)

Wet rub the previous coating with fine emery paper and flush with fresh water to remove all loose dust, flake etc, before applying topcoat.

9.4.3)

Apply subsequent coat and topcoat by airless spray to achieve dry film thickness as specified.

9.4.4)

If brushes are to be used the brush shall be of good quality and not more than 100 mm wide.

9.4.5)

After painting the equipment can placed at good environment so that any dust or dirt particles shall not stick on the top paint coat.

9.4.6)

The final colour of the paint coat shall be as per the schedule mentioned in this procedure.

9.4.7) After drying the inspection has been carried out. Surface texture shall be visually examined for defects like sagging, runs, missing, over sprays, foreign contamination, air pockets, drips, pin holes and the DFT shall be measured and recorded. 9.4.8) The internal coated surface of the air receiver shall be 100% pinhole free when tested using a pinhole tester. ( Wet sponge tester).

10.0) REPAIR PROCEDURE 10.1) When the coating is damaged but the metal substrate is not exposed, the damaged areas of paintwork shall be gently abraded back to the sound coating using emery paper and then gently wiped with a suitable solvent or by air.

Revision No: 01

Date: 08-04-2015

Page 3 of 6

Bader Al Mulla & Bros. Co. W.L.L. Trading & Manufacturing Group DOC. NO.: BMB/ PRO/9/PT-213 Rev.01

11.0

SURFACE PREPARATION AND PAINTING PROCEDURE

10.2)

When the coating is damaged back to the base metal such that areas of the metal Substrates are exposed, the metal shall be cleaned to the original specified standard prior to repainting it. For cleaning small power tools may be used and then gently wiped with a suitable solvent or by air.

10.3)

The periphery of the repair areas shall be feathered back for a distance of 25 mm into the adjacent undamaged coating by light abrasion.

10.4)

The same painting procedure which was followed for original painting shall be followed for repair painting.

INSPECTION AND TESTING 11.1)

Inspection and testing shall be conducted as per JO approved Quality Activity Plan (for Coating Inspection).

11.2)

The personnel involved in the Surface Preparation and painting shall be qualified as per KOC specification KOC-P-006 Rev.1

11.3)

All the blasting and painting materials shall meet the requirements of this procedure. The materials, relevant data sheets, batch certificates shall be offered to JO prior to start of blasting and coating application.

11.4)

The inspection and testing equipments such as Surface Profile Gauges, DFT Gauges, Pin hole Detectors, and Instruments to monitor ambient conditions shall be calibrated by external agencies and the certificates shall be kept ready for JO inspection.

11.5)

Prior to start of blasting/coating, during blasting / coating and upon completion of blasting/coating the environmental conditions such as ambient temperature, metal surface temperature and relative humidity (RH) shall be measured and recorded at every three hour intervals.

11.6)

After blasting the metal surface shall be checked visually to meet the requirements of the relevant standards mentioned in this procedure to ensure the absence of all types of imperfections and contaminants.

11.7)

On dry blast cleaned surfaces the profile height shall be spot checked by using TESTEX PRESS-OFILM & measurement shall be recorded on report.

11.8)

When agreed with KOC through Quality Activity Plan, Chloride test shall be carried out as per ISO 8502-6 & 9 on the blast cleaned surfaces and the chloride level shall never be more than 10µgm/cm2 for external surfaces and shall never be more than 5µgm/cm2 for internal surfaces. The acceptance value shall remain same unless a lesser value is recommended by the coating manufacturer.

11.9)

The blasted surfaces shall be free from dust and contaminants.

11.10)

All painted surfaces shall be visually inspected to ensure the absence of skips, overspray, sags, foreign particles contamination, air pockets, drip, holidays or any other paint defects.

11.11)

The DFT of each coating shall be measured at random and shall be recorded. There shall be at least one area each for horizontal, vertical and curved surfaces.

11.12)

The gauges shall be verified against the standard strips prior to any measurement, at once a hour if continuously measuring, at insides of angles and at points nearer than 15 mm from an edge.

11.13)

Internal coating additional requirements: a) If the thickness of internal coating found excess than the requirement then the paint shall be rub down to 10% minimum of required level. The dust shall be cleared by vacuum or air blow and shall be recoated as per this procedure. b) A thin film of epoxy coating [100 microns maximum] shall be applied at the nozzle edge extending on to the flange face. d) Repair shall be attended as per Clause 10.0 of this procedure and the total repair area shall not be more than 10%. c) Internal coated surfaces shall be holiday tested before final clearance. Holiday testing shall be done by using the wet sponge method by Pin Hole Detector with test voltage of 67.5 V minimum. No pinholes are accepted. Repaired area also be holiday tested after proper repair work has been carried out.

Revision No: 01

Date: 08-04-2015

Page 4 of 6

Bader Al Mulla & Bros. Co. W.L.L. Trading & Manufacturing Group DOC. NO.: BMB/ PRO/9/PT-213 Rev.01

SURFACE PREPARATION AND PAINTING PROCEDURE

11.14)

The words “STRESS RELIEVED VESSEL, NO WELDING ALLOWED” shall be marked on the Vessel shell in 100 mm high min. x 40 mm width letters.

11.15)

The words “INTERNALLY PHENOLIC EPOXY COATED” shall also be marked on the Vessel Shell in 50 mm high min. x 40 mm width min. letters.

12.0 SURFACE PREPARATION AND PAINTING SCHEDULE Paint Manufacturer: HEMPEL PAINTS.

12.1 SURFACE PREPARATION PAINTING SYSTEM

12.1.1 EXTERNAL SURFACE (As per coating system A1-1 Appendix 3, of KOC-P-001 Rev.3) SURFACE PREPARATION: METHOD

MATERIAL Steel

Blasting

Grit/shot

or

both,

Garnet

SURFACE ROUGHNESS VALUE

FINISH

35 microns

SA 2 1/2

PAINTING SYSTEM:

COAT

TYPE

PAINT DESCRIPTION

DFT

Under Coat

ZINC Rich Epoxy Primer

Hempadur Pro Zinc 17380- 10830

70 µ

Intermedia te Coat

High Build MIO Epoxy

Hempadur Mastic 45880 – 12430

125 µ

Top Coat

Polyuretha ne

Hempathane Top Coat 55210

50 µ

SHADE

Grey Mio Grey (Or) Reddish Grey Pure White RAL 9010

Total DFT range:

DRY TO TOUCH 1 hour minimu m at 20°C 6 hours at 20°C (or) 3 hours at 40°C 8 hours at 20°C (or) 4 hours at 40°C

OVER COAT INTERVAL (min.)

OVER COAT INTERVAL (max.)

POT LIFE

2 hours at 20°C

15 days at 40°C

---

7 hours at 20°C (or) 4 hours at 40°C

Extended to any time

6 hours at 20°C (or) 3 hours at 40°C

None

1 hour at 20°C (or) 1 1/2 hours at 30°C ---

Min 245 µ

12.1.2 INTERNAL SURFACE (As per JO Specification No: JOS-02-05 Rev.0)

SURFACE PREPARATION:

METHOD Blasting

Revision No: 01

MATERIAL Steel Grit/shot

or

Garnet

Date: 08-04-2015

both,

SURFACE ROUGHNESS VALUE

FINISH

60 to 100 microns

SA 2 1/2

Page 5 of 6

Bader Al Mulla & Bros. Co. W.L.L. Trading & Manufacturing Group DOC. NO.: BMB/ PRO/9/PT-213 Rev.01

SURFACE PREPARATION AND PAINTING PROCEDURE

PAINTING SYSTEM:

COAT

TYPE

Under Coat

Phenolic epoxy ( Novalac)

PAINT DESCRIPTION

Hempadur 85671

DFT

100 µ

SHADE

DRY TO TOUCH

Light Red

Intermedia te Coat

Phenolic epoxy ( Novalac)

Hempadur 85671

100 µ

OffWhite

Top Coat

Phenolic epoxy ( Novalac)

Hempadur 85671

100 µ

Light Red

6 hours at 20°C (or) 3 hours at 40°C

OVER COAT INTERVAL (min.)

OVER COAT INTERVAL (max.)

POT LIFE

36 hours at 20°C (or) 18 hours at 40°C prior to second coat

10 days at 40°C

---

24 hours at 20°C (or) 12 hours at 40°C prior to third coat

10 days at 40°C

---

24 hours at 20°C (or) 12 hours at 40°C

10 days at 40°C

---

Total DFT range: Min 300 µ 13.0

ATTACHMENTS 13.1

Hempel Paint Data Sheets.

13.2

Sample Painting Inspection Report.

Revision No: 01

Date: 08-04-2015

Page 6 of 6

BADER AL MULLA & BROS. CO. W.L.L. SURFACE PREPARATION AND PAINTING INSPECTION REPORT Client Contractor Company Location

Report No Date System

SURFACE PREPARATION DETAILS (EXTERNAL / INTERNAL) DETAILS:

REQUIRED

ACTUAL

PROCEDURE NO. TIME

TIME START:

TIME END:

Wet Bulb (C°) Dry Bulb (C°) Dew Point (C°) Relative Humidity (%) Surface Temperature (C°)

Type of Abrasive & Size Abrasive Batch Surface Cleanliness Std Surface Profile Visual Inspection DRG. / PROCEDURE REQUIREMENT: Date

Time

D.B.T (C°)

D.P RH% (C°)

S.T (C°)

Paint Details

1st Coat

2nd Coat

3rd Coat

3rd Coat-

Visual Insp.

Final Color

Paint Manufacturer: 1st Coat 2nd Coat 3rd Coat SL.NO.

Item Description

BMB

1st Coat-

BMB

TPI

2nd Coat-

TPI

BMB

TPI

BMB

TPI

BMB

TPI

Sign. & Date Sign. & Date Remarks:

PRESS-O-FILM

Total Dry Film Thickness : DFT Gauge Sl.No : Colour Coading (If any) :

Result: Calibration Due Date: Result:

BMB

CLIENT/TPI

CONTRACTOR

COMPANY

NAME SIGNATURE DATE Abbreviations:DBT-Dry BulbTemperature,D.P-Dew Point,RH-Relative Humidity,ST-SurfaceTemperature,A-Accepted,R-Rejected,AC-Acceptedwith conditions; S.P-Surface Preparation, BMB-Bader Al Mulla & Bros. Co. W.L.L.; PEL-Peerless Manufacturing; TPI - Third Party Inspection Agency.




 

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