JERES-H-001 Coating Selection Application Requirements

JERES-H-001 Coating Selection &

Application Requirements for Industrial Plants & Equipment

Revision 5

Responsibility JER Engineering Division

22 May 2009

Jubail Export Refinery Engineering Standards


JERES-H-001 Rev. 5

Coating Selection & Application Requirements for Industrial Plants & Equipment 22 May 2009

This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by

any means without prior approval by the Company.

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Revision Tracking

Revision Revision Date Scope of Revision

5 22 May 2009 Revised to update paragraph: 6.2 & 6.3.

4 09 February 2009 Revised to update paragraph: 6.2, 7.3, 7.5, 9.1, 10.3.5, 12.4, 12.6, Appendix A (Table A1and Table A2), Appendix C-Table C, Appendix E and Appendix F.

3 17 November 2008

Revised to update paragraph: Table of Contents, 3.1, 6.2, 6.3, 7.3, 7.5, 7.8, 10, 10.3.5, Table A (now Table A1), Appendix C and Appendix E. Adding Table A2 and also Appendix F- Painting System for Insulated and Fireproofed material. Adding requirements to paint stainless steel and insulated surfaces, Adding section 16 for warranties.

2 21 July 2008 Revised to update paragraph: 1.2, 3, 3.1, 3.2.1, 3.2.2, 7.7.f, 8.2, 8.3 9.2, 9.3.2, 10.4.7, 10.4.10, 12.1, 12.3, 12.5, 12.8, 15, Appendix A,

0 28 April 2008 Issued for bid package.

02 31 March 2008 Issued for bid package only for review.

01 22 October 2007 The first official JERES-H-001 is issued

00 08 March 2007

First draft issued is based on Saudi Aramco SAES-H-001 Coating Selection & Application Requirements for Industrial Plants & Equipment issue date 28 February, 2005. Document was modified to incorporate amendments and modifications.


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Table of Contents

Section Contents Page

1 Scope 5

2 Conflicts, Deviations and Clarifications 5

3 References 6

4 Definitions 9

5 Health, Safety and Environment 10

6 General Requirements 10

7 Approved Painting Systems 12

8 Packaged Equipment Coating Systems 14

9 Hot Dip Galvanizing 15

10 Coating Application 16

11 Equipment Used for Coating Preparation and Application 25

12 Inspection and Acceptance 26

13 Colour Schedule 30

14 Piping Identification Labels 30

15 Records 32

16 Warranties 32


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Appendixes

A Table A1: Selection of Coating Systems for Non- Insulated material. 33

Table A2: Selection of Coating Systems for Insulated and Fireproofed Material. 34

B Table-B: List of recommended manufacturers 35

C Table C: Basic colour scheduling and coding 36

D Form-1 Painting schedule 39

E Painting System Data Sheets for Non-Insulated Material 40

F Painting System Data Sheets for Insulated and Fireproofed Material 88


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1 Scope

1.1 This Standard covers the minimum mandatory coating requirements for the internal and external protection of industrial facilities inside plants.

1.2 The purpose is to define the painting of steel structures, equipment, machinery, piping, instruments, etc. subject to corrosion. It includes different coating systems, the surface preparation required, the limits of paint, the thickness to be applied, the application techniques and the requirements for inspection and testing.

1.3 This Standard does not apply to infrastructure facilities, powder coatings, or decorative coatings unless specified in the scope of work or other mandatory Company document.

1.4 This standard shall be attached to, and made part of, purchase orders when required.

2 Conflicts, Deviations and Clarifications

2.1 Any conflicts between this standard and other applicable Company Engineering Standards (JERES), Material Specifications (JERMS), Standard Drawings (JERSD), Engineering Procedures (JEREP), Company Forms or Industry standards, specifications, Codes and forms shall be brought to the attention of Company Representative by the Contractor for resolution.

Until the resolution is officially made by the Company Representative, the most stringent requirement shall govern.

2.2 Where a licensor specification is more stringent than those of this standard, the Licensors specific requirement shall apply.

2.3 Where applicable Codes or Standards are not called by this standard or its requirements are not clear, it shall be brought to attention of Company Representative by Contractor for resolution.

2.4 Direct all requests for deviations or clarifications in writing to the Company or its Representative who shall follow internal Company procedure and provide final resolution.


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3 References

The selection of material and equipment, and the design, construction, maintenance, and repair of equipment and facilities covered by this standard shall comply with the latest edition of the references listed below as of the CUT-OFF DATE as specified in the Contract unless otherwise noted.

3.1 Company References

Company Engineering Standards

JERES-B-067 Safety Identification and Safety Colors JERES-H-102 Safety Requirements for Coating Applications

Company Material Specifications

JERMS-H-9115 Hot Dip Galvanizing for Structural Steel and Pipes JERMS-J-4820 Instrument Control Cabinets - Indoor JERMS-J-4821 Instrument Control Cabinets - Outdoors JERMS-J-4711 Control Valves General Services JERMS-J-4716 Pneumatic Actuators On-Off Service JERMS-J-4611 Safety Relief Valves Conventional and Balanced Types JERMS-M-2014 Pre-Engineered Metal Buildings

3.2 Industry Standards

3.2.1 American Society for Testing and Materials (ASTM)

ASTM A780 Standard Practice for Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings

ASTM C871-04 Standard Test Methods for Chemical Analysis of Thermal Insulation Materials for Leachable Chloride, Fluoride, Silicate, and Sodium Ions

ASTM D3359 Measuring adhesion by tape test ASTM D4541 Pull-off strength of coatings using portable adhesion testers ASTM D4752 Measuring MEK resistance of ethyl silicate (inorganic) zinc-

rich primers by solvent rub


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ASTM D4940 Standard test method for conductimetric analysis of water soluble ionic contamination of Blasting abrasives

ASTM D5402 Assessing the solvent resistance of organic coatings using solvent rubs

3.2.2 International Organization for Standardization (ISO)

ISO 2178 Non-magnetic coatings on magnetic substrates - Measurement of coating thickness - Magnetic method

ISO 2409 Paints and varnishes - Cross-cut test ISO 2808 Paints and varnishes - Determination of film thickness ISO 4624 Paints and varnishes - Pull-off test for adhesion ISO 8501-1 Preparation of steel substrates before the application of paints

and related products -Visual assessment of surface cleanliness - Part 1: Rust grades and preparation grades of uncoated steel substrates and of steel substrates after overall removal of previous coatings

ISO8501-3- Preparation of steel subsdtrates before application of paints and related products Visual assessement of surface cleanliness Part3: preparation grades of welds, cut edges and other areas with surfaces imperfections.

ISO8502-1 Preparation of steel substrates before application of paints and related products Tests of assessment of surface cleanliness Part1: Field test for soluble iron corrosion products.

ISO 8502-3 Preparation of steel substrates before application of paints and related products -Tests for the assessment of surface cleanliness - Part 3: Assessment of dust on steel surfaces prepared for painting (pressure-sensitive tape method)

ISO 8503-2 Preparation of steel substrates before application of paints and related products - Surface roughness characteristics of blast-cleaned steel substrates - Part 2: Method for the grading of surface profile of abrasive blast-cleaned steel - Comparator procedure

ISO 8502-4 Preparation of steel substrates before application of paints and related products- visual assessment of surface cleanliness


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Part4: Guidance on the estimation og the probability of condensation prior to paint application

ISO 8502-6 Preparation of steel substrates before application of paints and related products- visual assessment of surface cleanliness Part6: Extraction of soluble contaminants for analysis. The Bresie method

ISO 8504 Preparation of steel substrates before application of paints and related products Surface preparation method

ISO 19840 Paints and varnishes Corrosion protection of steel structures by protective paint systems Measurement of, and acceptance criteria for, the thickness of dry films on rough surfaces

ISO 12944-1 Paints and varnishes Corrosion protection of steel structures by protective paints systems General introduction

ISO 12944-2 Paints and varnishes Corrosion protection of steel structures by protective paints systems classification of environment.

3.2.3 The Society of Protective Coatings

SSPC Manual, Volume 1 Good painting practice and surface preparation specifications SP1 to 10 SSPC-SP1 Solvent cleaning SSPC-SP2 Hand tool cleaning SSPC-SP3 Power tool cleaning SSPC-SP5 White metal blast cleaning SSPC-SP6 Commercial blast cleaning SSPC-SP7 Brush-off blast cleaning SSPC-SP10 Near white blast cleaning SSPC-SP12 Water Jetting SSPC Manual, Volume 2 Systems and specifications SSP-Vis 1 Guide to Vis 1 - 89 - Visual Standard for Abrasive Blast

Cleaned Steel SSPC-Vis 2 Standard Methods of Evaluating Degree of Rusting on Painted

Steel Surfaces


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SSPC-PA 2 SSPC Method of Measurement of Dry Paint Thickness with Magnetic Gages

3.2.4 Norsok Standards

Norsok M501 Rev.5 Surface preparation and protective coating

4 Definitions

4.1 Definitions presented in this Standard and other JER documents have precedence over other definitions. Conflicts between various definitions shall be brought to the attention of Company Representative by the Contractor for resolution.

Company: Jubail Export Refinery.

Company Representative: A designated person from the Company or an assigned third party representative.

Company Inspector: A designated person or an agency responsible for conducting inspection activities on behalf of the Company.

4.2 List of Definitions

Approved Product: A coating material that has been approved by the Company.

Contractor: The party which carries out all or part of the design, engineering, procurement, construction, commissioning or management of the Project

Manufacturer/vendor: The party which manufactures and/or supplies the equipment.

Coating manufacturer: The party which manufactures and/or supplies the coating products

Subcontractor: The party selected by the Contractor which carries out all or part of the material takeoff, design (in special cases), procurement, surface preparation, application, and testing of the coatings/systems.

Corrosive Industrial Atmosphere: Areas exposed to gases, fumes, mists or dusts from chemical or industrial facilities. This term does not include direct contact with splashed or spilled chemicals.


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Maintenance Coating/Painting: Application of coating to preserve the useful state of an existing coating. Repairing is the most common method to maintain a coating. Replacing completely an existing coating is not maintenance coating.

Mild Atmosphere: Areas not affected by either marine or industrial environments, but receive enough moisture in the air to cause corrosion if the carbon steel is not coated.

New Construction Coating: Application of coating on a completely new and uncoated facility, equipment or machinery. New coating also applies to the coating application on completely bare substrate that was previously coated.

Thick Film Coating: Coatings with an average dry film thickness greater than 20 mils (500 microns)

Thin Film Coating: Coatings with an average dry film thickness of 20 mils (500 microns) or less

Thixotropic Coating: A type of coating that thickens or gels in a relatively short time when at rest, but readily becomes more fluid when agitated or stirred.

Vessels: Where referred to in this standard, the term "vessels" includes, but is not necessarily limited to, columns, traps, drums, heat exchangers, and boilers.

Wet-on-Wet Coating Application: Technique of coating application where additional coating passes are employed over a coating that is still wet, making the composite film dry as a whole. A wet coat applied over another wet coat is considered one coat of application.

5 Health, Safety and Environment 5.1 For field applications only, the safety requirements per JERES-H-102 shall apply for

coating activities.

5.2 For shop applications, it is the responsibility of the shop Management to adhere to the safety rules and regulations applicable to their shop.

6 General requirements

6.1 Colour coding


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6.1.1 Colour coding schedule for the project shall be in accordance to paragraph 10 and will be chosen to match those of installations already present in the same block or country.

6.1.2 If the project has no specific requirements, then the colour coding can be defined according to the guidelines drawn in the Appendix C.

In any case, the painting works carried out by Contractor shall include all colour coding and marking required for item and service identification.

6.2 Surfaces to be coated

All non-insulated carbon steel and low alloy carbon steel surfaces Non-Insulated stainless steel surfaces (316, 304, 321 series, Duplex, etc) for

piping, vessels, tanks, and similar operating at 150o C and lower. Refer to 6.3 for the exceptions to this requirement.

Insulated carbon steel and alloy carbon steel surfaces Insulated stainless steel surfaces (316, 304, 321 series, Duplex, etc) for piping,

vessels, tanks, and similar operating at 150o C and lower. Refer to 6.3 for the exceptions to this requirement.

Fireproofed structures prior to fire proofing application Galvanized steel structure only when required for safety identification

6.3 Surfaces not to be coated

6.3.1 Unless otherwise specified, the following surfaces shall not be painted:

Other non-ferrous metal surfaces (aluminum, copper and nickel alloys, etc.), unless required for reasons of appearance or safety identification

Galvanized steel gratings Galvanized steel surfaces Machined surfaces as flange faces, screw threads Valves stems, gauge glasses and guards, Friction surfaces of assemblies using

friction

Surfaces used for identification purposes, such as nameplates, serial number plates, valve identification signs, gauge glasses and guards, gauge faces and light fixtures, valve stems and flange bolts.


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Plastic and plastic coated materials, provided their resistance to UV has been demonstrated, and colour coding is not necessary.

6.3.2 The following non-Insulated stainless steel surfaces (316, 304, 321 series, Duplex, etc) may not be coated:

Piping, vessels, tanks, and similar operating above 150o C. Structural non-pressure containing components Cable Trays and Ladder Junction Box Local Panel and Instrumentation Enclosures-Cabinet Cable Gland Instrument Impulse Tubing Line Instrument Air Supply Tubing Lines Rotating equipment casing and seal systems Rotating equipment appurtenances such as flushing piping and lube

oil system including piping, exchangers, tank, etc

7 Approved Painting Systems

7.1 Only approved products are allowed for use on Company Facilities. These requirements apply to all coatings referred to in all the JERES-H-series standards.

7.2 Applications that require coating or new coating system not covered by this standard or other Company standard shall be approved in writing by the Company Representative.

7.3 Approved Painting Systems:

7.3.1 Non-Insulated Surfaces

The painting systems A, B, C, D, E, F, P and Q listed in Table A1 of Appendix A, have been selected as approved painting system applicable for Non-Insulated material in accordance with ISO 12944 Part 2, high corrosivity category code C4 for industrial and coastal areas.

7.3.2 Insulated Surfaces


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Zinc-rich primer organic and inorganic shall not be used under insulation or fireproofing.

The painting systems E, G, H, K, L, M, N, O, P and Q listed in Table A2 of Appendix A have been selected as approved painting system applicable for insulated material. For those cases where the painting system data sheets are not fully developed, EPCC contractor shall submit them to Company for review and approval prior to application.

7.4 Painting Manufacturers

7.4.1 The painting material shall be supplied from the Company approved painting manufacturers listed in Table-B of Appendix B. The painting system data sheets with product trade names from the different manufacturers are provided in Appendix E and F. These systems are certified by Norsok M501 for low temperature services and ISO12944 for higher temperature.

7.4.2 Alternative manufacturers can be proposed, provided that their range of products meets the technical performance of this specification. The manufacturer shall be able to provide supporting data from exposure tests and/or cyclic weathering testing carried out in accordance to standard Norsok M501 rev.5 or equivalent.

7.5 Coating systems (Paint schedule Table A1 and Table- A2)

The coating systems suitable for the structures, equipment and piping are provided in Appendix-A.

Coating systems will be chosen depending on material of construction, the presence of insulation/fireproofing and operating temperature.

Zinc-rich primer organic and inorganic shall not be used under insulation or fireproofing.

7.6 A painting procedure (as per attached Form 1 in Appendix D) including description of the coating system (type and trade name of coating products, number of layers, dry film thickness of each layer, etc.) together with product data sheets shall be submitted for approval to Company by Vendor for shop painted items and by Sub-Contractor for paint work at field.

7.7 Coating composition


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All coating products used in shop or on site shall meet the following requirements.

a) All coating product formulation shall respect the local legislation of the place of application (e.g. VOC, isocyanates, etc) and to some extend they shall comply with the legislation of the country/state where the plant is built.

b) Coatings shall be free of heavy metals such as arsenic, barium, cadmium, lead, mercury, silver, chromium, selenium. However, zinc coatings containing barium sulfate and less than 0.02% lead are acceptable.

c) Two-pack finish coats shall be based on acrylic polyurethane media. Where isocyanate cured products are not allowed, alternative finish products shall be submitted to Company for approval. Finish coat shall have gloss retention and weather/UV resistance.

d) Two-pack epoxy finish coatings shall be based on a polyamide or amine adduct cured two-pack epoxy media and shall be pigmented with titanium dioxide and/or light fast colored pigments to provide the necessary opacity, film build and weather resistance. A semi gloss finish is required.

e) Silicone coatings shall be based on a one-pack formulation. They may comprise leafing aluminum pigment dispersed in the silicone or modified silicone media, except for application on stainless steel surfaces. The coating shall be able to dry completely at ambient temperature (no "tacky" surface) and shall withstand continuous exposure to temperatures up to 648C when required.

f) Inorganic zinc (zinc silicate) primers shall be based on ethyl silicate media and shall contain not less than 80 % zinc dust by weight in the dry film in accordance with ISO 12944. They shall be two-component products. Organic zinc (epoxy zinc) primers shall be based on 2 pack epoxy and shall contain not less than 80% zinc dust by weight in the dry film.

Zinc dust provided shall meet the requirements of ATM D520 Level II.

g) Alternative high performance two-pack waterborne coating products shall be submitted to Company for approval. In general, preference should be given to more environmental friendly systems consistent with meeting the performance/maintenance requirements

7.8 Coating Effects

7.8.1 The selected coating shall not cause any degradation to the chemical or mechanical properties of the coated surface.


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7.8.2 Special attention shall be made for selecting the coating type used on surface operating at high temperatures especially in the situation of insulated surface so that the coating will not cause material imbrittlement.

8 Packaged Equipment Coating Systems

8.1 This section covers packaged equipment (including mechanical parts, pressure vessels, piping, instruments, machinery, etc.) and equipment items, such as pumps, compressors, turbines, blowers, electric motors, transformers, generators, hoists and cranes, control valve, instrumentation etc.

8.2 Packaged equipment can be coated according to Manufacturers standard, provided it complies with the following requirements:

a) The Manufacturers coating system shall meet the minimum required design condition of the environment in which the facility is located (in terms of climatic and corrosive conditions), in order to match the same quality of corrosion protection of the other systems indicated within this specification. Any deviation shall be clearly highlighted and forwarded to Company for written approval.

b) A detailed Painting procedure shall be submitted to Company for written approval, including

description of the coating system (type and trade name of coating products, number of coating layers, dry film thickness of each layer, etc.)

product data sheets any further information to enable damaged primer or finish coat to be

touched/repaired, or overcoated with a compatible coating system

Information deemed appropriate by packaged equipment manufacturer of the system to give evidence of compliance with the above point a.

8.3 Where hot dip galvanizing is required it shall comply with Section 9 of this standard.

9 Hot Dip Galvanizing

9.1 In case galvanizing is required for structural steel grating, ladders, handrails, pipes and others, it shall confirm to the requirement of JERMS-H-9115.

9.2 All mechanical preparations, such as welding, drilling, shall be done before hot dip galvanizing. For placement of holes that will be necessary for venting air and distributing zinc liquid, contact the galvanizing firm for recommended locations. If


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the design of the item is not adequate for galvanizing, the galvanizing Contractor shall notify the steel fabricator for clarification.

9.3 Repair

9.3.1 Repair of damages at the galvanizing shop shall be according to the applicable industry standards and codes.

9.3.2 For damages occurring during transport or at construction sites, they shall be repaired in accordance with the guidelines of the following procedure (Zinc-rich Paint application)

PRODUCT DESCRIPTION: Zinc-rich paints (organic based, such as epoxy, is preferable) must contain >80% zinc dust by weight in dry film in accordance with ISO 12944.

Zinc-rich paints are usually formulated to deliver an excellent color match for both bright and matte gray galvanized coatings.

SURFACE PREPARATION: Basic indication of ASTM A-780 shall be followed. Preparation of the damaged surface will be influenced by the type of paint selected and the anticipated service conditions. The following general guidelines shall apply:

For highly aggressive service conditions and where feasible, the blast-cleaning of surfaces to SSPC-SP10/NACE No. 2, near-white metal, is recommended.

For less critical field exposure conditions and where blasting is not feasible (i.e. non-easily accessible surfaces), power tool cleaning to SSPC-SP 3, bare metal shall be adopted (as a minimum).

When abrasive-blasting or power-tool cleaning is not practical, hand-tools may be used.

In all cases, surfaces must be free of oil, grease, weld flux residue and weld spatter, paint and corrosion by-products. To ensure that a smooth reconditioned coating can be affected, surface preparation shall extend into the surrounding undamaged galvanized coating.

COATING APPLICATION: general guidelines indicated in this specification shall be adhered to. Reference to the paint manufacturer's instructions shall be also made.

The renovated area shall have a zinc coating thickness of 130% of that specified in JERMS-H-9115 but not more than four mils.


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10 Coating Application This section provides additional details on how to apply coating

10.1 Sources of Materials

10.1.1 Only the materials generically specified for a given service in this specification are to be used. The fabrication and/or painting Contractor shall state the name of the Coating Manufacturer and of the coating material. Mixing products of different Coating Manufacturers in the same layer/application for any given system is NOT acceptable. Next layer coating of any Coating Manufacturer which is different from the prior coat is to be individually supported by written statements from each Coating Manufacturer involved as to compatibility and integrity of finished coating system.

10.1.2 All paint and coating materials shall be delivered to site in the Coating Manufacturers unopened original containers, in good state and correctly labeled. Label shall feature the Coating Manufacturer's name, brand name, batch number, date of manufacture and shelf/pot life.

10.1.3 Technical data sheets shall also be supplied, clearly indicating all the features and requirements of the products (i.e. max/min over coating times for the specified DFT, max/min DFT, max temperature resistance etc.).

10.1.4 The paint should be stored in optimal conditions for their best conservation.

10.1.5 Coating that has passed their shelf life shall not be used.

10.2 Equipment for Surface Preparation and Coating Application

The coating Contractor shall supply and transfer to site all the equipment and material necessary to carry out the cleaning, masking, priming and painting work in accordance with this specification and Coating Manufacturer's recommendations. Test equipment including wet and dry film thickness gauges, blast profile testers, pinhole holiday detectors, hydrometers, temperature measuring devices, shall be provided by the coating Contractor.

10.3 Surface Preparation and Cleaning

10.3.1 General

The following method of surface preparation shall be used as specified in TABLE A1 and Table A2.


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In all cleaning methods the equipment and tools used shall be of suitable design and quality to properly complete the works to the specification. Where compressed air is used, air lines shall be provided with effective, well maintained oil and water traps. Efficient well maintained air filters shall be provided to control dust.

During cleaning, all weld areas and attachments shall be given special attention to ensure all welding flux and spatter is removed by the use of solvents, files scrapers, chipping hammers, power or hand brushes or grinders fitted with flexible grinding discs.

Prior to the commencement of any of the cleaning methods detailed below, the surface to be cleaned shall have all oil, grease or wax removed by swabbing with a suitable emulsion cleaner. The surface shall then be washed down with clean fresh water to remove dirt, stains and residues. Where necessary, hand brushing shall be included to ensure a clean surface.

10.3.2 Abrasive blast cleaning

In this method, millscale, rust and other surface contaminants shall be removed using blast or centrifugally propelled abrasives. After the specified standard has been achieved, all dust, loose materials and abrasive residues shall be removed from the cleaned surface and the surface shall be coated before contamination or flash rusting occurs.

Contaminants such as oil, greases, chemicals or soil shall be removed prior to abrasive cleaning by the use of a suitable emulsion cleaner. The surface shall be cleaned as specified in TABLE-A1 and Table- A2.

The applicable standard for surface preparation shall be as follows: the grade of cleanlinessis is according to ISO 8501-1; the surface roughness is according to ISO 8503; and the surface cleanliness is according to ISO 8502.

After blast cleaning and before application of the priming coat the surface shall be cleaned to remove dust and abrasives and in particular from pockets and corners. This can be done by vacuum cleaning or by blowing with dry, oil-free compressed air.

Due care shall be exercised to prevent the abrasive grit entering inside equipment and pipe work. On completion of blasting operations, the inside of equipment and piping shall be inspected and cleaned out if the presence of abrasive grit is detected.


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Any surface showing signs of handling contamination after blasting shall be solvent cleaned and re-blasted.

The use of abrasives containing silica is not permitted. The abrasive must be free from oil, grease, moisture, etc. Re-used abrasive shall be clean and reasonably sharp. They shall not be rusted or noticeably worn or dull when compared with fresh material and must be free from contaminants.

Re-used abrasive shall be approved by Company Inspector and shall meet the requirements as specified above.

Blast cleaning shall not commence unless a protective coating can be applied before contamination or flash rusting occur.

Blasting shall not be done outside normal daylight work hours unless authorized by Company Inspector.

Blasting operations shall not be carried out unless surfaces to be prepared are 3C above ambient air dew point.

All blasted surfaces must be clean, free of all dust, before applying paint.

10.3.3 Protection of surfaces not to be coated

Protect all surfaces not to be coated from damage and from paint products by adequate temporary coverings during all operations of surface preparations and painting. Remove coating that may have fallen on these surfaces e.g., valves stems, glass, adjacent equipment, flange bolts, etc.

In particular, stainless steel and non-ferrous surfaces shall be protected from blasting, overspray and coatings intended for carbon steel. The contractor shall protect all equipment that is not to be painted or liable to be affected by the presence of abrasive or paint. Special attention shall be given to avoid splashes of zinc-based paint on equipment of austenitic steels to prevent high temperature cracking corrosion.

10.3.4 Stainless steel

Surface shall be thoroughly degreased using an appropriate emulsion cleaner and abrasive cleaned (sweep blasting) to create sufficient anchor profile.


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Abrasive for blast cleaning of stainless steel surfaces shall be performed with a suitable non-metallic abrasive such as aluminum oxide.

When hand or power tool cleaning is required on stainless steel, only stainless steel wire brushes that have not been previously used on carbon steel surface may be used.

All coatings and solvents for use on stainless steel shall be free of substances such as chlorides and other halides, sulfur, and shall be free of low melting point metals (zinc, aluminum, tin and lead). All coatings and solvents used on stainless steels shall be free of low melting point metals (zinc, aluminium, tin and lead) and removeable chloride levels shall be < 100 ppm according to ASTM C871-04)

All coatings and solvents for use on stainless steel shall be free of substances such as chlorides and other halides, sulfur, and shall be free of low melting point metals (zinc, aluminum, tin and lead).

10.3.5 Galvanized surfaces that require coating (hot dip galvanizing, electroplating, Sendzimir process)

Surface preparation shall consist of thoroughly degreasing and treating with a mordant/etching solution. After the reaction period the surfaces shall be washed down with clean water. The Company Inspector shall approve water source prior to use.

Alternatively, sweep blast cleaning is acceptable after thorough degreasing by using lower air-blasting pressure at 3.5 4.0 barg (50 60 psig). Dust from blast cleaning operation shall be removed as previously described.

Top-coating like mastic epoxy system as approved under APCS-26 (Hempel Painting System) is recommended for galvanized surfaces in coastal areas exposed to marine environment with a high humidity. In any case, EPC contractor may propose another painting system to Company for approval prior to application.

Note: Weathered galvanized surfaces should be wire brushed first to remove all corrosion products.

10.3.6 Weld areas and sharp edges

All weld seams, sharp edges and surface irregularities shall be contoured and surface irregularities ground smooth as required.


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10.3.7 Anchor profile

Unless otherwise specified, the surface profile for carbon steel surfaces after blast cleaning shall have a min/max height of 50/75 microns with rough peaks to 100 microns (Rz).

10.3.8 Manual and Mechanical (Power-Tool) Cleaning

Manual cleaning shall only be carried out when the use of power tools is prohibited and with prior approval by Company Representative.

In this process dirt, rust, millscale and/or paint remains are removed and the metal surface prepared by hand chipping, scraping or wire brushing or preferably where possible by powered hand tools such as powered wire brushes or needle guns to achieve the specified standard. This method shall be limited to small sized surfaces and shall be only used with the written approval of Company representative.

The quality of surface cleanliness achieved by manual or mechanical cleaning is specified in accordance with ISO 8501-1 for manual or mechanical cleaning.

On completion of the surface preparation, all dust and other foreign materials shall be removed and the primer coat applied before any contamination or rusting occur, but in any case within four hours. Should the cleaned surface be left uncoated overnight surface preparation shall be repeated prior to painting.

10.4 Preparation and Application of Coating Material

10.4.1 General

Coating Contractor shall adhere strictly to the instructions and recommendations as prescribed by the coating Manufacturers for the preparation and application of all coating materials. Successive coats shall have a contrasting colors or tints.

10.4.2 Coating preparation

Coating components shall be power-stirred to obtain a homogenous consistency. No hand stirring is allowed for quantities greater than 5 liters. Before further use, coating shall be allowed to stand for a time long enough to remove aeration caused by stirring.


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Two-pack or multiple pack coating systems shall be mixed in the proportions and under the conditions recommended by the Manufacturer. The mixed coating shall not be used on expiry of its "pot life".

For inorganic zinc primers, after mixing the silicate binder and the zinc powder, the mixed product shall be sieved prior to application and continuously power-stirred during application.

The mixed coating shall color match with other prepared products of the same coat.

Coatings visually showing deterioration such as settling, separation, gelling, skin formation, etc. shall be discarded.

10.4.3 Coating Application

Painting shall be done according to the application instructions of the Coating Manufacturer and shall be performed by skilled and experienced staff, aware of health and hazard issues related to painting activities.

Coating may be applied by brush, roller, conventional spray or airless spray methods as approved or specified by the coating Manufacturer. Brush or rollers used shall be of a suitable size and shape and shall be kept clean by use of approved solvents. Where rollers are used, the nap shall be of sufficient length to work the coating well into the surface.

When using conventional spray or airless spray methods, all the equipment shall have adequate, well-maintained pressure regulating devices, effective strainers, traps, and separators, suitable size hoses and clean, well-maintained guns. The traps and separators for removing oil and water maintained from the compressed air shall be such that air atomizing guns will not deposit oil or water when directed on to a clean surface for 15 seconds.

Nozzles shall be of the correct size and provide the most suitable spray shape for the most effective and economical application of the coating without excessive overspray.

The specified coating thickness shall be achieved at all protrusions, corners and crevices. Edges, cracks, bolt heads, etc. may require the coating to be evened by laying off with a brush after roller application.


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All coating materials shall be applied evenly in a normal full coat free from mud cracking, wrinkling, sagging, curtaining, cissing, fish eyes, orange peeling, pinholes, brush and roller marks and other defects.

The dry film thickness shall be measured from the peaks of the grit blast profile and suitable pieces of grit blasted steel shall be prepared to enable the thickness meters to be calibrated in accordance with the indications from the equipment Manufacturer.

Due care shall be exercised whilst spraying to prevent overspray and contamination of other surfaces by the use of shields, etc.

Under no circumstances shall zinc or aluminum in the form of coating pigments or metal spray shall be allowed to come into contact with stainless steels, nickel based alloys or copper based alloys.

10.4.4 Priming

The priming coat shall be applied as soon as possible after the surface preparation has been carried out and before any contamination of the cleaned surface. The specified surface preparation is understood to be the one at the moment of the application.

Angles, corners, sharp edges, bolt or rivet heads, weld seams and other surface irregularities shall be stripe-coated by brush. This coat shall be the same product as the primer, but should be of a different color for identification purpose.

10.4.5 Subsequent coat

When the primer coat has cured and its correct application and thickness has been confirmed, and the primer surface has, if necessary, been cleaned to remove dust/moisture, the specified protective coating shall be applied.

When more than one coat is required, the Coating Manufacturer's recommendations on overcoating time shall be complied with.

Wet film thickness should be checked when each coat is applied to ensure that the full coating thickness will be achieved in the specified number of coats (as recommended by the Coating Manufacturer). Total system dry film thickness shall also be in accordance with this specification.

A final coat shall be applied in accordance with the undercoat overcoating time recommended by the Coating Manufacturer.


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The final coat shall provide a smooth, even finished coating surface, where gloss finish coats are applied, the surface shall be a smooth gloss finish with no breaks in the surface.

The multicoat system shall be free of all the defects previously mentioned.

10.4.6 Drying times

Each coat shall be allowed to cure thoroughly in accordance with the Coating Manufacturer's instructions for overcoating before the next coat is applied. Curing times are highly dependent on local conditions.

10.4.7 Weather conditions

Painting Contractor shall measure and record local conditions of temperature and humidity during blasting, painting and curing.

Coating shall only be applied when suitable weather conditions prevail. Coating shall not be applied under the following conditions or when such conditions are likely to prevail before the coating is cured.

a) At temperatures below 10C (or according to Coating Manufacturer recommendation) or when the temperature is likely to fall below this figure before the surface film is dry, or on surfaces registering low temperatures.

b) When the relative humidity of the atmosphere exceeds 85 %. c) The steel temperature is less than 3C above the dew point. d) During foggy or misty conditions. e) Before dew or moisture has evaporated. f) When it is raining or rain is imminent.

Guidelines for weather and other atmospheric suitability shall be agreed with Contractor but painting Contractor shall remain responsible for scheduling his activities.

Coating which is contaminated during curing, for example by dust, condensation or rain, shall, if deemed necessary by Company Inspector be removed and redone.


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10.4.8 Contrasting coatings

Where it is necessary to apply more than one coat of a particular product to obtain a specified dry film thickness, then the first coat shall be selected sufficiently different in color, in order to distinguish from the subsequent coats.

10.4.9 Storage of materials

All products shall be received in sealed containers, clearly marked with product description, reference number, batch number and date of manufacture. Thinners, solvents, etc. shall be stored in a well ventilated fireproof building, separate from other painting consumables. The building temperature shall be controlled if necessary in order that the coating products will not suffer from local climatic conditions.

10.4.10 Painting before installation

Prepared welding edges and surfaces within 50 mm to 75 mm of welding shall be left uncoated or coated with an approved welding primer only.

All surfaces that will be inaccessible after assembly or installation shall be cleaned and coated before installation. Such surfaces include underneath of base plate, skids, saddles, skirts, but also bored/punched holes in steel members, flange screw holes, etc. When painting is carried out before installation, all reasonable steps shall be taken by the painting Contractor to reduce to a minimum damage to the coating system before and during installation.

Metal contact surfaces -i.e. bolted joints in structures- should be coated with one full layer of the specified primer on both surfaces immediately before bolting up. Fretting surfaces where friction grip is required shall not be coated.

Piping may be painted before the hydrostatic test (hydrotest); however, all field joints, welds and threaded connections shall be left unpainted (approximately, within 50 mm to 75 mm each side) until the test has been completed and approved by the Company.

In case of specific need (i.e. due to prefabrication issues) and subject to Company approval on a case by case basis, field joints, welds and threaded connections may be primed only. Where piping is fully painted before hydrostatic test, each successive coat of paint will be stopped 50 mm to 75 mm before the preceding coat at each joint to allow for proper tie-in of subsequent coats after the completion of the test. In any


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case, coating of welds prior to hydrotest may be accepted limited to multi-pass welds: single run welds such as seal or socket welds are to be left uncoated.

10.4.11 Shipping, handling and storage of coated items

Coated items shall not be handled or moved until all coatings have been properly dried or cured as required in the Coating Manufacturer's instructions.

Coated items shall be handled with equipment such as wide belt slings, web belts, and wide padded skids selected to prevent damage to the coating. Handling equipment likely to cause damage to the coating shall not be used. Items such as chains, cables, hooks, tongs, metal bars, and narrow skids shall not be permitted to come in contact with the coating. Dragging or skidding coated items shall not be permitted.

Coated items shall be loaded, padded, and secured for transport in such a manner that the coating will not be damaged in transit.

Coated items shall be separated so that the items do not bear against each other. Coated items shall be stacked off the ground using suitable means (e.g. parallel

height ridges of rock-free sand, wooden timbers placed under the uncoated pipe ends) to avoid damages of the coating.

11 Equipment Used for Coating Preparation and Application

11.1 Blasting equipment

All blasting equipment supplied will have a current inspection certificate from a third party independent source if required.

The pressure and volume of the compressed air supply for blast cleaning shall meet the work requirement and shall be sufficiently free of oil and water contamination to ensure that the cleaning process is not impaired. Traps, separators and filters shall be emptied and cleaned regularly.

11.2 Hand tools

Chipping, scraping and steel wire brushing using manual or power driven tools shall be of a type acceptable to Company.


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11.3 Spray equipment

All spray equipment supplied will have a current inspection certificate from a third Party independent source if required.

The pressure and volume of the compressed air used for spray application shall meet the work requirement and be free from oil and water contamination. Traps, separators and filters shall be emptied and cleaned regularly.

12 Inspection and Acceptance

12.1 General

As part of the Quality Plan, the Company shall determine the inspection operations associated with the various phases of execution and inspection.

As part of the Quality Plan, the Company shall determine the inspection operations associated with the various phases of execution and inspection. . Inspection shall be performed by Company Inspector.

In case a third party is envisaged for the inspection of the painting works, the inspectors shall be certified by a recognized independent organization (ACQPA, FROSIO, NACE, or organisms approved by AFAQ, OLAS, SRAC, or any certification organism EA member).

The following inspection and testing shall be performed during the application of coating systems:

Checking on raw materials (integrity of packing, expiry dates etc.); checking of paints documentation (Technical Data Sheet, Material Safety Data

Sheet);

checking of meteorological and environmental conditions Visual examination of surface preparation in accordance with the international

standards ISO 8501

Profile checking with a suitable "profilometer" according to ISO 8503 Thickness checking (acceptance criteria shall be per (SSPC - PA 2 -Rule 80 -

20))

Curing checking Adhesion checking


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Porosity checking 12.2 Thickness check

Dry film thickness shall be measured with a magnetic or ultrasonic probe, such as "ELCOMETER" or "MICROTEST" etc ... The equipment shall be calibrated at least twice daily in accordance with the Coating Manufacturers' recommendations.

It is suggested that, in order to achieve the specified dry-film thickness, wet-film thickness be checked during the coating application with wet film thickness gauges such as the Elcometer wheel or comb type.

Reference is to ISO 2178 and ISO 2808. The acceptance criteria shall be according to SSPC-PA 2.

If the dry film thickness does not meet the specified value, additional coats shall be applied, except for inorganic zinc (zinc silicate) primers that shall be re-blasted and re-applied at the required dry film thickness.

Inorganic zinc (zinc silicate) primers applied at dry film thickness greater than 100m or showing mud-cracking shall also be re-blasted and re-applied at the required dry film thickness.

12.3 Drying/curing

For each coat, the curing shall be checked by assessing the solvent resistance.

Test shall be performed according to ASTM D4752 for inorganic zinc (zinc silicate) primers.

12.4 Adhesion check

The coating shall be examined and tested for measuring adhesion between coats and for adhesion of the first coat to the substrate by applying once per shift the Tape Test Method A of ASTM-D-3359 and the rating shall be between 4A and 5A.

For coating thickness greater than 5 mils, X-cut adhesion test with knife can be used.

An adhesion pull-off test shall be carried out at any location where there is evidence of any sort of failure in any coating including, but not limited to, lifting of coats or loss of adhesion between layers in coating system.


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The adhesion pull-off tests as well as their results shall be conducted and reported respectively in accordance with ISO 4624 or ASTM D4541.

Coating whose adhesion pull-off test result is less than 30 kg/cm2 (3 MPa) shall be considered to have failed, except on silicon based coatings.

12.5 Porosity check

Film continuity shall be checked as follows

All External surfaces will be subject to visual inspection for holidays, pinholing and excessive overspray. Inspection using electrical comb tester reveals defects such as porosity, and absence or discontinuity in the paint film. This inspection shall be carried out with an electrical comb tester set to a voltage calculated on a basis of 3volts per micron of the normal dry film thickness.

Areas found to have been improperly coated shall be reapplied.

12.6 Soluble salt contamination

Soluble salts contamination is a mandatory test, which is carried out to measure chloride and soluble salt concentrations and pH level from a steel surface. This test shall be conducted as follows:

One (1) time for every new surface preparation activities It shall be done after surface preparation has been completed and prior to coating

application.

The test area shall be 4 inches by 4 inches and using as material KTA Swab SCAT kit.

Testing for chloride and soluble salt concentrations and the pH level shall be done using a Blesle Method according to ISO 8502-6. The chloride and soluble salt concentrations shall be less than 10 ppm and the pH shall be neutral (between 6 and 8). When these levels are exceeded, the surfaces shall be either steam cleaned or high pressure water washed before abrasive blasting. The cleaned surface shall be retested to verify that the contaminant levels are within the acceptable range.

12.7 Supplementary testing

The following tests may be carried out at the discretion of the Company.


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Millscale test A copper sulfate test shall be performed to determine the presence of millscale.

12.8 Repair of defects or damages

Any defect or damage that may occur shall be repaired before the application of further coats.

Areas which are to be overcoated shall be thoroughly cleaned free from grease, oil and other contaminants and shall be dry.

The surfaces shall then be prepared to the standard as specified. Edges of sound coating around the repair area shall be feathered back approximately 50 mm for a smooth transition. If necessary vacuum blasting equipment shall be used for surface preparation.

Subsequently additional compatible coats shall be applied, until they meet the specification. Those additional coats shall be blend in with final coating on adjoining area.

Up to 120C damaged areas of non-insulated/insulated surfaces shall after cleaning be touched up with one or two coats of surface tolerant high solids epoxy (compatible with previously applied coats of different nature). The repair coat shall overlap sound coating.

Above 120C heat resistant coatings shall be used for touch up.

Galvanized steel presenting damages exposing the steel substrate shall be repaired. Prior touch up, the damaged surface shall be cleaned by mechanical wire brushing to SSPC ST3. Touch up shall be with zinc rich epoxy and shall match original grey color of galvanized steel. Minimum dry film thickness of zinc rich epoxy repair coat shall be 80 microns.

13 Colour Schedule

13.1 The basic colour selection is provided in Appendix-C and in line with requirements of JERES-B-067.

13.2 The final color coding shall be finalized by the Company prior to commencing the work.

14 Piping Identification Labels


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A label in English shall be used and explicit means of identification for the contents of all aboveground piping. The Labels shall spell out the service and in parenthesis show the abbreviation. The label shall be applied close to valves or flanges and adjacent to changes in direction, branches, and where pipes pass over or through walls, and on straight pipe runs, sufficient for identification.

NAME OF THE CONTENTS IN FULL AND ABBREVIATED FORM TEMPERATURE AND PRESSURE DEGREE OF HAZARD DIRECTION OF FLOW Identification Colour Label

All Lines Safety Yellow

Letters Black

Pipes application labels

Labels will be safety yellow flow direction adhesive.

The adhesive black letter will be applied into a white rectangular space on the yellow flow labels as a sample:

DIAMETER OF PIPE

mm A

mm B

mm C

mm D

mm E

mm Up to 100 350 50 25 30 20

From 101 to 250 680 200 40 50 35 Greater than 250 820 250 50 60 50


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FIGURE-1: Structural Steel of Pipe Support Identification


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15 Records

15.1 At the end of the project, the technical file, handed over by the Contractor and co-signed by the Manufacturer, at the end of the works, shall include, at least, the following:

the painting system;

the location of each painting system on the applicable painted structure;

the product data sheet and references of the batches used;

certificates specifying the durations, criteria and performance levels of the warranties;

reports of the inspections;

provisional acceptance reports;

personal certifications of operators and inspectors.

16 Warranties

16.1 The Contractors shall provide Company Representative with painting and coating life warranties to be reviewed and approved by Company.

16.2 The warranty shall be minimum five years.

16.3 After five years of application of the painting, the painting shall perform in according of the following:

Maximum degree of rust shall be Ri2 according to ISO 4628

Maximum degree of cracking, blistering or flaking shall be 3S3 according to ISO 4628


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Appendix A: Coating Systems TABLE-A1: SELECTION OF COATING SYSTEMS FOR NON-INSULATED MATERIAL (SUITABLE FOR MARINE ATMOSPHERE), for steel structures,

equipment, piping etc.

Scope Specification System

Non-insulated C.S. ambient temp to 120C

Surface prep. : abrasive blast cleaning to ISO Sa 2.5 (RZ = 50-75 m) Primer : 75m of 2-pack Epoxy zinc rich (organic zinc) Intermediate : 150m of 2-pack epoxy MIO Finish : 50m of 2-pack acrylic polyurethane

A

Non-insulated C.S. 121C to 200C

Surface prep. : abrasive blast cleaning to ISO Sa 2.5 (RZ = 30-75 m) Primer : 75m of 2-pack ethyl zinc silicate (inorganic zinc) Finish : 2 x 30m of silicone acrylic coating

B


Surface prep. : abrasive blast cleaning to ISO Sa 2.5 (RZ = 30-75 m) Primer : 75m of 2-pack ethyl zinc silicate (inorganic zinc) Finish : 2 x 25m of single pack silicone-based coating

C


Surface prep. : abrasive blast cleaning to ISO Sa 2.5 (RZ = 30-75 m) Coating : 2 x 25m of single pack silicone based coating D

Non-insulated C.S. vessels and cyclic temperature piping. Ambient to 400 C

Surface prep. : abrasive blast cleaning to ISO Sa 2.5 (RZ = 50-75 m) Coating : 2 x 100m of Titanium Modified Inorganic Co-Polymer.

P

Non-insulated C.S. Constant operating temperature piping. Ambient to 565 C

Surface prep. : abrasive blast cleaning to ISO Sa 2.5 (RZ = 50-75 m) Coating : 1 x 175m of Titanium Modified Inorganic Co-Polymer.

Q (Note 1)

Non-insulated Stainless.Steel. -196 C to 200C

Surface prep. : Light abrasive blast cleaning (RZ = 30-50 m) Primer : 100 m of 2 pack epoxy phenolic primer Finish : 100 m of 2 pack epoxy phenolic finish

E (Note 2)

Non-insulated/ non-fireproofed galvanized steel ambient temperature (in case of color coding)

surface prep. : light abrasive blast cleaning (RZ = 30-50 m) or treatment with mordant/etching solution primer : 75m of 2-pack zinc-free epoxy finish : 50m of 2-pack acrylic polyurethane

F

Note 1: Not to be used for cyclic temperature condition. Note 2: 100 m of 2 pack silicone base primer (Hi-Temp 1027 or Jotatemp 650) is also

recommended as an alternate primer. In this case, EPC contractor shall propose the detailed painting system data sheet for Company review/approval prior to application.

.


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TABLE-A2: SELECTION OF COATING SYSTEMS FOR INSULATED AND FIREPROOFED MATERIAL (SUITABLE FOR MARINE ATMOSPHERE), for

steel structures, equipment, piping etc. Important Note: Detailed painting systems data sheets for each of the cases shall be submitted by EPCC contractor to

Company for review & approval prior to application, with exception of painting system E, P and Q. Scope Specification System

Insulated C.S at cryogenic services. Up to - 4C.

Surface prep. : abrasive blast cleaning to ISO Sa 2.5 (RZ = 50-75 m) Primer : 12-16 mils of thin film epoxy phenolic primer. Intermediate : 150m of 2-pack epoxy MIO Finish : 50m of 2-pack acrylic polyurethane

K

Insulated C.S at cryogenic services. - 4C to lower temp.

Surface prep. : abrasive blast cleaning to ISO Sa 2.5 (RZ = 50-75 m) Primer : Silicone base primer (Hi Temp 1027 Cryogenic type) Intermediate : 150m of 2-pack epoxy MIO Finish : 50m of 2-pack acrylic polyurethane

L

Insulated C.S. Up to 150C

Surface prep. : abrasive blast cleaning to ISO Sa 2.5 (RZ = 50-75 m) Primer : 12-16 mils of epoxy phenolic or 16-20 mils of epoxy-novolac for severe wet environment and critical process. Intermediate : 150m of 2-pack epoxy MIO Finish : 50m of 2-pack acrylic polyurethane

M

Insulated C.S. Above 150 C to 400C

Surface prep. : abrasive blast cleaning to ISO Sa 2.5 (RZ = 30-75 m) Primer : Silicone base primer (HiTemp 1027 or Thurmaloux 70) Finish : 2 x 30m of silicone acrylic coating

N

Insulated C.S. Above 400 C to 648 C

Surface prep. : abrasive blast cleaning to ISO Sa 2.5 (RZ = 30-75 m) Primer : Silicone base primer (Hi Temp 1027) Finish : 2 x 25m of single pack silicone-based coating

O

Insulated C.S and S.S vessels and cyclic temperature piping - 196 C to 400 C

Surface prep. : abrasive blast cleaning to ISO Sa 2.5 (RZ = 50-75 m) Coating : 2 x 100 m of Titanium Modified Inorganic Co-polymer P

Insulated C.S and S.S constant operating temperature piping - 165 C to 565 C

Surface prep. : abrasive blast cleaning to ISO Sa 2.5 (RZ = 50-75 m) Coating : 1 x 175m of Titanium Modified Inorganic Co-polymer.

Q (Note 1)

Insulated S.S. -196C to 200C

Surface prep. : Light abrasive blast cleaning (RZ = 30-50 m) Primer : 100 m of 2 pack epoxy phenolic primer Finish : 100 m of 2 pack epoxy phenolic finish

E (Note 2)

fireproofed (with concrete) galvanized structural steel ambient temperature

Surface prep. : light abrasive blast cleaning (RZ = 10-15 m) or treatment with mordant/etching solution Coating : 2-pack polyamide epoxy

(for touch up of HDG surfaces; refer also to para. 5.9.2)

G

fireproofed (with concrete) structural carbon steel ambient temperature

Surface prep. : abrasive blast cleaning to ISO Sa 2.5 (RZ = 50-75 m) Coating : 75m of 2-pack polyamide epoxy H

Note 1: Not to be used for cyclic temperature condition.. Note 2: 100 m of 2 pack silicone base primer (Hi-Temp 1027 or Jotatemp 650) is also recommended as an alternate

primer. In this case, EPC contractor shall propose the detailed painting system for Company approval.


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Appendix-B: Approved Painting manufacturers

Table-B: List of recommended manufacturers

Manufacture name Plant Location Hempel Paints SA Dammam / Saudi Arabia Sigma Paints Dammam / Saudi Arabia International Paint SA Dammam / Saudi Arabia Jotun Paints Yanbu / Saudi Arabia Oasis Ameron Ltd. Dammam / Saudi Arabia SIPCO Dammam / Saudi Arabia AMERON CARBOLINE HEMPEL INTERNATIONAL JOTUN SIGMA


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Appendix C: Colour Schedule Table C: Basic colour scheduling and coding

No Description Colour RAL No Remarks

1.0 Structural Steel

Structural steel (Pipe Rack, etc.) Light Grey 7042 As per Para. 5.1.1 of JERES-B-067.

Structural column up to 1.5 m from base plate (ground level) Black 9005 Over either steel or galvanized steel

Structural column along the road and bridge up to 1.5 m from base plate (ground level) Black and Yellow

Stripe (*) 9005/1021 Over either steel or galvanized steel

Structural steel diagonal cross bracing up to 1.5 m from base plate (ground level) Black and Yellow

Stripe (*) 9005/1021 Over either steel or galvanized steel

Supporting Beam Light Grey 7042 As per Para. 5.1.1 of JERES-B-067.

Platform Light Grey 7042 As per Para. 5.1.1 of JERES-B-067.

Grating, stairways/Galvanized ------- ------- Hot dip galvanized

Handrail, ladder and cage Yellow 1021 Yellow-and-Black Stripes shall be used at the concrete base support of ladders to provide additional caution

Guard-rail , Safety bars, Stand bars (***), Black and Yellow Stripe (**) 9005/1021

Auxiliary Pipe Supports Same as piping (*) for reference see Figure 1 (**) stripe shall be 250 mm long (***) stand bars and chains around each process area

2.0 Equipment

Tanks, Column, Drum, Filter & Dryer, Air Cooler, Shell & Tube H/E Light Grey 7042 As per Para. 5.1.1 of JERES-B-067.

Equipment Skirt & Leg Light Grey 7042 As per Para. 5.1.1 of JERES-B-067.

Combustion Equipment (Burner, Reactor Furnaces, Thermal Oxidizers, Stacks etc.) Light Grey 7042

Galvanized Surfaces ---------- ----------

Equipment Skirt (fireproofing required) As fireproofing colour ----------

3.0 Machinery

Pump and Compressor (for Normal Temperature Condition) with Lube Oil Unit and Auxiliary Piping and Base plate

Light Grey 7042

Pump, Blower and Compressor (for High Temperature Condition) Aluminum 9006

Blower with Auxiliary Piping Light Grey 7042

Motor Machinery Green 6021

Gear Box Light Grey 7042

Coupling Guard /Coupling Cover Hood Orange 2000

Seal Gas Filter on Compressor Skid Light Grey 7042

Lube Oil Skid consisting Tanks, Pumps, Filters and Auxiliary piping Light Grey 7042

Lube Oil Cooler Light Grey 7042

Lube Oil Interconnecting Piping Light Grey 7042


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Other Skid Base Plate Light Grey 7042

4.0 Piping

Fire Water Piping Red 3000 For exceptions see Para. 5.2.1 a) of JERES-B-067 Potable Water Piping Blue 5015 As per Para. 5.2.5 of JERES-B-067

Other Piping Light Grey 7042 As per Para. 5.1.1 of JERES-B-067.

Inlet and Outlet Maintenance Block Valves for Pressure Relief Valves and other Automated Emergency Isolation and Depressuring Valves, Car-sealed Valves of any type

Orange 2000 As per Para. 5.2.4 of JERES-B-067

Break-away Spools that are used to temporarily connect Utilities to Process Systems to Process Equipment

Black/Yellow Stripe 9005/1021 As per Para 5.2.4 of JERES-B-067

Hose Connector for Demineralized Water in Utility Stations Blue/White stripe 5015 As per Para 19.4 of JERES-L-310

Hose Connector for Raw Water in Utility Stations Blue 5015 As per Para 19.4 of JERES-L-310

Hose Connector for Air in Utility Stations Green/Grey 6016/7042 As per Para 19.4 of JERES-L-310

Hose Connector for Steam in Utility Stations White 9010 As per Para 19.4 of JERES-L-310

Hose Connector for Nitrogen in Utility Station Green/Orange 6016/2000 As per Para 19.4 of JERES-L-310

5.0 Electrical Item

Switchgear, control gear Light Grey 7042 or ANSI 61

Motor Control Center (MCC) Light Grey 7042 or ANSI 61

Electrical Distribution Panel Light Grey 7042 or ANSI 61

Battery Charger Light Grey 7042 or ANSI 61

Uninterruptible Power Supply (UPS) Light Grey 7042 or ANSI 61

Transformer Light Grey 7042 or ANSI 61

6.0 Instrument

Indoor Cabinets: Exterior Refer to specific MR Refer to specific

MR

Any new cabinets installed in existing building should have the same colour of existing

cabinets in the same building. All new cabinets installed in a new building

should have same colour, which should match with the interior colour of the building

Indoor Cabinets: Interior White Mfr's Standards Interior white preferred or light Grey or off white as per Para 6.4.1 or JERMS-J-4820 Outdoor Cabinets: Exterior Mfr's Standards Mfr's Standards As per Para 6.4.1 of JERMS-J-4820

Outdoor Cabinets: Interior White Mfr's Standards Interior white preferred or light Grey or off white. No spec. given in JERMS-J-4821 but assume same requirement as JERMS-J-4820.

Analyzer House White 9010 Analyzer Shelters Mfr's Standards Mfr's Standards As per JERMS-M-2014, Para 7

Instrument Valves (CV, On-off Valve ) Mfr's Standards Mfr's Standards

CV and Actuator as per Para 9 of JERMS-J-4711. On-off Actuator as per Para 7.5 of

JERMS-J-4716. RV: No paint colour specified unless stated on P.O. as per Para 4.5a of

JERMS-J-4611


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All Relief Valves Green 6016

Control valve and On-off Valve actuators Mfr's Standards Mfr's Standards

Indoor ESD Panel Mfr's Standards Mfr's Standards

Junction Box Outdoor Mfr's Standards Mfr's Standards N/A if selected as stainless steel

Indoor Mfr's Standards Mfr's Standards

Other Instrument Items Mfr's Standards Mfr's Standards

7.0 Packaged Equipment

Structural Steel As per the requirement of No. 1.0 above

Equipment As per the requirement of No. 2.0 above

Machinery As per the requirement of No. 3.0 above

Piping As per the requirement of No. 4.0 above

Instrument As per the requirement of No. 6.0 above

8.0 Fire Protection Equipment

Portable and Fixed Fire Protection System Red 3000 As per Para 5.2.1 b) of JERES-B-067.

Mounting Background for Fire Extinguisher Red 3000 As per Para 5.2.1 b) of JERES-B-067.

Portable Fire-fighting Equipment Red 3000 As per Para 5.2.1 b) of JERES-B-067.

Shelters for Portable Fire-fighting Equipment Red 3000 As per Para 5.2.1 b) of JERES-B-067.

Fire water pumps Red 3000 As per Para 5.2.1 b) of JERES-B-067.

Fire water pumps control panels Red 3000 As per Para 5.2.1 b) of JERES-B-067.

Emergency Stop Pushbutton Devices and Switches Red 3000 As per Para 5.2.1 b) of JERES-B-067.

9.0 Others

Emergency Eye-wash and Shower Mfr's Standards

Background of Emergency Eye-wash and Shower Green 6016 As per Para 5.2.2 a) of JERES-B-067

Eye Protection Area/On Paving Black and Yellow Stripe 9005/1021 As per Para 5.2.3 a) of JERES-B-067

Manholes Cover Yellow 1021

Communication Manholes Cover Orange 2000 As per Para 5.2.4 e) of JERES-B-067

Lifting equipment and devices such as davits, monorails and lifting beams (whether permanent or used only for construction)

Yellow 1021 As per Para 5.2.3 of JERES-B-067

EDS System associated Instruments Isolation Valves Orange 2000

Background of Emergency Safety Equipment Green 6016 As per Para 5.2.2 a) of JERES-B-067


JERES-H-001 Rev. 3A

Coating Selection & Application Requirements for Industrial Plants & Equipment

26 November 2008



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Appendix D - Form PAINTING SYSTEM DATA SHEETS

Form 1 - Painting schedule PAINT SYSTEM:

According to project specification Surface preparation:

Brand name Product name (*)

Paint type (description) N of coat

D.F.T of coat (m)

Color

Primer

Intermediate

Finish

Total D.F.T. m): Note:

The manufacturer of the paint products shall be able to provide supporting data from tests carried out in accordance to standard Norsok M501 or equivalent.

To be repeated for each Paint system


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Appendix E - PAINTING SYSTEM DATA SHEETS FOR NON-INSULATED MATERIAL 1) PAINT SYSTEM A

SYSTEM A Manufacturer AMERON

1. REFERENCE SYSTEM

1.1. Surface preparation: SA 2 1.2. Coating:

1st coat 2nd coat 3rd coat 4th coat

Trade name AMERCOAT 68 G AMERCOAT 383HMIO AMERCOAT 450 E Type zn epoxy epoxy polyamideMIO acrylic polyurethane

Recommended colour Red/Gray 7035 RAL/BS Nominal dry film thickness (m) 75 150 50

Thinner Amercoat 9 HF Amercoat 65 Amercoat 920

1.3. Application

Relative humidity 85% 85% 85% Temperature min/max + 10C / + 35C + 10C / + 35C + 7C / + 35C

Recoating interval at 20C and RH 60% MIN/MAX

4h /12 months 10h /12 months 6h/12 months

Nominal system dry film thickness 275 m

2. REPAIR SYSTEM

2.1. Surface preparation: SA 2 2.2 Coating: SAME

3. REMARKS

3.1. Inspections:

Dry film thickness According to ISO 19840 Minimum adhesion 5 Mpa


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SYSTEM A Manufacturer CARBOLINE

1. REFERENCE SYSTEM

1.1. Surface preparation: SA 2 cording to ISO 8501-1 ISO 8503 Grade Medium G 1.2. Coating:


Trade name Carbozinc 858 P Carbomastic 15 LT Carbothane 834 Type Epoxy zinc rich Epoxy Mastic Aluminum

pigmented Acrylic polyurethane

Recommended colour Green/Gray Aluminum Nominal dry film thickness (m) 75 175 75

Thinner No.2 No.2 No.25

1.3. Application

Relative humidity 95% 95% 80% Temperature min/max + 4C / + 45C + 2C / + 40C + 4C / + 35C


4h / NA 6h / 14 days 5h / NA


2. REPAIR SYSTEM

2.1. Surface preparation: St3 according to ISO 8501-1 2.2 Coating: Touch-up with CARBOMASTIC 15 LT at DFT 75-100 m

Application of intermediate and finish coat at DFT provided for original system

3. REMARKS

3.1. Inspections:

Dry film thickness According to ISO 19840 Minimum adhesion 5 MPa


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SYSTEM A Manufacturer HEMPEL

1. REFERENCE SYSTEM

1.1. Surface preparation: Sa 2,5 1.2. Coating:


Trade name 15700 45880 55210

Type Inorganic zinc silic. Polyamide epoxy Aliphatic polyurethane

Recommended colour Grey 19840 Grey 12170 All colours available

Nominal dry film thickness (m) 75 150 50 Thinner 08700 08450 08080

1.3. Application

Relative humidity Min. 65% 85% 85% Temperature min/max + 0C / + 40C - 5C / + 40C -10C / + 40C


When fully cured / none

7 h / none 10 h / none


2. REPAIR SYSTEM

2.1. Surface preparation: SA 2,5 2.2 Coating: 17360-19830 System build-up

3. REMARKS

3.1. Inspections:

Dry film thickness According to ISO 19840

Minimum adhesion 5 MPa


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SYSTEM A Manufacturer INTERNATIONAL PAINT

1. REFERENCE SYSTEM

1.1. Surface preparation: Sa 2.5 (50-75m) 1.2 Coating:


Trade

JERES-H-001 Coating Selection Application Requirements

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