SP 1246(Part 4 2003) PDO Painting Spec

Specification for Painting and Coating of Oil and Gas Production Facilities – Part - 4 Version 1.0

Petroleum Development Oman L.L.C.

UNRESTRICTED Document ID : SP-1246July 2003 Filing key : xxxx

Specification for

Painting and Coating of

Onshore Process Facilities

PART 4:

SURFACE PREPARATION,

APPLICATION AND INSPECTION

OF COATING SYSTEMS

Keywords:

Abrasive

Blast cleaning

Coating

InspectionPainting

Safety

Spray application

Surface preparation

TestingThicknessVentilation

This document is the property of Petroleum Development Oman L.L.C. Neither the whole nor any part of this document may be disclosed to others nor reproduced, stored in a retrieval system, or transmitted in any form by any means (electronic, mechanical, reprographic recording or otherwise) without prior written consent of the owner.

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Authorised For Issue

Signed :……………………………UER/CFDH Materials & CorrosionM.Jansen

Version No. Date Author Scope / RemarksERD-65-12 Aug.91 TTH/5 Original ERD DocumentSP-1246 Ver.0 May 2002 OTT/11 Updated and in new PDO formatSP-1246 Ver.1 July 2003 TTO/11 For issue

INSTRUCTIONS TO USERMake sure this is the latest issue of this specification. Refer to the EMDS for the last issue date.

Where this Specification refers to DEPs and International Standards, it refers to the issues that were in-use when the author wrote this Specification. Exceptions are references to specific issues. If you use DEPs or International Standards with this Specification, make sure you use the relevant issues.

Do not change this Specification without approval. Only the Custodian, the Corporate Functional Discipline Head (CFDH) who owns this Specification, can give approval for changes. If you think the Specification is not correct, write your comments on a copy of the User Comment Form. The form is the last page of this Specification.

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Contents

1 Preface.......................................................................................................................................51.1 Background.......................................................................................................................................................51.2 Applicability.....................................................................................................................................................51.3 Language and Units of Measurement...............................................................................................................6

2 Introduction...............................................................................................................................72.1 General..............................................................................................................................................................72.2 Scope.................................................................................................................................................................7

3 Coating Materials.....................................................................................................................83.1 Procurement and Storage..................................................................................................................................8

3.1.1 Approvals..................................................................................................................................................83.1.2 Uniformity of Supply................................................................................................................................83.1.3 Packaging, Labelling and Shelf Life.........................................................................................................8

3.2 Preparation for Use...........................................................................................................................................83.2.1 Homogenising...........................................................................................................................................83.2.2 Mixing of Two-Component Coatings.......................................................................................................93.2.3 Thinning....................................................................................................................................................9

4 Equipment...............................................................................................................................104.1 Compressors....................................................................................................................................................104.2 Blast Cleaning Equipment..............................................................................................................................104.3 Abrasives.........................................................................................................................................................104.4 Spraying Equipment........................................................................................................................................114.5 Scaffolding, Staging and Accessibility...........................................................................................................11

5 Surface Preparation................................................................................................................125.1 General............................................................................................................................................................125.2 Prior to Blast Cleaning....................................................................................................................................12

5.2.1 Solvent Cleaning.....................................................................................................................................125.3 Power Tool Cleaning......................................................................................................................................125.4 Blast Cleaning.................................................................................................................................................13

5.4.1 Environmental Conditions......................................................................................................................135.4.2 Blast Cleaning Techniques.....................................................................................................................135.4.3 Grade of Surface Finish..........................................................................................................................145.4.4 Degree of Roughness..............................................................................................................................145.4.5 Post Blast Cleaning.................................................................................................................................145.4.6 Preparation of Coated Surfaces...............................................................................................................145.4.7 Preparation of Corroded Surfaces...........................................................................................................145.4.8 Stainless Steel and Galvanised and Non-ferrous Surfaces.....................................................................155.4.9 Inspection................................................................................................................................................15

6 Coating Application................................................................................................................166.1 Environmental Conditions during Coating.....................................................................................................16

6.1.1 Weather Conditions................................................................................................................................166.1.2 Weather Protection..................................................................................................................................166.1.3 Ventilation...............................................................................................................................................16

6.2 Application techniques....................................................................................................................................176.2.1 General....................................................................................................................................................176.2.2 Protection of Equipment.........................................................................................................................186.2.3 Airless Spray...........................................................................................................................................186.2.4 Brush Application...................................................................................................................................186.2.5 Roller Application...................................................................................................................................196.2.6 Glass Reinforced Epoxy Lining..............................................................................................................196.2.7 Specialist Coating Systems.....................................................................................................................196.2.8 Design Requirements for Effective Coating Application .....................................................................19

7 Control and Inspection...........................................................................................................207.1 General............................................................................................................................................................207.2 Project Co-ordination and Technical Service.................................................................................................20

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7.3 Inspection and Testing....................................................................................................................................207.4 Reporting.........................................................................................................................................................25

8 Safety........................................................................................................................................278.1 General............................................................................................................................................................278.2 Fire and Explosion Hazard..............................................................................................................................27

8.2.1 Ventilation and Extraction......................................................................................................................278.2.2 Sources of Ignition..................................................................................................................................278.2.3 Storage....................................................................................................................................................288.2.4 Cleanliness..............................................................................................................................................288.2.5 Fire-fighting Equipment..........................................................................................................................28

8.3 Toxic Hazards.................................................................................................................................................288.3.1 General....................................................................................................................................................288.3.2 Inhalation................................................................................................................................................298.3.3 Ingestion..................................................................................................................................................298.3.4 Skin Contact............................................................................................................................................308.3.5 Eye Protection.........................................................................................................................................308.3.6 Disposal of Residues from Cleaning and Coating Operations................................................................30

8.4 Safe Working Conditions................................................................................................................................308.4.1 Blast Cleaning and Painting Equipment.................................................................................................308.4.2 Blasting and Painting Operations in Confined Areas.............................................................................308.4.3 Drying.....................................................................................................................................................31

8.5 Scaffolding and Ladders.................................................................................................................................318.6 Safety Reporting.............................................................................................................................................31

9 Related Business Control Documents...................................................................................329 Appendix A Glossary of Definitions, and Abbreviations...................................................34

9.1 Standard Definitions.......................................................................................................................................349.2 Special Definitions..........................................................................................................................................349.3 Abbreviations..................................................................................................................................................35

Appendix B Contractor’s Daily Painting Report.....................................................................36

Tables

Table 1 Inspection and Testing Summary................................................................................................................21

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1 Preface

1.1 Background

This Specification SP-1246, covers the minimum requirements for protective painting and coating systems materials and application methods for the internal and external surface of steel structures and equipment within the oil and gas production facilities.

Relevant structures and equipment include aboveground and buried, onshore tanks, vessels, in-station pipework, structural steelwork, and electrical and mechanical equipment.

Whilst the Specification is directed predominantly at protection of onshore oil and gas installations, it also covers external protective coating of marine facilities such as mooring buoys, barges and launches.

Internal surfaces of pumps, valves and other mechanical equipment requiring special protective treatments, are not dealt with in this Specification. For guidance on this contact UER/CFDH Materials and Corrosion.

The external coating of new pipelines and existing pipelines requiring rehabilitation are covered in the alternative Specifications and procedures listed below.

GU-368 Guidelines For The Protection Of Buried Sections Of Surface Laid Pipelines/FlowlinesPR-1180 Procedure for Qualification of Pipeline Rehabilitation Coating Systems DEP 31.40.30.31-Gen. Technical Specification for External Polyethylene and Polypropylene Coating for Line PipeDEP 31.40.30.32-Gen. Technical Specification for External Fusion-bonded Epoxy Powder Coating for Line Pipe

1.2 Applicability

All coating work shall be carried out in accordance with this Specification. If a variance is required then approval, in writing, from the Custodian UER/CFDH Corrosion and Materials is required.

This Specification is not applicable retroactively.

This specification does not apply to concrete structures. For concrete structures in corrosive environment consult UER/CFDH Materials and Corrosion.

This is Part 3 of a five part Specification and must be read in conjunction with Parts 1, 2, 4 and 5.

PART 1 specifies technical and related requirements. This part includes performance tests and acceptance criteria for assessing the acceptability of paint/coating/lining systems for each service specified in Parts 2 and 3.

PART 2 contains recommended protective coating systems for the following categories with respect to new construction painting/coating activities:

- External surfaces of carbon steel structures, piping and equipment, onshore and marine

- External surfaces of buried carbon steel structures and piping (except Class I and Class II

pipelines)

- Internal surfaces of tanks and vessels

- Stainless steel and galvanised piping and equipment

- Areas beneath insulation

- Specialist applications

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This part also gives descriptions of the generic types of paint used for new construction projects. The descriptions apply equally to the maintenance paint systems presented in Part 3.

Protective coatings for new pipelines based on Polyethylene (PE), Polypropylene (PP) or Fusion Bonded Epoxy (FBE), are not specifically covered in this Specification but the general good practices described in this part are equally applicable to the coating of line pipe.

PART 3 contains recommended maintenance coating systems the following categories with respect to location and painting/coating activities and inspection of old coatings:

- External coatings on carbon steel structures, piping and equipment, onshore and marine

- External coatings of below ground carbon steel structures and piping including Class I and

Class II pipelines

- Internal coated surfaces of tanks and vessels

- Stainless steel and galvanised piping and equipment

PART 4 contains the detailed requirements for surface preparation and application of coatings to the categories stated in Parts 2 and 3. This Part contains HSE advice and general inspection requirements.

PART 5 Contains the list of approved coating systems and is a live document that will be updated by UER. This includes coating systems that have been grandfathered in.

New Projects

PARTS 1, 2 and 4 apply in their entirety to new projects where painting and coating activities are carried out at site or in the shop.

For painting and coating of package items, carried out prior to delivery to site or to existing facilities, the requirements, stated in PARTS 1 and 4, apply in their entirety, whilst those of PART 2 apply where applicable.

Maintenance

Where maintenance painting is to be done, PDO’s technical requirements are stated in PART 1 and those sections of PART 3 and 4 as appropriate, dependent upon the Scope of Work.

1.3 Language and Units of Measurement

This specification uses and requires the use of the International System (SI) units of measurement in all

documentation. Paint film thicknesses are expressed in microns, 1micron is 0.001mm.

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2 Introduction

2.1 General

This part of Specification SP-1246 outlines the minimum requirements for preparation and painting of steel surfaces of equipment and structures in the PDO oil and gas production and processing facilities. The costs and commitment for regular inspection and testing at all stages of a painting contract, whether for new construction or for upgrade, generally prove attractive by saving costs and time for premature coating repair and by ensuring that the protective system extends to its full service life.

Only PDO approved coating contractors who have an approved QA manual and HSE plans and procedures in place that include coating application and surface preparation are allowed to apply coatings on PDO equipment.

The Paint Contractor must have in place a Method Statement (MS) which covers all aspects of safety and an Inspection and Test Plan (ITP), approved by the PDO Materials and Integrity Management Department, prior to starting the work.

Only personnel, having the necessary, valid inspection qualifications and specific experience with the application of the particular system being used, will be permitted to undertake painting and coating inspection.

2.2 Scope

This Specification covers the minimum requirements for surface preparation, application and inspection of new construction and maintenance coating systems on steel structures for PDO oil and gas production/processing facilities and related utilities.

This Specification is intended for use by Petroleum Development Oman LLC in specifying painting and coating requirements for new construction and maintenance projects.

Cases not covered in this Specification shall be discussed with the Document Custodian UER/CFDH Materials and Corrosion.

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3 Coating Materials

3.1 Procurement and Storage

3.1.1 Approvals

The Purchaser shall approve all paint, coating and lining materials for each project.

3.1.2 Uniformity of Supply

All coating materials specified in a particular painting schedule or those intended for application to a group of similar surfaces shall be products from the same manufacturer.

3.1.3 Packaging, Labelling and Shelf Life

Paints shall be supplied in the original undamaged manufacturer’s containers, complete with product references, batch numbers and expiry of shelf life clearly shown. Except for specific sampling that may be taken for testing/inspection, the containers shall remain unopened until required for use.

The paint consignment shall be examined upon receipt to verify that containers are correctly labelled and that paperwork, confirming product composition and traceability, application method and health and safety information, is correct. Each container must have its own clear, securely fixed label that must contain the following information, legibly printed in English:

coating name coating description contents name and identification code colour reference batch number batch manufacture date shelf life expiry date manufacturer’s name and recognised trade mark basic information and instruction for:

- flammability and fire protection- ventilation and personnel protection requirements- spillage and skin contact

Each delivery of paint shall be supplied with a minimum of 4 copies of:- coating data sheet- application instructions- material safety data sheets- PDO SHOC cards

Paint that has exceeded its marked shelf life shall not be used. Additionally, paint shall not be used if it has thickened to such extent that more than 5% by part (10% by part for primers) of the correct thinners is required to bring it to application consistency. Any damaged containers and containers with loose fitting lids shall not be used.

The oldest paint in stock shall be drawn first to ensure correct stock rotation.

3.2 Preparation for Use

3.2.1 Homogenising

Mixing of painting and coating materials is critical and should be carried out under close supervision to ensure correct results. The drum should be opened and the bulk of the liquid portion poured into a clean drum of similar size with an open top. The residual paste shall then be broken up by stirring with a wide strong wooden paddle. Once the residue has been worked into a smooth and uniform paste, the liquid portion, originally poured off, shall be replaced in small quantities, while stirring with a power driven

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stirrer moving with a figure-of-eight motion. If the residue cannot be worked into a smooth and uniform paste by this treatment, the paint shall not be used.

When the paint appears to be completely uniform, it shall be ‘boxed’ by pouring repeatedly from one drum to the other. Before use, the paint shall be strained through 100 mesh metal gauze to ISO 3310 to remove any skin or small lumps.

Only thinner supplied, recommended or approved by the paint manufacturer for the particular paint type shall be used.

Where coatings are being used containing metallic or heavy pigments that have a tendency to settle, a power driven stirrer shall be used in a pressure pot or fitted in the supply drum for an airless spray pump.

3.2.2 Mixing of Two-Component Coatings

Paints that are supplied as two components in separate containers shall be mixed together immediately before use and shall be applied within the time specified by the Manufacturer. The methods of preparing these types of paint shall be as follows

3.2.2.1 Epoxy Resin-based Paints

Epoxy resin-based paints and high-build epoxy’ paints are supplied as two components in separate containers in the correct proportions for mixing. These components shall be mixed in the correct proportions since curing takes place by chemical reaction. Once mixed, the paint shall be used within the time limits specified by the supplier (pot life). When the base material has settled out it shall be stirred thoroughly in order to reduce its viscosity before adding the curing agent.

3.2.2.2 Polyester/vinyl Ester

Choose quantity of curing agent, accelerator and inhibitor according to the Manufacturers recommendations and ambient temperature. Inhibitor and/or accelerator ( as appropriate) must be thoroughly mixed with the glassflake before adding the required amount of MEK-peroxide

If the temperature is near the maximum permitted in the zone seek guidance from the manufacturer (changes will depend on the degree of pre-accelerator already applied). It is recommended to reduce the content of peroxide/accelerator respectively or to increase the content of inhibitor. For all stages of mixing follow the manufacturers recommendations.

Accelerator and MEK-peroxide must never be mixed directly together

3.2.2.3 Zinc-silicate Paints

Zinc-silicate paints are supplied as separate powder and vehicle in the correct proportions for mixing. They shall be mixed thoroughly before use and stirred frequently during application.

3.2.2.4 Products from Different Manufacturers

Products from different Manufacturers shall not be used in the same coating system, although in maintenance painting, this may be permitted at the discretion of PDO, when new systems are to be applied over existing sound coatings.

3.2.3 Thinning

Thickening is usually due to prolonged storage. If thickening prevents proper application by brush, not more than 5% by part of thinner shall be added. In all cases, thinners recommended or approved by the paint manufacturer shall be used.

Gasoline, kerosene or gas oil shall not be added to paint.

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4 Equipment

4.1 Compressors

Air compressors shall comply with the safety requirements in Section 8 of this Specification. The compressed air supply used for blasting shall be free from water and oil. Adequate dryers, separators and traps shall be provided and these shall be kept emptied of water and oil. Accumulations of water and oil shall be removed from the air receiver by regular purging.

Air compressors shall not deliver air at a temperature greater than 110oC

Compressors and associated pressure vessels shall be protected against over-pressuring by fitting relief valves. Pressure test certificates for all vessels and valves shall be made available on site for inspection.

4.2 Blast Cleaning Equipment

All blasting equipment shall comply with the safety requirements in Section 8 of this Specification and be of an intrinsically safe construction.

Blasting cleaning and spray painting equipment shall be continuously bonded from nozzle to compressor which shall be earthed and conductive hoses used to prevent build-up of static electricity.

The blasting abrasive shall be discharged with a pressure at the nozzle (measured with a hypodermic pressure gauge) of 700 kPa g, (100 psig) and shall not under any circumstances fall below 650 kPa g (95 psig). To restrict pressure drops, pressure hoses should be correctly sized and as short as possible. The inspector will check to ensure that all hose joints are wired to ensure earthing and connections are leak tight and properly maintained.

Venturi, rather than parallel bore, nozzles shall be used. These shall be constructed of tungsten carbide or boron and discarded when wear reaches 50%.

The blasting operator’s hood or headgear shall be ventilated by clean cool air served through a regulator/ filter to prevent blasting residues from being inhaled by the operator. The air supply shall come from the compressor, be passed through suitable filters and be free from oil and water. Ventilation of the hood shall meet the requirements laid down in BS 4275.

4.3 Abrasives

Abrasives that may be used in blast cleaning are specified in ISO 11126 parts 1-10 and ISO 8504-2. Suitable abrasives include the following:

Ferrous materials which are re-usable- Steel grit or shot

- Iron grit or shot

- Chopped steel wire

Crushed slags which are expendable are referenced in ISO-11126 parts 1-10

- Blast furnace slag –part 6 of ISO-11126

- Copper slag – part 3 of ISO-11126

- Aluminium silicate – part 4 of ISO-11126

Natural minerals which are re-usable

- Garnet – part 10 of ISO-11126

HIGH-SILICA SAND AND OTHER MATERIALS CONTAINING FREE SILICA SHALL NOT BE USED.

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Abrasive shall be free from oil, grease, moisture, salts, and shall not be rusty, noticeably worn or dull when compared with fresh material. The abrasive selected shall be suitable to achieve the degree of blast profile recommended by the paint Manufacturer and as stated in the painting schedules.

Expendable abrasives shall be free of metallic copper, chlorides and soluble salts and shall contain no more than 2% by weight copper oxide.

Isolated spot blasting on previously coated surfaces should be carried out using vacuum recovery blasting equipment.

Preparation of stainless steel may be done using aluminium oxide or other abrasives that are free of chloride and iron and steel contamination.

Abrasives, specified as re-usable to be properly recovered and cleaned

Abrasives, specified as non-reusable, shall not be reused without prior approval of PDO.

4.4 Spraying Equipment

The spraying equipment to be used shall meet the recommendations and instructions set forth by the Paint Manufacturer for each specific paint or coating system. For airless spray, the correct tip range and fluid pressure setting shall be used.

For conventional sprays an adequate moisture trap shall be placed between the air supply and pressure pot feed to the gun. The trap shall continuously bleed off any water or oil from the air supply.

Suitable working regulators and gauges shall be provided for the air supply to the pump or pressure pot.

Spraying units shall be earthed and precautions taken to prevent build-up of static electricity.

4.5 Scaffolding, Staging and Accessibility

Fixed scaffolding or staging shall be used as required for surface preparation and painting and shall comply with the PDO HSE specification SP-1257 and guideline GU-363. It shall be such that easy and sufficient access will be provided for correct preparation, paint or coating application, and inspection of all surfaces. Operators shall be able to stand up with body and arms unhindered by scaffolding, staging or the structure being worked on.

The contractor shall provide all rigging and scaffolding equipment needed to complete the work in accordance with the specification.

Scaffolding shall not be removed until after the final inspection of the coating.

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5 Surface Preparation

5.1 General

Surface preparation shall be carried out in general accordance with the following standards ISO-8501,ISO 8502, ISO-8503 and ISO-8504 which have been developed to cover all aspects of surface preparation.

Surface preparation shall not be undertaken when:

- surface temperatures below 5oC

- surface temperature is less than 3oC above dew point of the surrounding air

- the relative humidity of the air is greater than 85%

- outside day light hours on external surfaces.

PDO may authorise surface preparation outside daylight hours, but the Contractor must receive written approval before proceeding.

5.2 Prior to Blast Cleaning

Grease, oil, etc, shall be removed by means of solvent cleaning (see 5.3) or by high-pressure water jetting or steam cleaning with, where necessary, a biodegradable alkaline cleaning agent. The cleaned surface shall be rinsed with clean fresh water and allowed to dry. Rags shall not be used for drying. Excessive rust scale may need to be removed using power cleaning tools.

To prevent damage during blast cleaning, sensitive components such as valve stems, gauges, nameplates, areas to be welded, etc, shall be protected by masking with adhesive tape. Such items and areas shall remain protected until the painting is completed.

5.2.1 Solvent Cleaning

Solvent cleaning where specified, shall be in accordance with SSPC-SP-1 ‘Solvent Cleaning’. Solvent cleaning shall normally be carried out prior to blast or power tool cleaning. Any traces or smudges of oil or grease discovered on the blast cleaned surface shall be removed by solvent washing and the whole area re-blasted.

All bolt holes shall be solvent-cleaned prior to blast cleaning.

All surfaces to be painted which do not require blast cleaning or power tool cleaning shall be cleaned down thoroughly, followed by washing down with copious amounts of fresh water. A high-pressure cleaning unit is particularly effective in this application.

Acid washes, or other cleaning solutions or solvents shall not be used on metal surfaces after they are blast or power tool cleaned and prior to paint application.

Wet grit blasting may be considered where dust control is required. Contact UER/CFDH Materials and Corrosion for specific details.

5.3 Power Tool Cleaning

Metal surfaces for which blast cleaning is specified but which because of their location cannot be open blasted shall be prepared wherever practicable by vacuum/blasting. Where this is not possible such areas shall be fully cleaned and prepared using powered equipment.

Power tool cleaning, by scraping, chipping or wire brushing cannot remove firmly adherent millscale and shall be carried out according to ISO 8504-3:1993 and only with the approval of PDO. The following tools shall be used:

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electric or air driven needle guns followed by hand or electric powered wire brushes

electric or air driven disc sanders followed by needle guns where required to achieve the specified profile

electric or air driven vibratory or rotary hammers

Power Tool cleaning shall extend to a minimum of 25 mm into adjoining coated areas and shall be to an equivalent to a visual standard in accordance with ISO-8501-1 St 3.

Needle guns shall have needles of small cross-section, either chisel or pointed tips appropriate for the item under preparation.

The profile of a surface prepared by needle guns shall not exceed 50 microns differential and no sharp edges, craters, etc. shall be left on the metal surface. All rough peaks shall be removed.

Stainless steel tools and wire brushes shall be used to prepare stainless steel surfaces. Carbon steel shall not be used

Brass tools can be used in areas where all sparking must be avoided.

Areas prepared for painting by power and hand tool cleaning shall be primed within four hours and never left unprimed overnight.

5.4 Blast Cleaning

5.4.1 Environmental Conditions

It is essential to ensure that no condensation occurs on blasted steel. To prevent dust and abrasive contamination, blast cleaning shall not be done in open areas close to painting operations or where freshly coated surfaces are still wet. As with other surface preparation methods, blast cleaning shall not be permitted outside daylight hours, except that rough blasting shall be allowed during the night providing that the surface is given a light blasting to the specified standard in subsequent daylight.

When blast cleaning in enclosed spaces, such as tanks and vessels, adequate ventilation shall be provided as detailed in section 8. Full details to be submitted for review by PDO prior to commencement of the work.

In enclosed vessels acceptable environmental conditions can be maintained by the use of dehumidifiers.

Adequate lighting shall be provided to ensure that a minimum lighting level of 500 lux is achieved.

5.4.2 Blast Cleaning Techniques

Surface preparation using abrasive grits shall be performed generally in accordance with ISO 8504-2.

Maximum speed and the most effective cleaning are obtained by systematic, even blasting. Blasting the work in squares may be helpful.

Plate and small sections may be cleaned, prior to fabrication or assembly, in closed containers such a wheelabrators or in manual blast cubicles where the abrasive may be recovered, cleaned and reused.

Blast cleaning shall overlap by a minimum of 25mm into any adjacent coated areas. Steel work not primed and/or wetted by rain or moisture shall be blasted again prior to being painted.

5.4.2.1 High-pressure Water Jetting

Although seldom used for surface preparation prior to painting, blasting a surface with high-pressure water is widely used for removing surface debris and contaminants, The technique is commonly used underwater

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for removing marine growth on ships, jetties and offshore structures at typical pressures of 20 MPa. (3000 psi)

When using high-pressure water jetting to clean a lined or coated surface, the nozzle pressure must be controlled to prevent coating damage and should generally be less than 700 kPa (100psi).

5.4.3 Grade of Surface Finish

Mill scale, rust, corrosion products, paint or any other foreign matter shall be removed by blast cleaning to the grades specified.

For any coating, painting, lining or wrapping work, the standard grades of surface finish by blast cleaning shall be specified using ISO 8501-1.

5.4.4 Degree of Roughness

The required degree of surface roughness or peak-to-valley height after blast cleaning depends on the type of paint to be applied. In general, a surface roughness in the range of 30 to 75 microns is usually required for coating systems with a maximum DFT of 400 microns. For DFTs greater than 400 microns, the surface roughness should be 75-100 microns. Refer to Part 2 for surface profiles for each PCS. The surface profile shall be measured using methods A and C as detailed in ASTM D4417. These are for use of surface comparator and Testex tape. The mean value as described in Method C shall be used to determine the surface profile. The actual measurement for inspection shall be the mean value using Method C and this shall be recorded in the daily painting record sheet.

5.4.5 Post Blast Cleaning

A dry abrasive blast cleaned surface shall be brushed with clean brushes made of hair, bristle or fibre, blown off with compressed air (free from oil and water) or vacuum cleaned to remove all traces of blast-cleaned products from the surface or from pockets and corners. Surface cleanliness shall be in accordance with ISO 8502-3 and other relevant sections of ISO 8502 as required by coating application procedure. Tests shall be carried out to confirm the degree of cleanliness and full details shall be included in the Method Statement.

For external coating no surface shall be blast cleaned which cannot be painted within the same working day. For internal surfaces where humidity is < 30% then application of coating can be delayed depending on measured humidity levels. Any time constraints between blasting and the application of paint coatings as specified by paint Manufacturers shall be strictly applied. Should delays between blasting and painting cause flash rusting of the steel surface, that surface shall be given a sweep blast before painting can proceed.

5.4.6 Preparation of Coated Surfaces

Coated surfaces that are to be overcoated shall be cleaned of contaminants (see 5.2 above) and rinsed in fresh water and allowed to dry before overcoating.

All defective coatings shall be removed by scraping, sand discing or sweep blasting back to sound coating in general accordance with the requirements of ISO-8501-2. Any surface gloss shall be made matt using abrasive paper, light discing or sweep blasting. At areas for spot repair, a 25mm margin of the existing coating shall be prepared and the interface feathered to a fine edge taking care not to damage the undercoat. For pipeline repair the interface shall be feathered and the area shall extend to 150mm.

5.4.7 Preparation of Corroded Surfaces

Previously uncoated areas that have corroded during service normally should be included in the scope of work for any future maintenance painting.

Methods for cleaning old corroded steel will depend on the nature of the surface. If the surface is hot rolled, it is likely to be covered with a tenacious layer of millscale which, if left, will lead to pitting corrosion. The only effective way to remove it is by grit blasting.

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Loose rust, millscale, and other corrosion deposits can be removed from corroded cold rolled steel by the aid of hand brushing, scraping, chipping and other hand impact methods. Layered and stratified rust scale can be removed by chipping and hammering. Final grit blasting will be needed to achieve a surface suitable for subsequent paint application on completion of the removal of corrosion products.

For tanks and vessels that are to be lined for the first time after some time in service, care must be taken to remove all rust scales contaminated with soluble salts. The equipment must be initially thoroughly washed with fresh water or with water abrasive blasting. Heavily pitted surfaces shall require steam cleaning to remove deeply embedded more adherent contaminants. Tests shall be carried out to confirm the degree of cleanliness and full details included in the Method Statement.

5.4.8 Stainless Steel and Galvanised and Non-ferrous Surfaces

Require thorough degreasing by solvent cleaning to ISO-8501 or by high-pressure water jetting after applying a biodegradable detergent, rinse with fresh water. The surface may be prepared for coating application by keying the surface by hand or power methods or by light blast cleaning using suitable abrasives.

Stainless steel surfaces shall not be treated with carbon steel cleaning tools.

Zinc salts shall be removed from galvanised surfaces by jetting with fresh water and suitable solvent followed by scrubbing with stiff bristle brushes or by sand papering.

Areas of damaged galvanising shall be lightly power tool cleaned to ISO 8504-3 St 3 in preparation for treating with an approved zinc-rich epoxy primer. Larger areas may blast cleaned to ISO 8501-1 Sa 2½. See part-3 for details of repairs

5.4.9 Inspection

The blast cleaned surfaces shall be inspected and shall comply with the requirements specified in Section 7 and as detailed in the Method Statement and ITP.

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6 Coating Application

6.1 Environmental Conditions during Coating

6.1.1 Weather Conditions

As with cleaning and surface preparation, coating work shall not be undertaken in unsuitable environmental conditions, including:

- High wind speeds (greater than 15 knots)

- In the presence of airborne dust or sand

- Rain, fog, mist or when there is free moisture on the prepared surface

- Steel temperature less than 5oC

- Steel substrate temperature greater than the maximum allowable application temperature as

specified in vendors data sheets.

- Steel temperature less than 3oC above dewpoint of the surrounding air or relative humidity greater

than 85%

- Air temperature less than 5oC

- In conditions of insufficient lighting where available light is <500 lux

- Where there is a likelihood that weather conditions will change within 2 hours such that the above

conditions apply.

PDO shall reserve the right to stop the work when such conditions prevail or when rain is imminent.

6.1.2 Weather Protection

Where environmental conditions and/or Contractor’s programme and/or construction methods require weather protection of all or part of the structure to be painted, the Contractor shall provide plant and equipment such as tents, heating ventilation or equipment for dehumidification, scaffolding, screening, etc.

6.1.3 Ventilation

Where painting is carried out in enclosed spaces, adequate ventilation shall be provided. The capacity of the ventilation shall be as described in Section 8, sufficient to keep the concentration of solvent vapour in the air below 10% of the lower explosion limit at all areas within the workspace. As a guide, six full air changes are required each hour.

For information on current regulations covering emissions from Volatile Organic Compounds (VOC) see Section 3.2.6 in Part 1. Requirements for the threshold limit values for chemical substances and Physical Agents are referenced in ACGIH (American Conference of Governmental Industrial Hygienists) which is the document used by PDO. For further details see Section 8.3.

Direction of ventilation shall be from top to bottom to withdraw vapours, which are heavier than air. Where access at the bottom of the space is not available, suction ducts shall be suspended from the roof with openings near to the bottom of spaces served.

The Contractor shall prepare a Method Statement explaining clearly how he will provide adequate ventilation and how he will monitor it during the blasting and coating operations.

SP-1246 16 July 2003


6.2 Application techniques

6.2.1 General

PDO will use only approved coating contractors and, in certain cases, only contractors approved by the Paint Manufacturer can be used. Contractor must submit a Method Statement for approval and have it approved prior to starting any work. Where applicable, the Method Statement to contain reference to techniques described in this section.

The method of application shall be selected to ensure that the coating is applied in a uniform manner to the specified dry film thickness without runs, sags, drips or other imperfections.

Application of coatings shall be in accordance with the Manufacturer’s recommendations. Application shall be by brush, roller or by airless spray, except in the case of stripe coats, which shall be by brush only. Brush marks shall be avoided, as these are indicative of variable coating thickness.

Each coat shall be allowed to dry for at least the time recommended by the Manufacturer. Subsequent coats shall not be applied until the previous coat has dried. The Contractor shall make good all damage caused to previous coats such as wrinkling, lifting or loss of adhesion, resulting from premature overcoating.

Paint shall not be applied within 50mm of an edge prepared for a field weld, by masking for a distance of 50mm on each side of the weld line.

On completion of finish coating, the plant identification, flow direction arrows, pipe identification colour bands, etc. shall be applied as requested and directed by PDO.

6.2.1.1 Stripe Coating

Extra coats of paint shall be applied to certain areas and features to achieve adequate thickness where the structure shape or restricted access may result in thinly applied coating. Such areas include:

- edges of plate or flanges

- section ends

- fasteners, bolts and studs

- weld areas

- irregular or heavily pitted areas.

To provide additional cover, all such areas will receive a stripe coat for each coat of paint applied. The Contractor will include details of stripe coating in his Method Statement.

6.2.1.2 Precautions for Zinc rich primers

Apply zinc silicates with care, to avoid film defects due to excessive thickness. Brush apply paint

to small areas. Any surfaces that show mud-cracking shall be blast cleaned and reprimed in

accordance with this Specification.

Blast clean damaged areas, previously coated with zinc silicate and prime with a two-pack zinc

rich epoxy primer (containing at least 90% by weight of zinc in the dry film.

Minimise the need to repair surfaces coated with zinc silicate primer. Surfaces with excessive

damage shall be reblasted and reprimed.

Overcoat zinc silicate and zinc rich epoxy primers before the formation of zinc salts.

Inorganic zinc silicates require the application of a mist coat prior to the application of any

subsequent coat.

SP-1246 17 July 2003


Do not apply zinc silicate primers over hand or mechanically cleaned steel surfaces.

Prevent overspraying zinc rich paints onto adjacent duplex or austenitic stainless steel or nickel

alloys or 9% nickel steel, components by providing adequate masking off.

6.2.2 Protection of Equipment

The Contractor shall protect all equipment and structures and any other areas required by PDO, from mechanical damage and from paint droppings or overspray.

Equipment or structures to be protected shall include the following:

- threaded components and sliding surfaces such as valve spindles and stem threads, actuators,

linkages

- gauge glasses, instruments, and light fittings

- nameplates giving makers specifications, etc, on tanks, vessels, mechanical equipment

- machinery and electric motors

- electrical and control cables

- mating faces of flanges

- stainless steel pipework

- gratings,

- adjacent buildings, vehicles or any other areas of the structure not specified for painting.

Special attention shall be paid to protecting equipment that is operating at the time of painting.

6.2.3 Airless Spray

All lines and pots shall be thoroughly cleaned before any addition is made of new materials. The coating shall be spray applied in accordance with the coating Manufacturer’s recommendations. Even, parallel passes shall be made, each pass overlapping the other by 50%.

The compressed air, used for spray application, shall be free of water contamination and at the correct pressure and part for the specific work requirements.

Large surfaces shall be ‘cross-coated’ by receiving passes in two directions at right angles to each other. The gun shall not be operated continuously but will be triggered before and after each pass to obtain the correct spray pattern and to avoid runs and sags.

Spray width adjustments on the gun and re-adjustment of atomising pressure at the regulators shall be made until the desired spray pattern is obtained within manufacturers recommendations.

Each coat shall be applied uniformly and completely over the entire surface. Great care shall be taken to avoid areas of low DFT and ‘misses’. All runs and sags shall be brushed out immediately or the paint shall be removed and the surfaces resprayed.

Before spraying each coat, all areas such as corners, angles, edges, welds, flanges, brackets, bolts, nuts and interstices shall be given a brush ‘stripe’ coat to ensure that these have at least the minimum specified film thickness.

6.2.4 Brush Application

Coating shall be brushed on to all areas that cannot be adequately spray coated, such as difficult access, complex shapes, areas adjacent to sensitive components that cannot be masked and areas requiring astripe coating.

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6.2.5 Roller Application

Application by roller shall only be done on large flat or slightly curved surfaces where application by spray is not possible. This method is not suitable for painting rough areas or crevices.

6.2.6 Glass Reinforced Epoxy Lining

When glassflake or fibreglass reinforced lining systems are used, a project specific Method Statement will be prepared which will detail how the particular structure will be lined. Reference will need to be made to the application instructions of the coating system Vendor.

6.2.7 Specialist Coating Systems

A specific Method Statement will be prepared for application of specialist coatings in accordance with Materials and Corrosion Engineering Dept guidelines. Specialist coatings shall be applied by the Vendors approved applicator.

6.2.8 Design Requirements for Effective Coating Application

To minimise the risk of coating failure the following shall be considered in the design and fabrication of the steel work to be coated.

All internals of vessels and tanks that require coating must be made accessible so that coating can be applied to all areas to be wetted by the process fluids. Such areas include internal piping, beneath base plates of tank roof supports, roof plates and trusses.

During fabrication all edges shall be ground to a minimum radius of 3mm and flame cut edges will not be permitted. Stitch welding shall not be permitted, all welds must be continuous and be correctly dressed to remove weld spatter and slag.

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7 Control and Inspection

7.1 General

The Painting Contractor shall submit an Inspection Test Plan (ITP) and Method Statement for approval by PDO prior to commencing the work. The Method Statement should cover the following aspects of the work:

Details and sequence of working activities

Application details as given by Coating Vendor and in data sheets

Contractor’s responsibilities

Roles and responsibilities of key personnel such as supervisors and inspectors

Quality control measures

Compliance with HSE requirements

7.2 Project Co-ordination and Technical Service

Start-up meetings at which representatives of PDO, the Contractor and the Manufacturer, shall be present shall be arranged prior to starting the work. Regular meetings will be held during the course of the work to review and manage the progress.

The Manufacturer will be expected to provide technical back-up and advice in respect to the application of his products.

PDO shall have the right to witness and inspect all aspects of the operation from acceptance of the raw materials to final close-out inspection at the conclusion of the works.

The PDO nominated Inspector will inspect all works associated with the entire surface preparation and paint application processes in accordance with the following Sections and as stated in the ITP and Method Statement. Inspection results shall be included on a daily record sheet as shown in Appendix B.

PDO will establish a system of ‘Hold Points’ whereby the Contractor may not proceed until he receives clearance. The following Hold Points will be identified:

Approval of safety procedures and protection of sensitive equipment (mandatory)

Completion of surface preparation (mandatory)

Prior to application of each paint coating (advisory)

After application of the finishing coat and holiday testing (mandatory)

On completion of remedial works (mandatory).

The Contractor shall strictly observe all Hold Points. Any non-observance will require him to repeat the relevant work at his expense.

7.3 Inspection and Testing

In spite of the requirements of ISO 9000, it is strongly recommended that some measure of inspection independence be adopted for ensuring the quality of all surface cleaning and coating application activities. All operations need to be monitored so that the desired specifications are achieved safely and in a cost-effective manner. Table 2 below presents the minimum requirements for inspecting and monitoring the Contractors painting and coating operations.

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Table 1 Inspection and Testing Summary

Work Stage Assessment Assessment Method Test Equipment Notes

Safety Procedures

PDO HSE rules Observation Visual, documentation, Method

Statement

Ref. Section 7.1

Working practices Visual, documentation, Method

Statement

Check requirements for working on live stations and operating equipment

Equipment condition Equipment safety checks Replace faulty equipment

Ventilation Check VOC and air flow rate

Protection

Sensitive equipment Observation Visual Ensure all protection in place

Adjacent structures/

vehicles

Ensure all protection in place. Isolate work area. Remove vehicles to safe

area

Raw Materials

Paint Conformance to specification Visual, documentation, viscosity check

to ISO 2431

Flow cup type B No. 4 Packaging, labelling, shelf life, etc. Ref. Section 3.1.3

Make available to PDO record, of paint consumption

Abrasives Conformance to specification,

cleanliness, particle size.

ISO-8504-2

Documentation, physical/chemical

analysis, particle size distribution to ISO

11125-2

Standard Wire Sieves Reject if wetted by salt water, rain or condensation or moisture content

too high.

Reject any work blasted with wet abrasive1

Climatic Conditions

Weather Monitor climatic conditions Observe and measure variables Ref. Sections 5.1 and 6.1

Air temperature Measurement Monitor air temperature Digital Thermometer Allow time for temperature to stabilise

Surface temperature Monitor surface temperature Contact Thermometer

Humidity Monitor humidity to ISO 8502-4 Whirling/Sling or Psycro-Dyne

Hygrometer

Read relative humidity from Hydrometric Tables

Dew point Measure directly or calculate Direct reading digital Dewmeter, Confirm by charts or conversion calculator

Lighting Measure >500 lux

Surface Preparation

Personnel protection Conformance to HSE

regulations

Observe and confirm conformance Check operators have proper protective clothing. Ref. Section 8

Equipment Observe and confirm conformance Check equipment electrical earthing, safety valve ‘dead man’s handle’

operation. Ref. Section 8

Climatic conditions Monitor all variables as above As above As above Stop work when conditions are outside acceptable limits

Ventilation for

enclosed spaces

Size of enclosure. Capacity of

air moving equipment.

Monitor dust levels. Measure air part

flow

Stop work if dust levels become excessive .

Air 6x per hour

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Surface cleanliness

Observation Visually examine and compare with

relevant parts of ISO 8502

Inspection Mirrors. Illuminated

Magnifier. Pictorial Standards

Reject surface having large embedded particles that cannot be removed.

Tightly adherent fine particles are acceptable. Removing particle by wire

brushing is not acceptable.(2)

Surface cleanliness (cont.) Observation Contaminant Pick-up ‘Sellotape’ test –ISO-8502-3

Soluble salts Chemical analysis Bresle Method to ISO 8502-6

Test papers

Bessle Sampler,

‘Quantab’ Indicator Papers

Confirm cleaning has been adequate3

Qualitative checks for Cl, Fe and S etc.

Surface profile Observation, comparison Visually examine, compare with

standards to ISO 8503

Surface Comparator, Keane-

Tator, Rugotest

Anchor pattern Observation, measurement Measure record values to ASTM

D 4417

Digital /Mechanical Profile

Gauges

Measure profile height

Surface roughness Replication Surface replica to ASTM D4417 Textex Tape and Micrometer Provides permanent record of surface profile

Coating Application

Climatic conditions Monitor all variables as above As above As above Stop work when conditions are outside acceptable limits

Application temperature range as specified by Manufacturer

Recoat intervals will depend on ambient temperature

Ventilation for

enclosed spaces

Size of enclosure. Capacity of

air moving equipment.

Check LEL, TLV or MAC values.

Monitor vapour concentrations. Measure

air part flow

Product documentation.

Explosimeter

Personal Air Sampling.

Control vapour to 10% of LEL.

For some paints having mixed solvents, it is difficult to ventilate to below

the TLV. Applicators working in tanks and vessel must wear breathing

apparatus4 Ref. Section 8.3

Application of Coatings Visual Inspector to check conformance with

datasheets

Details to be included in ITP and in daily record

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Inspection Wet Film Thickness Measurement Use gauges in accordance with

ISO 2808 Method 7 A/B

Wet Film Comb. Wet Film Wheel Spot check during application to ensure specified film thickness is being

maintained

Dry Film Thickness Measurement Use gauges in accordance with

ISO 2808 Method 6

Magnetic and Electromagnetic

and Eddy Current Gauges

Calibrate instruments at least twice daily using standard foils.

Use statistical methods for determining acceptability5

Destructive test using special inspection

instruments

‘PIG’ Paint Inspection Gauge Destructive test on any substrate to confirm DFTs (Not for production

painting)

General appearance Observation Visual inspection Optical magnifier Reject if appearance and condition are unacceptable6

Degree of cure Observation Solvent swabbing Appropriate solvent Rubbing for 1 min. should not soften coating to fingernail scratch

Adhesion

Pull Off Measurement for New

Coating Systems

45 oCross cut test

Pull-off tests to ISO 4624

Cross-cut and peel tests to ASTM-3359

Mechanical and Hydraulic

Adhesion Testers

45 oCross cut test

Acceptance: Pull-off force as specified in performance testing. Typically

3-10 N/mm2 . Tests to be done on cuopons

For checking internal surfaces and local repairs.

For repairs test adhesion between first coat and substrate and between

coats. Acceptance: Classification 5A or 4A

See note 7 for details

Film integrity/

porosity

Conductivity Holiday Testing to

NACE RP0188-99

High Voltage Spark Tester Calibration: High voltage - 5-6V per 1μ coating thickness9

SP-1246 23 July 2003


Notes to Table 2

1. Blasting Abrasive QualityAbrasive must come from a recognised supplier and be certified in respect of cleanliness and particle size distribution. If there is any doubt about the quality of the blasting grit, the Contractor shall provide a specification covering sieve grading, chemical analyses and physical properties. If such a specification is not available, the Contractor shall take two samples, of minimum 1 kg each, from each of abrasive and arrange for analysis by an independent third party. Specification and/or analysis results shall be submitted to PDO for comparison with accepted values.

2. Surface Cleanliness The Contractor shall visually examine the surface to ensure that dust or dirt has been removed.

The Inspector shall not accept a blasted surface contaminated by large embedded abrasive particles that can not be brushed off using a stiff brush. If such contamination is detected, no further blasting shall be performed, using the same batch of abrasive. Tightly adherent embedded fine particles, however, need not be a cause for rejection.

Work may be allowed to continue using a different batch, make or type of abrasive approved by PDO.

When using copper slag abrasive under high ambient temperature condition, as in Oman, the visual standard Sa 2½ may not be obtained due to embedded fine particles causing a different shade. If there is any doubt on the acceptability of the prepared surface, the Contractor shall provide a dedicated visual standard for Sa 2½ using copper slag under these conditions.

3. Soluble SaltsSoluble salts on a steel surface are taken up in distilled water using a Bressle Sampler. The Bressle titration method shall be used to measure the chloride content. From titration measurements, the recommended maximum salt contamination for immersed surfaces or for tank and vessel coatings is 20-40mg/m2

chloride. Note the value for maintenance work is higher at 60-80mg/m2

4. Ventilation Before and during blasting and coating work in enclosed spaces, adequate ventilation shall be established. During coating operations the vapour concentration shall be monitored at regular intervals using approved equipment and should never exceed 10% of Lower Explosion Limit. This is considered adequate for personnel health protection, avoidance of explosion hazards and to ensure adequate evaporation of solvent from the paint. The TLV (Threshold Limit Value) or MAC (Maximum Allowable Concentration) of the paint used must be known. Ventilation shall be such as to maintain, wherever practical, a safe atmosphere below the TLV.

5. Materials Safety and Handling Data SheetsVendors are required to supply SHOC cards for each generic paint product in the total coating system.

6. Dry Film Thickness (DFT)After the film is sufficiently dry or cured, the Contractor shall measure the coating thickness and submit the results to PDO.

Guidelines for the number of DFT measurements for external coatings to be made after each coat may be usefully based on the ‘80-20 Rule.’ This rule suggests that:

- the measured thickness must not be less than 80% of the specified DFT and

- a maximum of 20% of the total area painted may be below the specified DFT

The following statistical measurement procedure for the Rule is suggested:

1. Select a number of randomly chosen and continuous 10m2 areas in such a way that 5% of the

entire control area is covered.

2. In each area, select a minimum of five 50cm2 sized test fields.

SP-1246 24 July 2003


Take three DFT readings in each field and calculate the mean value to be as one single measurement

Acceptance criteria:

- No more than 20% of the total of single measurements to be less than the minimum

specified DFT

- The lowest single measurement should be at least 80% of the minimum specified DFT

The DFT of different layers of a paint system may be measured using a paint inspection gauge using calibrated cutters and microscope. This however is a destructive test and not suitable for production painting.

For internal coating systems use a 90:10 rule and apply the same procedure as above.

7.0 Adhesion Testing

Pull off adhesion testing in accordance with ISO-4624 and cross cut testing in accordance with ASTM D3359 shall be carried out on test panels to ensure the coating system meets the performance requirements. The panels will then be used as a check to compare the cross testing results done on the actual structure. Cross cut testing shall be carried out at the following frequencies. For external coatings and repair work 1 per 100m2 with a minimum of 2 per structure. For internal coatings and repairs the frequency shall be 1 per 10m2 with a minimum of 2 per structure. For repairs only cross cut testing shall be used and this will be carried out on the structure. Adhesion testing is not applicable to GRE lining or pipeline repairs.

8. Visual Inspection

Each coating applied shall be inspected visually. The paint system applied should have the correct shade, degree of gloss and evenness and be free from tackiness after drying/curing and free from cracks, holidays, runs, sags, wrinkles, brush or roller marks or other defects that may deleterious to the quality of the coating. Finishing coats shall be even in colour and gloss.

9. Integrity Testing

For internal coating systems 100% of the surface shall be tested using a metallic brush type holiday detector in accordance with NACE RP 0188-99. Special attention shall be paid to welds, edges and irregular surfaces. For external surfaces, random inspection, which shall be representative of the entire surface shall be conducted.

A high voltage spark detector shall be used for all heavy-duty systems including glassflake, GRE, high DFT epoxies and pipeline coating repairs. Testing shall be in accordance with NACE RP 0188 and RP0274 (for pipeline coatings). The type of brush shall be suitable for the surface being inspected. The voltage setting shall be according to the Manufacturer’s recommendations or as given in the coating system specification. Generally the detector voltage is set at 5-6V for every micron of coating thickness.

7.4 Reporting

The Inspector or Contractor shall record and report daily all inspection results as stated in the Method Statement. If work is carried out within the Sultanate of Oman, standard Daily Report Sheets as shown in appendix-B shall be used for reporting. Such a report shall contain the following minimum information:

1. General- Date, project and job identification, Contractor and Inspector names- Inspection location and times- Safety Aspects

2. Ambient Conditions- Air and substrate temperatures, relative humidity, dew point - Presence of wind or dust, sunlight or shade- Access and illumination conditions

SP-1246 25 July 2003


3. Surface Preparation- Condition of surface before cleaning, cleaning method, abrasive used, nozzle sizes

and pressures- Standard achieved surface profile (microns)

4. Coating Application- Manufacturer, type, and batch number, amounts of paint and thinners used,

overcoating times- Application method, equipment used, spray nozzle sizes- Inspection tests, WFT/DFT, holiday etc. including instruments, calibration details- Repairs.

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8 Safety

8.1 General

The Contractor shall perform his work in compliance with the PDO HSE manual and this shall be covered in the Method Statement or in separate documents.

When paints containing volatile solvents are applied in enclosed or confirmed spaces, two hazards exist:

- fire and explosion hazard

- toxic hazard (including skin contact)

Precautions must be taken to eliminate these dangers.

8.2 Fire and Explosion Hazard

When the following factors are present, there is a high risk of creating a fire or an explosion:

- When the concentration of vapour in air is between the lower explosion limit (LEL) and the upper explosion limit (UEL).

- When a flammable liquid, in contact with air (open container) is at a temperature above its flash point.

- When there is a source of ignition with high enough temperature and energy to initiate the explosion reaction.

These conditions shall be avoided at all times during the handling and application of paints or coatings.

8.2.1 Ventilation and Extraction

Adequate ventilation and extraction must be provided in enclosed work places such as tanks and vessels to prevent a potentially flammable concentration of vapours by maintaining the concentration of vapour in air at no more than 10% of the Lower Explosion Limit. Solvent vapours are generally more dense than air so air draw-off should be arranged near floor level. In general, after coating application, a ventilation rate of 6 times the part of the confined space per hour should be achieved.

The flash point is a rather rough but quick way of indicating the relative combustibility of volatile solvents. It determines the approximate temperature below which combustible substances may be stored and used without creating an explosive atmosphere.

The use of solvents with a flash point below the working temperature is prohibited.

Booths and similar enclosures should be designed, installed and maintained to prevent any vapours, overspray and droplets escaping into the general atmosphere of the workplace. The exhausts from such booths should be designed to minimise external environmental pollution.

All booths and ducts shall be fire resistant structures and shall be subject to regular cleaning to prevent the accumulation of solid paint residues.

8.2.2 Sources of Ignition

All potential sources of ignition shall be strictly controlled. Likely sources of ignition are:

naked flames

hot surfaces

SP-1246 27 July 2003


smoking

sparking due to:

- striking metal surfaces

- electrical power supplies

- static electricity

Smoking shall be prohibited in all areas where paint is stored, handled or used.

Sparks, hot surfaces, flames and all other sources of ignition must be absolutely prevented. Where it is not practical to maintain an atmosphere free of flammable gas, the Contractor shall use low-energy sparking tools and will employ lighting and electrical equipment that are flameproof.

All hot work in adjacent compartments shall be prohibited.

8.2.3 Storage

Special storage precautions are necessary for products having flash points below 32C. Storerooms shall be separated from workshops and constructed to PDO approved standards. The amount of paint stored in the workshop or working area shall be limited to one working day’s requirements. All containers of paint and thinners not in use shall be kept in bins or cupboards constructed of fire-resistant materials.

Polyester and vinyl ester coating materials shall be stored at 20C and epoxy coating systems shall be stored at 30C to preserve the pot life.

8.2.4 Cleanliness

Strict attention to cleanliness shall be observed. All places, where dry paint deposits can accumulate, shall be cleaned regularly. Cleaning brushes and equipment shall be of non-ferrous metal or non-sparking material. All scrapings and sweepings must be placed immediately in metal containers with suitable covers, wetted down and removed from the work area.

All spillages shall be cleaned up as they occur by absorption into sand, earth or other suitable inert material. All oil, solvent, paint-soaked rags and other combustible materials must be stored in closed metal containers and removed to a safe place outside the work area. If combustible material is used to protect floors or other surfaces from paint drips or spillage, it should be removed daily and deposited in a safe place for disposal.

Contaminated clothes, overalls and similar materials shall be similarly safely retained to prevent the possibility of instantaneous combustion.

Solvent storage drums shall be grounded and containers receiving solvent streams shall be electrically bonded to the drum using temporary bonding straps and clamps. No plastic containers shall be used for storing, mixing or thinning paint.

8.2.5 Fire-fighting Equipment

Adequate fire prevention and fire-fighting equipment shall be provided and maintained in all areas where paint is used, handled or stored. Guidance regarding the type and amount of equipment to install shall be obtained the PDO Safety Department.

8.3 Toxic Hazards

8.3.1 General

The organic solvents given off from paint products are, to varying degrees, toxic to humans. The vendor shall submit SHOC for the guidance of personnel in toxicity and treatment of injurious effects of contact with chemicals.

SP-1246 28 July 2003


Application of paint containing a high proportion of solvents may, in poor conditions of ventilation, result in high atmospheric concentrations of solvent vapour. Over exposure may cause adverse physiological effects. Certain paints, that may give rise to specific hazards, must have warnings indicated on their container labels and in the Manufacturer’s literature and on the PDO SHOC card.

The Threshold Limit Values (TLV) refer to levels of substances in the air and represent conditions under which it is assumed that operators may be repeatedly exposed without suffering adverse affects. The guidelines on TLV laid out in the ACGIH document adopted by PDO shall be followed.

Since the TLVs for paint solvents are much lower than the safe explosion limit concentrations, it is almost impractical to ventilate tanks and vessels sufficiently to below the TLV limit for volatile mixtures.

PAINT APPLICATORS WORKING IN TANKS AND VESSELS MUST WEAR BREATHING APPARATUS WHEN COATINGS ARE BEING APPLIED.

Particular care must be taken when handling and using paints containing heavy metals, eg, lead and precautions taken to protect against skin contact and fume inhalation.

8.3.2 Inhalation

Inhalation of fumes, dust or sprays during surface preparation, application of paint and sanding processes shall be avoided. Employees shall be protected against the inhalation of dust, fumes or sprays during any of the above activities by the provision of adequate ventilation at all times and where appropriate, local extraction and dust masks or respirators.

When working in workshop areas, spraying shall be confined, so far as possible, to spray booths that are designed, installed and maintained to prevent any vapours escaping into the general atmosphere of the workplace.

A cartridge respirator should be worn, and fitted with a vapour/particulate cartridge designed for paint spray and light fume protection. In some cases a higher degree of protection from an air-line breathing apparatus may be advisable, and where this is so it will be stated in the manufacturer’s technical literature and marked on paint and solvent containers. For dry-sanding operations a cartridge respirator shall be worn.

In the open air, work or operations down wind of the spraying area shall be restricted as necessary or personnel protection devices worn.

In an emergency, resulting in personnel in jury or sickness, the patient shall be moved to a fresh air location as quickly as possible and kept warm until medical attention arrives. In case of unconsciousness the patient breathing should be checked and artificial respiration given when breathing stops.

8.3.3 Ingestion

Accidental ingestion (swallowing) of paint may cause irritation of the mouth, throat and digestive tract, resulting in vomiting and abdominal pain. Significant absorption of paint containing a high proportion of solvents may cause drowsiness or loss of consciousness.

Ingestion of paint must always be avoided. Food should not be brought into, stored, prepared or consumed in workshop or work areas where paint is handled or stored. Receptacles and utensils that could be used for food or drink should also be excluded. Washing facilities should be provided and their use encouraged before food is consumed or handled.

In an emergency, follow the directions of the Safety Manual and information contained in SHOC data sheets.

Vomiting shall not be induced because of the risk of introducing solvents into lungs by inhalation of vomit. This can result in serve lung damage. If spontaneous vomiting occurs, the patient shall be turned on his face.

SP-1246 29 July 2003


8.3.4 Skin Contact

Some substances used in paint may cause irritation after repeated or prolonged contact with the skin. In some cases there may be a risk of dermatitis. Operatives with a history of skin sensitivity should not be employed in processes where skin contact can occur.

Prolonged or repeated contact with skin should be avoided.

Barrier cream shall be provided and used. Protective gloves and overalls shall be worn.

8.3.5 Eye Protection

Splashes of paint products will irritate the eyes and goggles shall be worn wherever possible. Emergency treatment shall consist of irrigation of the eyes with copious amounts of clean water until medical attention has been obtained.

8.3.6 Disposal of Residues from Cleaning and Coating Operations

Blast cleaning and coating operations generate large parts of unwanted residues in the form of grit contaminated with organic and mineral deposits, particles of old paint and corrosion products, empty paint and thinners containers, cotton waste, contaminated protective clothing and other unwanted equipment and consumables.

The Contractor shall dispose of all residues and by-products from cleaning and coating operation strictly in accordance with the relevant PDO, national and international regulations as detailed in the ACGIH guidelines

Consideration shall be given during his operations to any materials that may usefully recycled and reused. Specifically designated and controlled areas shall be used for the disposal of unused paints, solvents, thinners and toxic substances and contaminated clothing that cannot be cleaned and reused.

Requirements for particular disposal methods of paint products and solvents must be shown on the product containers or in SHOC data sheets.

8.4 Safe Working Conditions

Safe working is of the greatest importance particularly during the application of coatings in confined spaces such as tank and vessels.

The following principal measures will ensure safe working.

8.4.1 Blast Cleaning and Painting Equipment

No air hoses, blast hoses and spray lines and any other hoses subjected to internal pressure shall be used without valid test certificates indicating safe working pressures. Hose couplings shall be wired together using soft iron wire. The Contractor shall check all hoses and pressure items for wear and electrical conductivity. Defective and worn items shall be immediately replaced.

The ‘Deadman Handle’ type safety control valve shall be attached to the blast hose close to the blast nozzle. In no circumstances shall it be held in the ‘on’ position by any means other than hand pressure.

All blasting and spraying equipment shall be electrically earthed to the mass of the tank, vessel or structure being cleaned or painted.

The blast cleaner shall be provided with an air-fed helmet and ear protection.

8.4.2 Blasting and Painting Operations in Confined Areas

All mixing of paint shall be performed outside the confined area unless they are solvent free.

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Paints not conforming to current regulations for VOC emissions (See Section 3.2. in Part 1), shall not be used in confined areas such as tanks and vessels. High solids, low solvent or solvent-free products shall be used. These products have much higher viscosities and there may be a need to adjust application methods to achieve the desired surface characteristics.

When voice communication between the blast cleaner and the blast operator is not practical a reliable system of communication by signals shall be established.

All paint sprayers shall wear air-fed protective masks that are coupled to a clean filtered air supply. A regulator and filter system will ensure that the operator’s breathing air is not contaminated with paint residues. (See Section 4.2).

Exhaust and fresh air ducts and fans shall be provided. The fresh air shall be directed to the bottom of the tank and the exhaust duct shall be close to the bottom of the tank.

The work area shall be condoned off and warning signs provided around the structures being painted, indicating that grit blasting, paint mixing or paint spraying operations are in progress.

A supervisor shall be in continuous contact with painters and shall have his own safety equipment ready for an emergency entry to the vessel.

Unauthorised personnel shall not enter the tank or vessel during blasting or spraying.

Lighting and other electrical equipment shall be suitably certified for use in hazardous areas likely to be encountered during paint spraying. A 24 volt supply, with ELCB and armoured cable shall be used.

Painters shall be provided with lifelines, where necessary.

Eye protection is a mandatory requirement for all persons within the vicinity of grit blasting or spray painting operations.

All Contractors’ personnel will have to attend, as a minimum requirement, the PDO Safety Induction Course before being allowed to enter or work on the site.

8.4.3 Drying

A fresh dry air supply shall be provided. The end of the exhaust duct shall be installed close to the bottom of the tank or vessel.

8.5 Scaffolding and Ladders

Fixed scaffolding or staging shall be used as required for surface preparation and painting and shall comply with the PDO HSE specification SP-1257 and guideline GU-363

8.6 Safety Reporting

In addition to indicating, on his Daily Painting Report, that all safety aspects have been satisfied, the Contractor or his representative/personnel must conduct regular Safety Inspections throughout the duration of the painting and coating project. He will maintain a record of dates, findings and action taken during all inspections carried out by his personnel on his work site and equipment. Such records shall be routinely made available to PDO.

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9 Related Business Control Documents

The following standards, codes and specifications shall form part of this Specification. Except where a specific edition or revision is identified by date or revision/edition number, the latest edition in effect at the date of contract shall govern.

PDO and SIEP Documents

GU-363

SP-1257

PR-1180

DEP 31.40.30.31-Gen.

DEP 31.40.30.32-Gen.

Guidelines for use of Scaffolding

PDO HSE- Specification- Scaffolding, Working at Heights or Over Water, Lifting Operations and Earthworks.

Procedure for Qualification of Pipeline Rehabilitation Coating Systems

Technical Specification for External Polyethylene and Polypropylene

Technical Specification for External Fusion-bonded Epoxy Powder Coating for Line Pipe

International Standards

ASTM D 4417

ASTM D3359

Standard Test Methods for Field Measurement of Surface Profile of Blast Cleaned Steel

Standard Test Methods for Measuring Adhesion by Tape

BS 4275 Guide to implementing an effective respiratory protective device programme

NACE RP0188 Recommended Practice. Discontinuity (Holiday) Testing of New Protective Coatings on Conductive Substrates

NACE RP0274 Recommended Practice. High-Voltage Electrical Inspection of Pipeline Coatings Prior to Installation

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

ISO 2360: Non-conductive coatings on non-magnetic basis metals – Measurement of coating thickness – Eddy current method

ISO 2409: Paints and varnishes – Cross-cut test

BS EN ISO 2431BS 3900-A6

Paints and varnishes – Determination of flow time by use of flow cups

ISO 2808 Paints and varnishes – Determination of film thickness

ISO 3310-1 Test sieves: Technical requirements of metal wire cloth

ISO 4624: Paints and varnishes – Pull-off test for adhesion

ISO 8501-1 Preparation of steel substrates before application of paints and related products – Representative photographic examples of the change of appearance of steel when blast-cleaned with different abrasives

ISO 8501-2: Preparation of steel substrates before application of paints and related

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products – Visual assessment of surface cleanliness – Part 2: Preparation grades of previously coated steel substrates after localised removal of previous coatings

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 substrates prior to paint application

ISO 8502-4 Preparation of steel substrates before application of paints and related products – Tests for the assessment of surface cleanliness – Part 4: Guidance on the estimation of probability of condensation prior to paint application

ISO 8502-6 Preparation of steel substrates before application of paints and related products – Tests for the assessment of surface cleanliness – Part 6: The Bresle method

ISO 8502-10 Preparation of steel substrates before application of paints and related products – Tests for the assessment of surface cleanliness – Part 10: Field method for the titrimetric determination of water soluble chlorides.

ISO 8503-1 Preparation of steel substrates before application of paints and related products – Surface roughness characteristics of blast-cleaned steel substrates – Part 1: Specifications and definitions for ISO surface profile comparators

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 grading of surface profile of abrasive blast-cleaned steel - Comparator procedure

ISO 8503-4: Preparation of steel substrates before application of paints and related products – Surface roughness characteristics of blast-cleaned steel substrates – Part 4: Method for calibration of ISO comparators and for the determination of surface profile-Stylus instrument procedure.

ISO 8504-2 Preparation of steel substrates before application of paints and related products – Surface preparation methods – Part 2: Abrasive blast-cleaning

ISO 8504-3

ISO 11124

ISO 11125

ISO-11126

Preparation of steel substrates before application of paints and related products – Surface preparation methods – Part 3: Hand- and power-tool cleaning

Preparation of steel substrates before application of paints and related products – Specification for metallic blast-cleaning abrasives

Preparation of steel substrates before application of paints and related products – Test Methods for metallic blast-cleaning abrasives

Preparation of steel substrates before application of paints and related products- Specification for non-metallic blast cleaning abrasives. Parts 1-10

ISO 11127-2 Preparation of steel substrates before application of paints and related products – Test methods for non-metallic blast cleaning abrasives – Part 2: Determination of particle size distribution

SSPC-SP-1 Solvent Cleaning

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9 Appendix A Glossary of Definitions, and Abbreviations

9.1 Standard Definitions

Within the context of this specification the following words shall have the meanings stated:

must/shall Indicates a mandatory requirement.

should Indicates a preferred course of action.

may Indicates one acceptable course of action.

SIEP Shell International Exploration and Production bv.

PDO Petroleum Development Oman.

Contractor The PDO appointed Contractor, or his representative, for a defined piece of work.

Inspector Person qualified to examine, measure, test, gauge or otherwise compare the work of the Contractor with applicable standards and specifications.

Vendor The supplier of materials or equipment - not necessarily the Manufacturer.

Manufacturer The company responsible for the manufacture - not necessarily the Vendor.

Paint Vendor The supplier of paint and coating materials.

Paint Vendor’s Technical Data Sheet

Data sheet, published and maintained by the Paint Vendor, detailing the properties of the paint/coating materials and the requirements for their application. These data sheets also state the conditions for surface preparation prior to application of paint/coating materials and associated acceptance criteria.

Paint Vendor’s Health and Safety Data Sheet

Data sheet, published and maintained by the Paint Vendor, detailing the hazardous properties of the paint/coating materials and the health and safety requirements for their storage, preparation and application.

Painting Contractor The company responsible for a defined piece of painting, coating or lining work.

Purchaser The organisation, responsible for ordering or buying materials required for a defined piece of painting, coating or lining work, generally PDO or it’s nominated Contractor.

9.2 Special Definitions

Amplitude Peak to valley height in a steel surface profile, usually after surface preparation.

Dew point Temperature of an air-water mixture, at which condensation starts. ie where the

mixture has reached water saturation point.

DFT Dry Film Thickness (thickness of paint film in its dry cured state)

Holidays Pinholes or small defects in a coating film that penetrate through the film to the

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underlying substrate.

Micron One thousandth part of a mm ().

Pot Life The length of time a two-pack paint will remain usable, at a given temperature,

after mixing.

Shop Permanent enclosed facility used for painting/coating with temperature and

humidity control.

Surface Profile (Anchor Pattern)

The cross-section of a prepared steel surface. Measured distance from depth of

troughs to tops of peaks on the blast cleaned surface. (Amplitude)

WFT Wet Film Thickness (thickness of a wet paint film prior to evaporation of any

solvent

9.3 Abbreviations

ASTM American Society for Testing and Materials

CFDH Corporate Functional Discipline Head

COSHH Control of Substances Harmful to Health (Regulations 1999)

CIPS Close Interval Potential Survey

BS British Standards

DCVG Direct Current Voltage Gradient (Survey)

DEP Design and Engineering Practice (SIEP)

ERD Engineering Reference Document (PDO)

ISO International Organisation for Standardisation

ITP Inspection Test Plan

LEL Lower Explosion Limit

MAC Maximum Allowable Concentration

MS Method Statement

NACE National Association of Corrosion Engineers

SHOC Safe handling of chemicals

SSPC Steel Structures Painting Council

TLV Threshold Limit Value

UEL Upper Explosion Limit

UER CFDH Materials and Crrosion

μm micron

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Appendix B Contractor’s Daily Painting Report

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PETROLEUM DEVELOPMENT OMAN MATERIALS AND CORROSION ENGINEERING Contractor’s Daily Painting Report

1.1

Work Description

Ambient Conditions

1.1.1.1

Contractor: ………………… Location: ……………………… Date: …………….

Contract No: …………………… Work Type: New Construction □ Maintenance □

Internal □ External □

PDO Paint Schedule: ……… Ref. Specification: …………. % Completion: …………

Check min. 5 times during day Exterior/Interior Instrument Type

Time Hrs.Air Temp. oCRelative Humidity %Dew PointSubstrate Temp. oCWind, Dust etc.Illumination Level


Surface PreparationCleaning Method: Abrasive Blasting □ Mechanical Cleaning □ Type: ……………….. Standard Required: ……….. Standard Required: ………….

Surface Profile: …………… microns Grit Type: ……………….. Grade: ………… Nozzle Size: ………… Nozzle Pressure: …………

Cleanliness Standard Achieved: ……………. Comparison Standard Used: ……………………………

Measured Surface Profile: …………. microns Measuring Instrument: ………………. Attach

Contractor Comments:

Safety Aspects Satisfied:

Contractor: ………………

PDO Comments:

Accepted for PDO: ………………

Ref. Ind. : ………………

Date:

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Replica Tape

Coating Manufacturer: ……………….. Specified DFT: ……….. micronsPaint Type ID No. Batch No. Method Shade WFT μ DFT μ Interval

PrimerIntermediate Coat 1

2Top Coat 1 2

DFT Measuring Instrument: ……………………….. No. single measurements < 20% specified DFT: ……. % total Lowest single DFT measurement: …………microns

Other Inspection……………………………………….


10 User Comment Form

User Comment Form If you find something that is incorrect, ambiguous or could be better in this Procedure, write your comments and suggestions on this form. Send the form to the Document Control Section (DCS). They make a record of your comment and send the form to the correct CFDH. The form has spaces for your personal details. This lets DCS or the CFDH ask you about your comments and tell you about the decision.

Procedure Details Title: Issue Date:Number:

Page Number: Heading Number: Figure Number:

Comments:

Suggestions:

User’s personal detailsName: Ref.

Ind.:Signature: Date:

Phone:

Document Control Section ActionsCommentNumber:

Date: CFDHRef. Ind.:

Recd.: To CFDH:CFDH Actionsrecd.Date:

Decision:

Reject:Accept, revise at next issue:

Accept, issue temporary amendment

Inits.: Ref. Ind.

Date:

Comments:

OriginatorAdvised:

Date: Inits.: DocumentControlAdvised.

Date: Inits.:

SP-1246 38 July 2003

SP 1246(Part 4 2003) PDO Painting Spec

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Transcript of SP 1246(Part 4 2003) PDO Painting Spec