SK-SPP-07 (Painting Coating) - Rev. 00 [PDF]

Zitiervorschau

00

12/25/201 4

Rev.

Date

Issued For Review/Approval

MOH’D REHAN ABDULLAH TAHAT KAMAL AZZAM QA/QCM

Description of Revision

Prepared By

PM

GM

Reviewed By

Approved By

PROJECT:

ONSHORE MAINTAIN POTENTIAL ZONE NA-2 CLIENT:

SAUDI ARABIAN OIL COMPANY Dhahran - 31311, Saudi Arabia

CONTRACTOR:

SAUDI KAD CONTRACTING CO P.O. Box 70443, Al Khobar – 31952, Saudi Arabia

PAINTING& COATING DOSSIER

P111

FILE NO.

05.00

PAGE/SCALE

L

JOB NO.

DOCUMENT NO.

REV

6600033951

SK-SPP-07

00

CONTENTS 1. PROCEDURE................................................................................3

SAUDI KAD CONTRACTING COMPANY

DOCUMENT NO. SK-SPP-07

SPECIAL PROCESS PROCEDURE

REV. NO. 00 DATE: Dec. 25, 2014

PAINTING & COATING 2. SCOPE AND PURPOSE..................................................................3 3. APPLICABILITY............................................................................3 4. REFERENCES...............................................................................3 5. RESPONSIBILITY..........................................................................4 6. SAFETY REQUIREMENTS...............................................................5 7. GENERAL....................................................................................6 8. PROCEDURE................................................................................6 8.1 8.2 8.3 8.4 8.5

SURFACE PREPARATION PROCEDURE....................................................................6 PAINTING MATERIALS........................................................................................7 PREPARATION OF COATING MATERIALS.................................................................8 APPLICATION OF PAINT MATERIALS......................................................................8 REPAIR PROCEDURE FOR DAMAGED COATINGS......................................................8

9. QUALITY CONTROL EQUIPMENT KIT...............................................9 10. INSPECTION PROCEDURE.............................................................9 11. ATTACHMENTS........................................................................... 11

SK-SPP-07 Painting & Coating Rev. 00 - CN #6600033951

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SAUDI KAD CONTRACTING COMPANY

DOCUMENT NO. SK-SPP-07

SPECIAL PROCESS PROCEDURE

REV. NO. 00 DATE: Dec. 25, 2014

PAINTING & COATING 1. PROCEDURE The paint system to be used shall be APCS – 26 for all above ground piping, valves, fittings, structural supports including field girth welds and APCS-113A for Transition line from buried to above ground and underground piping as per SAES – H-001, SAES-H-101, SAES-H-101V, SAES-H-002, SAES-H-002V and as per construction/project specification requirements. The mentioned paint systems are also applicable for damage areas and structural accordingly. For more details see page 10. 2. SCOPE AND PURPOSE 2.1

This method statement will cover the surface preparation and painting works at Saudi Kad coating shop & site location. Activity will cover the surface preparation and painting works for pipe spools, straight run pipes and pipe supports.

2.2

All spools that require FBE coating are not covered in this method statement.

2.3

This procedure is limited to ensure the execution of surface [preparation and paint application works in accordance with project specification and paint manufacturer’s recommendation.

3. APPLICABILITY Painting of above ground as well as buried piping and small bore valves 4. REFERENCES 4.1

SAES-H-001 Requirements for

4.2

SAES-H-101V and

4.3 4.4 1

SAES-H-002 SAES-H-002V SAES-H-100 Requirements for

-

-

Coating Selection & Application

IndustrialPlants and Equipment Approved Saudi Aramco Data Sheets – Paints Coatings Internal and External Coatings for Steel Pipelines And Piping. Approved Saudi Aramco Data Sheets for the Pipeline Maintenance External Coatings Coating Materials and Application IndustrialFacilities

SK-SPP-07 Painting & Coating Rev. 00 - CN #6600033951

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SAUDI KAD CONTRACTING COMPANY

DOCUMENT NO. SK-SPP-07

SPECIAL PROCESS PROCEDURE

REV. NO. 00 DATE: Dec. 25, 2014

PAINTING & COATING 4.3

4.4 4.5

SAES-H-101 Industrial

-

Plants andEquipment Safety Requirements for Coating

SAES-H-102 Applications SAES-H-200 Externally Coated

-

4.6 4.7

SAEP-316 09-SAMSS-060

-

4.8 4.9 4.10

APCS 113A APCS 26 APCS 26T Coating NACE RP-0287

-

4.11

Approved Protective Coating Systems for

-

Storage, Handling and Installation of

Pipe Performance Qualification of Coating Personnel Saudi Aramco Material System SpecificationPackaging Requirements for Coating High volume solid epoxy Mastic Epoxy with Polyurethane Mastic Epoxy with Polyurethane Top-Coat System Surface Profile Measurements of Abrasive Blast Cleaned Steel Surface Using Replica Tape

5. RESPONSIBILITY 5.1

QA/ QC Manager: has responsibility to support and provide enough resources for the control and implementation of this procedure.

5.2

QA/QC Supervisor; has responsible to directly coordinate with QC inspectors to resolve their issues.

5.3

QC Personnel: Monitor daily coating activities and conducts inspections in accordance with approved project SATIP and associated documents.

5.4

Discipline Foreman: will directly oversee the activities of workers. Basic manpower will include but not limited to as follow

  

Blaster Painter Helper

General Requirements TOOLS AND EQUIPMENT Tools and equipment shall be made available to support continuous work. Tool and equipment shall include but not limited to as follows: 

Air compressor

SK-SPP-07 Painting & Coating Rev. 00 - CN #6600033951

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SAUDI KAD CONTRACTING COMPANY

DOCUMENT NO. SK-SPP-07

SPECIAL PROCESS PROCEDURE

REV. NO. 00 DATE: Dec. 25, 2014

PAINTING & COATING              

 

 

Moisture separator Oil free filter Blast machine Pressure pots Airless Spray machine Airline filter Portable air blower Paint brush/Paint roller Steel brush Power brush Salt contamination meter

All site protective coating applicators shall be qualified and certified as per SAEP316 requirements. Coating inspector shall be NACE Level II or equivalent. Blasters shall have a medical examination including chest X-ray and a pulmonary function study. These examinations shall be repeated at least every two (2) years as per G.I. # 6.021 (Para 3.0) requirements. Breathing air quality test shall be done as per G.I #1780.001 (Para 6.0 and Table 2) requirements. The material and equipment used for surface preparation, painting application, and inspection shall confirm to the requirements grit or garnet and as per SAESH-100. Trained and experienced operators shall be used for surface preparation and painting application. Extreme care shall be taken to avoid the damage to the painted materials during handling.

Storage, Handling of Paint and Abrasives 

   

Paint and thinner shall be stored in well-ventilated area or shelter according with recommended storage temperatures given in Saudi Aramco Paint data sheet, SAES-H-101V. Shelter storage temperature shall not exceed 35C unless stated otherwise in the paint manufacturer data sheet. Paints which have exceed the shelf life given in the Saudi Aramco data sheet shall be set aside and removed. Expired shelf life paint shall not be used. Temporary storage of paint materials covered with canvas, tarpaulins shall not exceed 14 days period as per SAES-H-100, Para 6.2. Paint container showing signs of leakage shall be discarded and not to be used for coating. Abrasives shall be stored in dry and clean areas and shall be covered with tarpaulin during storage.

SK-SPP-07 Painting & Coating Rev. 00 - CN #6600033951

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SAUDI KAD CONTRACTING COMPANY

DOCUMENT NO. SK-SPP-07

SPECIAL PROCESS PROCEDURE

REV. NO. 00 DATE: Dec. 25, 2014

PAINTING & COATING

6. SAFETY REQUIREMENTS 



Safety during abrasive blasting and application of coating shall meet the requirements of SAES-H-102, Sect. 4. GI-0002.100 (Work Permit System) & GI0006.021 (Safety Requirement for Abrasive Blasting) All the areas shall be barricaded prior to start of abrasive blasting and coating and necessary sign boards to be made visible near the area of work. All the personnel involved in this process should wear proper Personal Protective Equipment.

7. GENERAL 



  

The responsibility for the Process Control of the Painting Works rests primarily with the Crew Supervisor, Discipline Engineer, QC Inspectors, and QA/QC Supervisor and audit by the QA & QC Managers. The discipline Engineer and the Crew Supervisor shall ensure the required work permits are available and in place on a daily basis. Similarly they shall ensure that utilized drawings are latest revision. Surface preparation shall conform to the project specifications. Client specifications and drawings, manufacturer instructions/recommendations shall supersede the techniques detailed in this procedure when they differ. The following procedure is a basic outline of requirements and in all cases the relevant SATIP (if available) shall be reviewed by QA/QC Manageror QC Supervisor to ensure Inspectors are fully aware of tests and documentation requirements prior to start of work.

8. PROCEDURE Blotter Paper Test 



Attach a piece of blotter paper to a clip board, then hold it approximately 4560cm in front of the blast nozzle during air flow only, with a nozzle pressure of 50 psi for approximately 1minute. Satisfactory result shall be no water or oil contamination on the blotter paper. All Blasting equipment shall have an operational dead-man control fitted.

SK-SPP-07 Painting & Coating Rev. 00 - CN #6600033951

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SAUDI KAD CONTRACTING COMPANY

DOCUMENT NO. SK-SPP-07

SPECIAL PROCESS PROCEDURE

REV. NO. 00 DATE: Dec. 25, 2014

PAINTING & COATING 

8.1 

     

      

 

8.2

Minimum nozzle pressure for blasting of steel shall be 90 psig.

Surface Preparation Procedure In preparing any surface to be coated, all loose paint, dirt, grease, rust, scale, weld slag or any other extraneous material shall be removed and defects repaired, so as to obtain a clean, dry even surface. Sharp or rough welds shall be rounded and contoured. Sharp edges shall be rounded or chamfered. Abrasive shall be kept dry and clean. Abrasive blasting shall be carried out only when the steel surface is at least 3°C (5°F) above the Dew Point. As per SAES-H-001 Para.6.4.3. Compressed air supply quality check shall be done by blotter test at the start and midpoint of each 8 hour shift. Minimum air pressure measured at blasting nozzle side of the blasting hose shall be 90 psig. All blasting pots and compressor shall be fitted with efficient water/moisture separator and water traps etc. to maintain dry oil free air supply. Traps and filters shall be cleaned regularly. External blasting using tungsten carbide ventury type blasting nozzles with maximum orifice size 9 mm shall be used maintaining correct air pressure. Blasting shall not be carried out when the wind speed reaches 56 Km /hr and during dusty weather condition. Dead-man handlesshall be fixed to the blast line as close as practicable to the blast nozzle and shall be held by the blast operator alone. All Blasting equipment shall have an operational dead-man control fitted. Minimum nozzle pressure for blasting of steel shall be 90 psi. Quality Control Equipment shall be available as required by project scope and SAES-H-100 attachments All compressed air used for abrasive blasting or coating operations shall be free of oil moisture and contamination. The QC Inspector shall as a minimum check air quality at the start and mid points of each 8 hour period. Abrasive Garnet 30/60 shall be used for surface preparation, Degree of cleanliness shall be Sa 2.5 for external surfaces while for internal coating the degree of cleanliness shall be Sa 3

Painting Materials

SK-SPP-07 Painting & Coating Rev. 00 - CN #6600033951

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SAUDI KAD CONTRACTING COMPANY

DOCUMENT NO. SK-SPP-07

SPECIAL PROCESS PROCEDURE

REV. NO. 00 DATE: Dec. 25, 2014

PAINTING & COATING 

 

All painting materials shall be chemically pure and free from inclusions and foreign contaminants. The age of material components shall not exceed the recommended pot-life given by the manufactures. Batch No. /Code no. and date of manufacture shall be clearly given on all painting materials. All the painting materials shall be from one manufacturer:  External painting Aramco standard APCS-113A Each coat: Two or more coats of coal tar epoxy coating Total system: Minimum two coats of epoxy coating, 600-1000 micron min/max, and micron max DFT per coat  External painting as per Aramco Standard APCS 26 Primer:

Two or more coats of one coat of mastic epoxy primer 200300micron, min/max DFT. Top coat: One coat of polyurethane 40-60 microns min/max DFT Total system: 240-360 microns min/max DFT  

   8.3 

8.4 



Top coat color shall be specified in the paint manufacturer’s data sheet and got it approved. All Abrasive Blasters, Painting/Coating Applicators and Crew Supervisors shall be qualified, approved and possess valid certification in accordance with Saudi Aramco SAEP 316. Each paint container shall be clearly marked in accordance with 09-SAMSS060. As per SAES-H-100 Para. 6.2. Paint which has gelled shall not be used. Partial mixing is not allowed. Preparation of Coating Materials Primer or paint shall be mixed in accordance with the paint manufacturer’s datasheet. Mixing of the paint ingredients shall be done in open containers in a well-ventilated area. All ingredients in any container shall be thoroughly mixed and shall be agitated by mechanically (manual agitation not allowed) frequently during application to keep the solids in suspension. Application of Paint Materials The substrate surface temperature shall not be less than 10C or more than the temperature limit given in applicable manufacturer data sheet or client specification. Do not leave the blasted materials unpainted overnight. The compressed air supply shall be free of oil, moisture and contamination.

SK-SPP-07 Painting & Coating Rev. 00 - CN #6600033951

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SAUDI KAD CONTRACTING COMPANY

DOCUMENT NO. SK-SPP-07

SPECIAL PROCESS PROCEDURE

REV. NO. 00 DATE: Dec. 25, 2014

PAINTING & COATING 





 

8.5  



 

Used abrasive shall be removed from cleaned surface by dry brushing and blowing down with clean, dry compressed air. Avoid handling the blasted steel surface with bare hands. Spraying of the paint shall be done by means of airless spray to obtain uniform and correct film thickness as specified in the contract. Wet film thickness shall be monitored to control the required minimum dry film thickness. Between applied coats the minimum and maximum drying time and temperature has to be observed strictly in accordance with paint manufacturer’s recommendations. Large surfaces shall be painted with passes in two directions at right angles and spray overlap of previous pass shall be by 50%. Damaged area of painting during the transportation and erection shall be repaired with the original material. Repair Procedure for Damaged Coatings Clean defective area by solvent or detergent wash. For area less than 0.1 m2, grind to a rough metal surface using at least 80 grit disc sander. Alternatively spot blast to bare steel. Feather edge the coating at least 50mm beyond bare metal. If the area is very less manual application of abrasive papers may be performed to prepare the surface. For areas greater than 0.1 m2, blast clean to obtain the metal surface pretreatment originally specified. Feather edge the coating at least 50mm beyond bare metal Remove dust and debris by brush or vacuum Apply coating by brush for area less than 0.1 m2and by spray for areas greater than 0.1 m2 to the original specification except that the first coat of a multi-coat system shall be thinned by 15%.

9. QUALITY CONTROL EQUIPMENT KIT -

Anchor Pattern Measurement Device(s) Wet Film Thickness Gauge Dry Film Thickness Gauge (with a range appropriate for the Coating) Thermometer for Air Temperature Humidity Gauge or Sling Psychrometer Dew point calculator/meter Contact Thermometer for Metal Temperature Sharp Knife Hypodermic Needle Pressure Gage

SK-SPP-07 Painting & Coating Rev. 00 - CN #6600033951

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SAUDI KAD CONTRACTING COMPANY

DOCUMENT NO. SK-SPP-07

SPECIAL PROCESS PROCEDURE

REV. NO. 00 DATE: Dec. 25, 2014

PAINTING & COATING  

Measuring and testing equipment shall be properly calibrated as per Schedule Q requirements. Equipment calibration shall be performed at established periods as specified of Saudi Aramco standards, other applicable standards, or manufacturer recommendations, if no standards apply, the calibration shall not exceed six months.

10. 

  

 



    

INSPECTION PROCEDURE

QC Inspector shall check the surface of the blasted materials as per required surface preparation and ensure that clean surface must be free from mill scale, oil, grease, soil, cement, salt, acid or other corrosive material, which are harmful for painting. Surface profile shall be inspected by using Testex Tape (Press-O-Film). Degree of surface cleaning shall be inspected visually by comparing the blasted surface with photographic standards as per SSPC or ISO 8501. Relative humidity, dew point and substrate temperature shall be recorded at least thrice per day by the supervisor in daily log book and shall be transfer to inspection report. Blasting shall not be performed if the substrate temperature is less than 100C or less than 30C above the dew point. Before painting, paint mix ratio shall be as per paint manufacturer’s recommendations. After completion of painting, dry film shall be visually examined to establish application defects such as over spray, dirt inclusion, blister, sag, runs, adhesion, pinholes, voids, spatter and thin spots. Paint coating dry film thickness (DFT) shall be measured by using a paint thickness gauge (DFT Gauge) observation data shall be recorded in blasting & painting inspection Report. (Attachment No. 1) Paint thickness gauge, surface profile gauge, Digital Thermometer shall be calibrated prior to use. If the result of DFT is varying from the specified value or if any defect is observed on the paint surface, it shall be rectified, before proceeding further application. Rectified surface shall be re-inspected for its completeness. In addition to the above, QC Inspector shall visually inspect the quality of welds after blasting to ensure that it is free from welding defects. The coating contractor supervisor shall fill out a log, on a daily basis, recording all problem areas, delays non-compliances, and corrective action taken for Saudi Aramco inspector witnessing and surveillance per SAES-H-100 para.9.2.2.

SK-SPP-07 Painting & Coating Rev. 00 - CN #6600033951

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SAUDI KAD CONTRACTING COMPANY

DOCUMENT NO. SK-SPP-07

SPECIAL PROCESS PROCEDURE

REV. NO. 00 DATE: Dec. 25, 2014

PAINTING & COATING

Paint System

Surface Preparati on

APCS26

Abrasive blast cleaning Sa 2.5

APCS113A

Abrasive blast cleaning Sa 2.5

APCS-4

Abrasive blast cleaning Sa 2.5

APCS-6

Abrasive blast cleaning Sa 2.5

APCS1B

Abrasive blast cleaning Sa 2.5

Pipe, flanges and fittings (internal)

APCS102

Abrasive blast cleaning Sa 2.5

CS

Pipe, flange and fittings

APCS104

Abrasive blast cleaning Sa 3

CS

Item Pipe, flange and fittings,valves etc. Transition line from buried to above ground

Steel Pipe supports PZV block valves

Scraper trap, above ground concrete surfaces

11.

Materi al

Primer Coat

Intermedia te Coat

CS

Epoxy mastic 125200um

-

CS

High build epoxy 6001000um

-

Top Coat

Final Color & DFT

Epoxy mastic 125200um

Aluminum25 0-400um

Total DFT 60001000um

-

CS

75um

-

Aluminu m top coat 25um

CS

Zinc chromat e primer 3575um

-

Alkyd top coat 35-75um

Total DFT 70150um

CS

Epoxy primer 50100um

-

Epoxy top coat 175275um

Total DFT 275-375um

Fusion bond epoxy 5001000um Fusion bond epoxy 375625um

Aluminum 100um

-

-

Total DFT 500-1000um

-

-

Total DFT 375-625um

ATTACHMENTS      

Technical Data Sheet of Sigma cover410 SATIP-H-100-01 SAIC-H-2024 SAIC-H-2025 SAIC-H-2026 SAIC-H-2027

SK-SPP-07 Painting & Coating Rev. 00 - CN #6600033951

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SAUDI KAD CONTRACTING COMPANY

DOCUMENT NO. SK-SPP-07

SPECIAL PROCESS PROCEDURE

REV. NO. 00 DATE: Dec. 25, 2014

PAINTING & COATING      

SAIC-H-2028 SAIC-H-2029 SAIC-H-2030 SAIC-H-2031 SATR-H-2004 SATR-H-2006

SK-SPP-07 Painting & Coating Rev. 00 - CN #6600033951

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