( soft copy of procedure for surface preparation ) bd1253aa-mbab-q-pro-0005
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RAJASTHAN NORTHERN AREA DEVELOPMENT PROJECT
BHAGYAM FIELD DEVELOPMENT
PROCEDURE FOR SURFACE PREPARATION AND PAINTING FOR STRUCTURAL STEEL AND PIPING
BD1253AA-BHAG-Q-PRO-0005
ARTSON ENGINEERING
A1 26-03-11 FOR CEIL REVIEW SS Perumal Jayachandra N. Makwana
Rev
Date Purpose of Issue Prepared By Checked By Approved By
Proc. No.: BD1253AA-BHAG-Q-PRO-0005 Rev. A1 Page 1 of 24
PROCEDURE FOR SURFACE
PREPARATION AND PAINTING FOR
STRUCTURAL STEEL AND PIPING
TABLE OF CONTENTS
DESCRIPTION PAGE NO
1. Purpose 03
2. Scope 03
3. Reference Documents 03
4. Definitions 03
5. Health and Safety 04
6. Process 04
7. Inspection 11
8. Documentation 12
9. Personnel 12
10. Equipments for construction 13
11. List of annexure 13
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1. Purpose
The purpose of this method statement is to provide guide lines for surface
preparation and painting of pipes and structural items and to ensure that proper
quality control and documentation are maintained at site.
2. Scope
This scope of method statement describes the method for abrasive blasting, paint
Application, touch-up painting and inspection on exterior surface of structural
Steel, above ground piping, & Equipments during construction in the Rajasthan
Northern Area Development project of CAIRN India.
3. Reference Documents
3.1. “INSPECTION TEST PLAN” ITP No. BD1253AA-BHAG-Q-ITP-0005
3.2. BCT1201-BHAG-L-SP-0002 "Specification for External Painting and
Protective Coating”
3.3. BD1253AA-BHAG-Q-PLN-0001”Project Quality Plan”
3.4. ISO 8501-1 'Preparation of steel substrates before application of paints”
3.5. SSPC VIS 1 "Visual Standard for Abrasive Blast Cleaned Steel”
3.6. SSPC PA 2 "Measurement of Dry Film Thickness with Magnetic Gauge”
3.7. ASTM D4417”Standard test methods for measurement of surface profile”
3.8. Drawing references.
4. Definition
MTC Material Test Certificate
HSE Health Safety and Environment
WFT Wet Film Thickness
DFT Dry Film Thickness
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MSDS Material Safety Data Sheet
JSA Job Safety Analysis
ASTM American Society testing of materials
NACE National Association of Corrosion Engineers
SSPC Society of Protective Coating
ISO International Organization for Standards
5. Health and Safety
As per HSE plan, the following systems shall be followed.
All relevant elements of HSE Plan BD1253AA-BHAG-R-PLAN-0001
Emergency Response plan BD12533AA-BHAG-R-PLN-0003 shall be followed
in any case of emergency.
Daily tool box talk shall be conducted prior to proceed for the work
First Aid arrangements shall be followed as BD12533AA-BHAG-R-PLN-0001.
HSE personnel shall be present at site during all activities.
Qualified Scaffolders shall be used in scaffolding works.
Fire Extinguishers shall be placed at work locations at all times.
6. Process
6.1. General
6.1.1. Material
Paint materials shall be purchased from the company approved
manufacturers. All painting materials shall be stored indoor only.
Materials shall be stored and used as per the manufacturer's
recommendation. All necessary precautions shall be taken to prevent
fire. Warning signboard shall be clearly displayed. Thinners shall be
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stored in separately and in sealed containers.
6.1.2. Extent of Painting
All above ground piping and structural steel shall be painted as per the
painting system specified in BCT1201-BHAG-L-SP-0002 "Specification
for External Painting and Protective Coating”. Touch-up painting shall be
done for the equipments, piping. All valves, fittings & flanges shall be
painted.
The following surfaces shall not be painted
Welded joints of the pipe & ends of the pipe (During shop painting)
Identification mark (During shop painting)
Machined and threaded surface like flange faces, valve stem, sliding
surfaces in equipments etc.
Galvanized surfaces
Name plates
6.1.3. Weather condition
Surface shall not be blasted & painted during rain, heavy wind, dusty
wind, fog, moist. When the steel surface temperature is less than 3°C of
dew point, surface temperature is below 5°C, whether relative humidity is
greater than 85% or when the air temperature is below 10°C, the surface
shall not be painted.
6.2. Surface Preparation
The type of surface preparation shall be in accordance with BCT1201-
BHAG-L-SP-0002 "Specification for External Painting and Protective
Coating”
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6.2.1. Abrasive Blast Cleaning
Sand or other material producing silica shall not be used. Abrasive to be
used for blast cleaning are listed below.
Chilled Iron Grit or Shot
Non & Metallic Iron Grit or Shot
Non Metallic Abrasive (Aluminium, Oxide, Copper Slag, Garnet)
Grit Spec- Particles that are predominately angular have fractured
faces and sharp edges and are less than half round in shape.
The surfaces shall be blast at appropriate pressure, distance and right
angles to the surface maintaining constant velocity and pressure.
Compressed air shall be free from moisture, oil and other
contaminations. The compressed air temperature shall be less than
110°C. Knock-out pots or vapour traps shall be installed to remove oil /
moisture regularly.
Prior to blast cleaning of pipes and pipe spools the identification of spool
shall be covered by masking tape or Aluminium tag shall be tied to the
spools/pipes.
Machined surface such as flange faces and threaded surfaces shall be
covered by masking tape so as not to damage the surface while
blasting / painting.
Surface profile of blast surface shall not be less than 25µm nor be
greater than 40µm. Paint manufacturer’s data sheet shall be referred for
the required surface profile. Grade surface finish shall be accordance
with ISO 8501-1. Dead-man’s handle shall be installed for safety
purpose.
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Sa 1 -" Light Blast Cleaning" (SSPC SP 7)
Sa 2 - " Through Blast Cleaning" (SSPC SP 6)
Sa 21/2 - "Very Through Blast Cleaning" (SSPC SP 10)
Sa 3 - " Blast Cleaning to Virtually Clean Steel" (SSPC SP 5)
On completion of blasting operation, the blasted surface shall be
clean and free from mill scale, rust, oil, grit or other foreign material
and first coat of paint shall be applied within 4 hrs of blasting.
Presence of oil, grease shall be cleaned and removed with an
approved solvent. Degree of surface cleanliness shall be checked
with SSPC VIS 1 standard. Surface profile shall be checked recorded
with Testex tape & Dial micrometer.
6.2.2. Hand Tool Cleaning
Rust, mill scale spatters, old coating and other foreign and other foreign
matter, shall be removed by scrapping tool, emery paper cleaning,
brushing or combination of the above methods. On completion of
cleaning, loose material shall be removed from the surface by clean rags
and the surface shall be brushed, swept, and blown off with compressed
air to remove all loose matter.
Hand tool cleaning shall be done for touch up and repair works of
painting.
6.2.3. Power Tool Cleaning
Power Rotary Wire Brushing, Rotary Power Discing, grinding machines
shall be used for removal of rust mill scale, spatter, old coating and other
foreign matters. On completion of cleaning, loose material shall be
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removed from the surface by clean rags and the surface shall be
brushed, swept, and blown off with compressed air to remove all loose
matter.
Power tool cleaning shall be done at site for touch up painting.
6.3. Painting
Painting system and colour coding system shall be in accordance with
BCT1201-BHAG-L-SP-0002 "Specification for External Painting and
Protective Coating".
Paint material shall be identified as per incoming Material receipt inspection
procedure and also verification of material with respect to
a) Specification
b) Manufacturer
c) Batch Test Certificates
d) Pot life/Expiry date
e) Storage area
The paint manufacturer's recommendation shall be followed for mixing, thinning, storage, application of paint, drying time and weather condition.
Paint application shall be carried out by air less spray.
Brush and roller application shall be used for touch up and field painting of small areas and stripes coats.
Surfaces that should not be painted shall be covered by masking tape.
Zinc based paints shall be agitated continuously while painting.
If there is rain just after application, before drying then protection will be done by covering tarpaulin.
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In case of air spray application, traps or separators shall be installed to remove oil and condensed water from the air.
Blast cleaned surfaces shall be coated with one complete application of primer as soon as practicable before flash rusting occurs.
Blast cleaned surface allowed to set over night shall be reblasted prior to priming.
All paint containers shall be opened prior to utilisation and shall be carefully
closed immediately after withdrawal of material. Material which become
unserviceable during storage shall not be applied. All painting material shall
be kept in weather proof barracks and shall be kept cool and dry.
Paint materials which exceed its pot life shall be removed and destroyed
immediately.
Partial mixing of 2 pack system paints is not allowed.
Mixing ratios, induction time & pot life period of paints shall be strictly
observed as recommended by the paint manufacturer.
Each pass of the spray paint shall be overlapped by 50% and the spray shall
be continuous until all paint material used up which has been taken out from
the paint containers.
Each coat shall be in proper state of dryness before the application of
succeeding coat. The curing time shall be as per the manufacturer's
recommendations.
In case of two or more coats of painting, the successive coat shall be of
contrast dark shade to the previous coat shade.
Paint film thickness shall be maintained as indicated in painting system and
the painted surface shall be free from defects. Proper application of paint
shall be checked by measuring their WFT while painting. DFT will be
measured with the help of coating thickness gauge after curing at every
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stage.
All runs and sags shall be brushed out immediately or the paint shall be
removed and surface re-painted.
After painting, paint shall be visually checked with regards to unfinished
surface, drips, wrinkles, peeling, crewing, decolourisation, strains, pinholes
and dry spray. Where there are no marked defects in appearance the paint
is accepted with respect to meeting the required DFT.
When paint has been damaged, all damaged and loosely adhering paint
shall be removed and surface cleaned mechanically to bare metal. Surface
preparation of defective or damaged areas shall be extended over the
surrounding sound coating for a minimum of 25mm on all sides. Priming
shall be done in the area with primer specified to the required DFT. Then 2nd
& 3rd coat paint shall be applied as per specification.
Shop coating of all members should be completed before erection.
The left out unmixed paint will be preserved in a drum with tight cover.
Scaffolding arrangement shall be done for painting of erected pipelines and structural works and equipments.
Field painting of weld joints shall be done after the completion of applicable NDT and hydro test.
6.4. Color coding and Identification sign
The strip color coding shall be in accordance with the Table M - Piping
Painting color code of DECO-RX-L-SP-2003 "Project General Piping Design
and materials"
The Three strips 150mm width each shall be painted over the final coat.
The three strips shall be placed each 9 meters length whenever necessary
for identification (branches, valves, tanks, at curves, close to equipments,
close to entrance and exit of equipments and before and after crossing of
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bulkhead).
All strip colors shall be painted with polyurethane paint of specified colors.
Flow direction shall be an arrow mark, colours of shall be black
or white and in contrast to the colour on which they are
superimposed.
Line tags and arrows to indicate flow direction shall be painted with
polyurethane paint. The text height shall be 20mm for DN 15 to DN 50 pipe
sizes and 50mm for pipe sizes above DN 50.
Insulated piping shall also be identified.
7. INSPECTION
Inspection of surface preparation and painting shall be carried out as per the ITP
No. BD1253AA-BHAG-Q-ITP-0005
7.1. DEW POINT MEASUREMENT
Dew point shall be measured 3 times a day as a minimum and records shall
be maintained.
Before any coating or painting activities commence, the substrate
temperature shall not 3° C or less than the Dew point.
7.2. SURFACE PREPARATION VISUAL INSPECTION
Surface preparation shall be visually inspected in accordance with SSPC
VIS 1 & 3.
The measurement of surface profile shall be as per NACE RP 0287 or
ASTM D 4417 and ISO 8502.
Acceptance of the blast cleaned surface shall be made by visual comparison
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with 'Anchor Pattern Standards' or 'Surface Profile Comparator'.
Surface profile shall be measured & recorded with Testex tape & Dial
micrometer.
7.3. DRY FILM THICKNESS
Painted area shall be devoid of bare metal and is free of holiday. The DFT
requirements and color codes shall be achieved as per the requirements.
The DFT shall be checked in the spots at random and documented, as per
SSPC PA2
8. DOCUMENTATION
Documentation shall be as follow
Refer Inspection and Test Plan for Surface preparation and Painting for
structural steel and piping ITP No. BD1253AA-BHAG-Q-ITP-0005
Format for surface preparation and painting Report No. BD1253AA-BHAG-Q-
RPT-0011
Color coding & Identification Mark report No. BD1253AA-BHAG-Q-RPT-0012
9. PERSONNEL
I. Peoples involved
Construction Manager
Project QC Manager
QC Engineer
Site Engineer
HSE engineer
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QC Assistant
Foreman
II. Roles & Responsibilities - Refer Contract Quality Plan
10.EQUIPMENTS FOR CONSTRUCTION
a) Compressor along with hose and nozzles
b) Hoppers
c) Paint agitators
d) Paint spraying equipment.
e) Dry Film thickness gauge
f) Surface profile comparators
g) Cleaning tools like wire brush, scrappers, etc.
h) Painting brush and rollers
i) Hygrometer
j) Wet Film Thickness gauge
11.LIST OF ANNEXURE
Appendix 1.0 - Color Code
JSA for Surface Preparation and Painting
Format for surface preparation and painting Report No.
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Appendix 1.0 COLOR CODE
ITEM EQUIPMENT COLORRAL COLOR
(Note 1)
1 Tanks (except U/G), Vessels, Towers Medium Gray 7004
2 Storage Bullets White 9010
3 Vendor Supplied Equipment Medium Gray 7004
4Structural, Skids (except for handrails,
safety cages and ladders)Medium Gray 7004
5 Handrails, Safety Cages and Ladders Safety Yellow 1024
6 Process Gas Piping Medium Gray 7004
7 Instrument Gas Piping Medium Gray 7004
8 Fuel Gas Piping Safety Yellow 1024
9
Process Hydro-Carbon Liquid Piping
(Including inlet, Sales, Multi-Phase Oil
Streams)
Medium Gray 7004
10 Instrument Air Medium Gray 7004
11 Drain, Flare, Relief Piping Medium Gray 7004
12 Fire and Emergency Systems Safety Red 3020
13 Water (Except Fire water) Medium Gray 7004
14High Pressure Gas and Water (Over
10,204kpa or 1480 psi)Medium Gray 7004
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15Amine Streams (Or Other Gas
Sweetening Agents)Medium Gray
7004
16 Glycol or Glycol/lf\later Streams Medium Gray 7004
17 Refrigerant Streams Medium Gray 7004
18 Flare and other Stacks Black 9005
JSA for Surface preparation and Painting
Sl. No. Activity Hazard Control Measures Action By
1 Painting work for the MS Structural material
1. Eye Injury
2. Toxic Inhalation
3. Hearing Loss
4. Impact and Piercing Injury
5. Back and Limb Injury
6. Soil Contamination
7. Air and Nose Pollution.
1. Permanent installations, instruments, fragile items, hazardous items to be removed or protected.
2. Material handling ergonomics posture shall be explained.
3. All work related to painting i.e., material handling, grit and spraying jobs shall be under supervision only
4. Painting material shall
Fabrication Shop In-Charge.
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2. Area Preparation and Barricading
1. Insufficient accessibility and material stacking. Unauthorized personnel
be stored in a well protected place.
5. Fire extinguishers and fire buckets shall be readily available nearby in-case of emergency.
6. No hot work shall be carried out within the radius of 10 mts of area where spray painting is carried out.
7. Provide the necessary PPE’s like dust musk, safety goggles ,etc to protect from paint spray
1. Painting procedure shall be explained to all employees.
2. JSA to be
Fabrication Engineers
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3.Material Storage – Paint and GritWaste Disposal
movement ventilation
Spillage and Soil contamination, fumes and dust and fire hazard, chemical reaction hazards.
made and its hazards, control measures to be communicated to all personnel.
3. Toolbox talk to be given to all persons
1. MSDS shall be provide
2. Use secondary confinement and spillage tray
3. Shed and confinement area shall be made of fire proof material.
4. Electrical connections shall be of standard at a continuous hazard zone
5. Worker shall be trained on fire fighting Approved Recycler.
Fabrication Engineers and HSE Team
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4.
5.
Material Handling and Arrangement (Manual)
1. Material handling by equipments.
1. Unauthorized personnel shall not be at the job
2. Manual shifting of material leads to back injury, limb injury and cut injury.
1. Unauthorized operating of lifting equipments.
2. Fall of materials and dropping & swinging of
1. Ensure sufficient accessibility, proper barricading shall be done in lifting operation area.
2. Ensure use of all proper PPE’s while entering the site.
3. Ensure all personnel are following safe manual handling procedures
4. Never overload.
1. Ensure all personnel are following safe manual handling procedures.
2. Never overload the crane
3. Work shall be under supervision
HSE Team and Site Supervisor
Fabrication Engineer
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6. Air compressor
loads.
3. Impact, crush injury and pinching injury.
1. High Pressure air injury - Eyes & Skin due particular / splinters.
2. Exhaust and noise pollution.
3. Soil Pollution due to oil leakage
4. Use safety boots, hand gloves and goggles.
5. Lifting equipments shall have a inspection sticker
1. Compressor must be certified by Third Party and valid.
2. Ensure all hose connection properly fitted and whip check installed.
3. Ensure all other workers are using ear plugs while working or staying nearby.
4. Fire extinguisher to be readily available.
5. Use spill tray or plastic containment.
6. Use coverall and leather
Fabrication Engineer and HSE Team
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apron for blaster
7.
8.
Use of Electrical Hand tool like buffing wheel and grinder, etc
GRIT Blasting using copper slag using Air Compressor
1. Electrocution
2. Electrical shock
3. Burn injury
4. Splinter / piercing injury form failed – consumables.
5. Noise pollution, repeated strain and injury to limb
1. Improper operation.
2. Unauthorized
1. Regular tool box talk and training on hazards involved to all the related workers.
2. Always maintain good housekeeping.
3. Use coverall and leather apron.
4. No parallel works to be permitted in front of the buffing and grinding work area.
5. Ensure good earthing and insulation for the electrical cable.
6. No tampering with guards and other devices.
1. Only authorized workers to carry out blasting work.
Fabrication Engineer and HSE Team
Fabrication Engineer and HSE Team
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entry.
3. Compressor hose or clamp and Nozzle failure.
4. Dust and noise pollution.
5. Personnel injury like eyes, lungs, piercing and impact injury.
6. Fire/ Explosion
7. Tripping Hazards
8. Used grit waste
2. Worker s shall be explained about the hazards involved in the blasting and painting work.
3. Whip check to be provided to Hose and Compressor out ports and joints.
4. Deadman switch has to be connected to the hose to be filled on blasting nozzle.
5. Workers shall be provided with Breathing HOOD and Ear Muffs.
6. Interim break/ stop; shall be provided to workmen to relax & rest and machine for checking critical parts.
7. Sparking nozzle shall be on hold or arrested when compressor ON avoid wipe
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9.Spray painting works
1. Inhalation of fumes at work area
2. Skin contact.
3. Eye contact4. Fire hazards
5. Handling full paint cans
6. Damage to paint containers
7. Paint spillage
and wastages
8. Compressor hazard
9. Tripping hazard
moment.
8. Sign board of grit blasting shall be clearly displayed.
1. All painting and blasting works shall be carried out in the booth to prevent spreading of grit particles and paint sprayed.
2. No drinking water container shall be used for storage of paints/ thinners, etc
3. Use of half mask face piece with chemical cartridge by the painter and helper at work area.
4. Use secondary containments for transferring of paints.
5. Provide plastic sheet for preventing soil contamination.
Fabrication Engineer and HSE Team
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6. Smoking/source of ignition not permitted in vicinity of spray area.
Format for Surface preparation and Painting Report
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ARTSON ENGINEERING LIMITED
SURFACE PREPARATION & PAINT INSPECTION REPORT
CLIENT: CAIRN ENERGY INDIA LTD. REPORT NO:
PROJECT: RAJASTHAN NORTHERN AREA DEVELOPMENT PROJECT DATE:
ITEM: LOCATION:
PAINTING SYSTEM:
IDENTIFICATION No: (Line No/Spool No. /Drawing No.) Total Surface Area :
PROFILE REQUIRED
mm mm ACTUAL mm SURFACE PREPARATION ACHIEVED
Sa 2 ½
ABRASIVE TYPE: SIZE: BATCH No:
Stage of Painting Operation
DDDStart Time
Dry Bulb Temp.
Wet bulb Temp.
Surface Temp.
Dew Point
%RH Maximum
Dry Film Thickness (DFT)(Total average readings)
Blasting °C °C °C °C % ---
Primer °C °C °C °C % mm
Intermediate Coat
°C °C °C °C
% mm
Final Coat °C °C °C °C % mm
Paint Manufacturer: AKZO NOBLE/AMERON/CARBOLINE
Painting Sequence Paint Details Batch NumberDFT Required
Primer mm- mm
intermediate mm- mm
Final coat mm - mm
TOTAL
Remarks:
AEL CAIRN
Name: Name:
Signature: Signature:
Date: Date:
BD1253AA-BHAG-Q-RPT-0011
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