Surface Preparation and protective coating

. Classification 0f Surface preparation Solvent cleaning Hand tool cleaning. Power tool cleaning. Brush off blast. Commercial blast. Near white metal blast. White metal blast.

Blasting Equipment Selection. Compressors. Nozzle. Abrasive

General

Material Specification Coating application Spray equipment

Spray application

Brush application

Good house keeping Clean and orderly work area Storage and issue area Mixing utensils and container Wet coating safe guards Surface preparationPrior to surface cleaning Blast cleaning equipment Abrasive medium. Final inspection

Coating application. Application procedure Equipment. Coating inspection Wet film thickness. Dry film thickness. Holiday detection.

General Good housekeeping. Sand blasting. Coating application

Coating specification Contractor selection

Job scheduling Coating job progressive inspection.

What is Corrosion? Corrosion is the result of a conversion process that takes place when oxygen and moisture come in contact with metal.

The oxygen and water combine with iron to create a brown coating (hydrated ferric oxide) on the surface of the metal.

The interaction between the water and iron is accelerated if salts are added to the mix.

Because the oxide that is created is bulky and porous, it allows oxygen access to the iron below, causing additional oxidation.

If allowed to continue, the iron metal will be completely converted to ferric oxide or solid rust, which is weak and flaky.

This chemical process can be stopped if water and moisture are not allowed to contact the metal surface.

Typically, metal is coated with some substance to seal it off from oxygen and water.

These coatings can be as simple as oil and grease or chemically complex primers and paint.

Coatings are effective as long as the separation between the metal and oxygen and water is maintained.

If the oil or grease is wiped off or dries out, rust begins to form. In the case of paints, they begin to shrink and crack over time.

When this happens, cracks develop in the coating, allowing rust to start.

Even a deep scratch in a painted surface will expose the metal.

Once the rust starts, it travels under the paint forcing the paint away from the metal, allowing more moisture and oxygen to come in contact with the metal surface.How can we protect against corrosion

Generally the only way to reseal the surface is to mechanically or chemically remove all the rust before the surface can be sealed again.

If any rust remains, and paint is applied over the surface, enough moisture and oxygen will travel through the paint molecules to start the rusting process again.

For this reason, most paints directions require you to remove all rust before you paint the surface.How can we protect against corrosions?

Why do we prepare Surface?

For application of Coating, required a particular type of Surface cleanliness and roughness

Surface - How do we prepare? Solvent Cleaning (SSPC-SP-1)

Hand Tool Cleaning (SSPC-SP-2, SIS St. 2)

Power Tool Cleaning (SSPC-3, SIS St.3).

Brush-off Blast (SIS Sa-1, SSPC-SP-7, NACE 4).

Commercial Blast (SIS Sa 2, SSPC-SP 6, NACE 3).

Near White Metal Blast (SIS Sa 2.5,SSPC SP10,NACE- 2).

White Metal Blast (SIS Sa-3, SSPC SP-5, NACE 1).

Solvent Cleaning. (Also called SSPC SP 1)This involves removal of oil, grease, dirt, soil, salt, and other contamination by cleaning with solvent, vapor, alkali, emersion, stream, or detergent

2. Hand tool cleaning (also called SSPC-SP-2, SIS St-2)This type of cleaning requires removal of loose rust, mill scale, and paint by hand chipping, scraping, sanding or wire brushing. The resulting surface has a faint metallic sheen. The cleaned surface appearance corresponded to the Swedish standard designated as St-2.

3. Power tool Cleaning (Also called SSPC- SP-3, SIS St-3)This requires removal of loose rust, mill scale, and paint by power tool chipping, sanding wire brushing, and grinding. The speed of surface preparation is higher than hand tool cleaning, and the resulting surface has a pronounced metallic sheen. It appearance corresponded to the Swedish Std designated as St-3

4. Brush-off Blast (also called SIS Sa-1, SSPC-SP 7, NACE 4 ).This is a surface preparation method in which all oil, grease, dirt, rust scale, loose mill scales, loose rust, and loose paints and coating are removed completely, but tightly adhered rust, paint, and coating and permitted to remain provided that all mill scale, and rust have been exposed to abrasive blast pattern sufficiently to expose numerous flecks of underlying metal fairly uniformly distributed over the entire surface.Surface - How do we prepare?

5. Commercial Blast (also called SIS Sa-2, SSPC-SP 6, NACE 4).This is a surface preparation where at least 2/3 of each element of area is in white metal condition. All oil, grease, dirt, rust scale, and foreign matter shall be completely removed from the surface and all rust, mill scale, and old paint shall be completely removed except for slight shadows, streaks, or slight discoloration caused by rust stain, mill scale oxides, or slight, light residues of paint or coating that may remain. If the surface is pitted slight residues of rust or paint may be found in the bottom of the pit.

6. Near White Metal Blast (also called SIS Sa-2.5, SSPC SP-10, NACE 1).This is a surface preparation where at least 95% of each element of area, is in white metal condition. All oil, grease, dirt, mill scale, rust, corrosion products, oxides, paint or other foreign matter shall be completely removed from the surface except for very light shadows, very light streaks, or slight discoloration caused by rust stain, mill scale oxides, or slight, tight residues of paint or coating that may remain.

7. White Metal Blast (also called SIS Sa-3, SSPC SP-5, NACE 1).This is the degree of surface cleanliness required to achieve a surface with a greywhite, uniform metallic color, slightly roughened to form a suitable anchor pattern for coating adhesion. The surface, when viewed without magnification, shall be free of oil, grease, dirt, mill scale, rust, corrosion products, oxides, paint or may other foreign matter.

Surface - How do we prepare?

Corrosion Grades?A? B? C? D?

How we define the Corrosion Grades.How we define the Corrosion Grades.A. Steel surface covered completely with adherent mill scale with little, if any, rust. B. Steel surface, which has begun to corrode, and from which the mill scale has begun to flake. C.Steel surface on which the mill scale has corroded away or from which it can be scraped, but with little pitting visible to the naked eye. D. Steel surface on which the mill scale has corroded away and on which considerable pitting is visible to the naked eye.

According to SIS 055900,

Pre-treatment for these degrees of corrosion is respectively wirebrushing and blast cleaning to the following quality scale:-

Bad. (Light brushing or light scraping).

Middle quality (thorough scraping with hard metal scrapper and wire brushing or thorough blast cleaning).

3.Thorough scrapping or wire brushing till distinct metal luster is obtained or blast cleaning to clean gray steel.Pre-treatment

Blast Cleaning

St. (Standard tool)St1 St2 St3 Sa.(Standard abrasive) Sa1 Sa2 Sa2.5Sa3 SIS 055900 Standard

Profile Gauge

Press-O-Film Gauge

Testex Tape / Press-O-Film Testex Tape is popularly called as Press-O-Film.

Press-O-Film provides surface profile of a blasted cleaned surface. It can produce virtually exact replicas of the blasted surface profile, which can be measured, using a snap gauge. Testex offers a simple and very accurate method of measuring blasted profiles. Press-O-Film consists of layer of crushable plastic micro foam coated onto a pollster film of highly uniform thickness.

Testex Tape (Press-o-film) complies with ASTM, NACE and SSPC methods measurement

Sand Blasting - History Sandblasting is nothing new; the occupants of deserts around the world have had to deal with natural sandblasting as a part of everyday life. Artificial sandblasting, however, was created and patented by Benjamin Chew Tilghman on October 18th in 1870. By using sand of uniform size through sieving, operators of sandblasting equipment could have predictable results. Over time it was discovered that silica dust that was produced as a byproduct of the sandblasting process caused silicosis after long-term inhalation of the dust.

Compressor All pots require air compressors. The volume of air the compressor can disperse and the pressure at which it operates are important considerations. For the most basic of needs, the compressor should be able to handle ninety cubic feet per minute at a hundred pounds per square inch.

Pot The pot is the vessel that holds and discharges the material used in the blasting, often referred to as sand regardless of its actual composition.

There are two pot types, the pressure-pots and the siphon system pots.

Siphon systems are similar in operation to paint sprayers, with the sand being sucked out (or siphoned out) from the pot via a connecting hose, mixed with air and blasted out of the nozzle onto the surface. Siphon systems are slower than pressure-pots and require a large amount of air to draw the sand from the pot.

Blast-cleaning Ideal

2. Mechanical wire Risk of polishingbrushing

3. Mechanical disk Some risk of polishingsending

4. Needle chipping Some risk of indentations

5. Mechanical rust- chippingNot good heavy indentations

6. Mechanical scraping Combined with other methods (air powered)

7. Hand brushing Poor

8. Hand scraping Only to be used with in combinations other methodsMETHODRESULT

Selection of Blasting Equipment?Compressors The ideal working pressure for air blast cleaning equipment is 90 100 psi is at the abrasive discharge nozzle.

This can be verified by utilizing a hypodermic needle gauge inserted through the blast hose immediately behind the nozzle when the equipment is under normal operation, discharging the abrasive. Compressor shall deliver the volume and pressure of air required to perform work effectively and safely. Oil-lubricated compressors shall have an overheat sensor or carbon monoxide sensor if a respirator (other than air-supplied) is used in poorly ventilated areas. A regulator valve shall be used at the compressor, set to manufacturer specifications, to provide adequate air pressure to abrasive blast equipment. Inspect the compressor starting sand blasting. Open the air discharge valve and put a white paper in front of valve (for 30 Second) to check that: -Oil in air. Purification of air. Any other contamination.

Nozzle.The abrasive blast cleaning nozzle shell be equipped with an operatingvalve which must be held open manually. The sizing of the abrasive discharge nozzle should be correctly matched with the discharge volume capacity of the compressor.To conform in optimum conditions, a compressor should not be required to operate above 75% of its rated capacity. Sand Blasting Nozzles are made of alumina, tungsten carbide or boron carbide, used for sand blasting purpose as required in many industries, such as machinery, bearing, electric and electronic, etc. There are two kinds:

Straight bore nozzles and venture bore nozzles. ,

AbrasivesGarnetCopper SlagSteel AbrasivesGlass BeadsSilica SandAluminum Oxide

Blast Cleaning Equipment? Correct Nozzle Size

Correct Air Hose Blasting Machine with Dead man Coupling Traps Nozzle Pressure PPE Abrasive Skilled Labor Compressors Inspection equipment Proper Scaffolding (If Required)

Rules to be followed Correct Pressure Removal of Lose Paint and Rust Check the hardness of abrasive

Use Lab tested correct abrasive (Free of chloride and Iron) Use good quality sharp quartz abrasive

Check the salt contamination level

How to perform Test Select a fresh, clean surface on the specimen to be tested. Hold the specimen firmly and attempt to scratch it with the point of an object of known hardness. In this example, we use a sharp quartz (H=7) crystal.

Press the point of the crystal firmly against the surface of the unidentified specimen.

If the "tool" (in this case the quartz crystal) is harder, you should feel a definite "bite" into the surface of the specimen.

Look for an etched line. It is a good idea to rub the observed line with your finger to ensure that it is actually etched into the surface of the specimen. In this case, the crystal left a deep, definite scratch in the surface. Because the specimen was scratched by the quartz crystal, we know its hardness is less than that of the quartz - less than H=7.

If there is any question about the result of the test, repeat it being sure to use a sharp point and a fresh surface.

Salt Contamination Ideally, the salt level remaining on steel surface after surface cleaning and prior to painting or any other construction operation should be zero.

In practice it is not possible to achieve this due to various environmental factors and a working salt level need to be specified.

In the case of painting, this level is matter for discussion between the client, the applicator and the paint manufacturer and it will depend on the working conditions, the paint system used the required service life and what can be economically achieved.

Consequently, it is not possible to specify in these instructions which salt standards are best suited to all industries.

However, during the development salt contamination meter, the effect of salt contamination on the life of coatings under a range of realistic and accelerated environmental conditions for a number of common generic coating systems was assessed.

It cant be recommended as a specification that which limit is suitable for coating. The work has shown that a salt level of better than 4g. cm is a sensible working limit. SPECIFICATION OF SALT LEVELS.

1.Salt Contamination Meter Soluble salts on the surface are taken into solution by placing a wetted 11 cm dia Elcometer 130 SCM 400 high purity sample paper on the area to be sampled. By leveling the paper in contact for a timed period, salt removal from the surface is maximized. Using a paper of known size allows contamination to be expressed in terms of surface area. These papers retain a known amount of water because of their consistent absorbency characteristics and therefore the concentration of the solution formed is related to the quantity of soluble salt remover. The sample paper containing the salt solution is placed over the electrodes on the meter and its resistivity is determined. This is achieved by measuring the minimum resistance of the solution over a fixed solution path length and cross section, governed by the electrode spacing and paper thickness respectively. The solution consideration is inversely proportional to its resistivity. The meter release the latter to a calibration with known concentrations of sodium chloride solution and the known surface area sampled, to give surface salt levels in g. cm

Salt Contamination Meter

Object: Determination of chloride salts on steel surface after blastingTest Details: SampleBlasting Standard:Sa 2 Test Area: 1 ftTest Temperature:AmbientProcedure:- 1.100 ml distilled water is used to swab 1 ft of steel surface (Pipe, steel plate or structure) with clean cotton. After blasting.2. Swabbing is carried out 2 3 time within 5 minutes.3. Piece of cotton is dipped-n-mixed in water with a glass rod so that expected salt can be well diluted in water. 4. Finally Quantab strip is approximately half dipped in water till yellow string of strip turns brown. Meanwhile white color appears from bottom indicating salt connection.5. Always use rubber gloves before performing the test.

Whirling & Sling HygrometerClimatic Condition Testing. During the application of a coating, the presence of moisture in the environment, or on the work surface, often results in a poor quality finish. Problems such as poor adhesion of the coating or premature corrosion of the substrate can occur. To determine the likelihood of moisture affecting the quality of the finish, it is essential that the surface temperature, air temperature, relative humidity (RH) and dew point are all measured.

Dew point Calculator

This provides accurate values of Relative Humidity (RH) and Dew point from the wet and dry bulb temperatures measured by a Whirling or Sling Hygrometer - such as the Elcometer 116 range.The range of the Elcometer 114 is -10C to 50C (14F to 122F) and it has an accuracy of 1% of standard tables.Dew meter Has been designed to incorporate all the needs required for climate condition monitoring, in a single gauge. This simple to use dew check measures all the parameters required to determine if the climatic conditions are correct for coating to commence - including - air temperature, relative humidity, surface temperature, dew point temperature and delta - the difference between dew point and surface temperature.

Coating Material Adequate facilities for storage

Quality

Application Surface

Mixing (With agitator)

Shelf Life (Check Expiry Date)/Pot life

Humidity

Manufacturers recommendation

What is Paint?

Paint is a liquid material, which, when applied on a substrate, turns into a solid, adhering film that forms a protective and / or decorative coating. Its main constituents are binder and pigments (and filler). In its liquid form the binder is usually diluted by a solvent to render the paint fir for application. The combination of binder and solvent is called the vehicle. The BINDER determines the film formation and the general performance of the paint coating. In most cases it is of a rather complex nature, which is determined by the specific conditions the paint has to be used under and to withstand. Because of the wide variety of conditions, the universal binder does not exist, and most likely never will. The PIGMENT is responsible for the decorative value, including color, hiding power, , gloss, light fastness, etc. Certain types are used for other purposes. Such as corrosion inhibition and resistance to biological attacks, e.g. Fouling under water. Like the binder, the pigmentation of a paint represents a balance of properties. The FILLERS are non coloring pigments especially used to influence some of the physical properties of the paint. The SOLVENT act as a servant for the other two. It is responsible for the viscosity and for the application properties. When the paint is applied the solvent has served its purposes and disappears by evaporation. Paint can be divided into two main groups according to their solidification or film formation which may be either a physical or a chemical process.

Paint can be divided into two main groups according to their solidification or film formation which may be either a physical or a chemical process.

1. Physical film formation. This mechanism can also be described as evaporation drying. The solidification safely relies on the evaporation of the solvent which is a physical process. The binder in the dry film is chemically the same as it was in the paint can. The principle binders are of widely different nature, ranging from bitumen to vinyl. Acrylics and chlorinated polymers. Physically drying paints are thermoplastic. They are also sensitive to solvents, including their own solvents.2. Chemical film formation.The chemical process differ which accounts for the division in to sub groups:-Oxidative drying.The drying mechanism is due to the fact that the binder contains drying oil. When exposed to air the binder takes up oxygen and is thus converted into a chemically new material. The most widely used type of oxidative drying binder is alkyd, but many others exist.II. Chemically curing.In chemically curing paints the film is formed by chemical reactions in the binder. By definition the reactions do not include oxygen uptake. Ordinarily, the paint is delivered in two parts to be mixed prior to use. The best known types are epoxy and urethane.

There are three specified painting zones1. Atmospheric Zone.Enamel/Polyurethane2. Splash Zone (High Tide).High Build Epoxy3. Submerge Zone (Low Tide).Coal Tar Epoxy123HTLTLEVELWeather Condition1.Minimum 5 C2.Maximum 55 C3.Maximum Humidity 85%4. Dew Point 5. Surface Temp Max 70 C

Epoxy history

The word epoxy is derived from two Greek prefixes - epi, which means "upon" and oxy, which means "sharp/acidic". The history of epoxy chemistry probably began in the early 1900s, when the Russian chemist Prileschajev discovered that olefins react with peroxybenzoic acid to form epoxides. In the mid-1930s, the German P. Schlock applied for a patent on the preparation of high molecular weight polyamines by making the amines react with peroxide compounds that contain more than one peroxide group. The patent was described as the peroxide compounds' reaction of epichlorohydrin with biphenyl A. The epoxy chemistry that we know today within the fields of marine and industrial protection was recognized simultaneously by P. Castan from Switzerland and S. Greenlee from USA. These two chemists applied for various patents in the late 1930s. The first type of epoxy resin was commercialized by Ciba in 1946. Hempen launched its first epoxy products in the mid-1950s, under the names Tanker Protect Primer and Tanker Protect Topcoat. Epoxy has since grown to become the most important product used as surface protection in marine and industrial applications.

The word epoxy is derived from two Greek prefixes - epi, which means "upon" and oxy, which means "sharp/acidic".

The history of epoxy chemistry probably began in the early 1900s, when the Russian chemist Prileschajev discovered that olefins react with peroxybenzoic acid to form epoxides. In the mid-1930s, the German P. Schlock applied for a patent on the preparation of high molecular weight polyamines by making the amines react with peroxide compounds that contain more than one epoxide group. The patent was described as the epoxide compounds' reaction of epichlorohydrin with bisphenol A.

The epoxy chemistry that we know today within the fields of marine and industrial protection was recognized simultaneously by P. Castan from Switzerland and S. Greenlee from USA. These two chemists applied for various patents in the late 1930s. The first type of epoxy resin was commercialized by Ciba in 1946.

Hempel launched its first epoxy products in the mid-1950s, under the names Tanker Protect Primer and Tanker Protect Topcoat. Epoxy has since grown to become the most important product used as surface protection in marine and industrial applications.

Spray Equipment Spray Application

Brush / Roller ApplicationCoating Application

The compressor should be capable of supplying continuous volume of 20 cfm at a minimum of 80 psi to each nozzle. A supply of tips with varying spray angles and washers, as recommended by paint suppliers for each specific steel configuration to be coated should be available. Lines and pots must be cleaned with solvent / thinner before adding new coatingmaterial.

Adequate moisture trap shall be placed between the air supply and the pressure Pot feed to the gun. Water or oil from the air supply should be continuously bledoff.

Suitable working regulator and gauges should be provided for air supply to pressure pot, and air supply to the pressure gun. Spray equipment should begrounded and non conducting hoses should be used.

For air less spray, equipment should use a 28:1 or 30:1 pump ratio. Air supply should be 80 100 psi. For conventional air spray, equipment should include pressure pot with mechanical agitator and separator atomizing and fluid pressure regulators. Spray Equipment

Spray application The gun should held at right angles to the surface. For airless spray, the spray gun should be held no closer than 1 ft, and no further than 2 ft from the surface.

For air spray the spray gun should be held no closer than 6"and no further than 10" from the surface.

Even and parallel passes should be made with the spray gun. Each spray should overlap the previous by 50%. Large surface should be always receiving passes in two directions at right angles to each other.

Each coat should be applied uniformly and completely over the entire surface. All runs and sags should be brushed out immediately or the coating/paint should be removed and the surface resprayed.

Before spraying each coat, all areas such as corners, edges, welds, small brackets, bolts, nuts, etc. should be recoated by brush to ensure that these areas have at least the minimum specified film thickness.

Airless PumpSpray Gun

Brush / Roller application. Brushes used in brush application should be of a style quality and will permit proper application of the paint. Round or oval brushes Generally are considered most suitable for rivets, bolts, irregular surfaces, and rough or pitted surfaces. Wide flat brushes are suitable for large flat areas, but they should not have a width of over 4.5". No extending handles should be allowed on paint brushes.

Brushing should be done that a smooth coat as nearly uniform in thickness as possible, is obtained. There should be no deep or detrimental brush marks. Paint/coating should be worked into all crevices and corners.

Runs or sags should be brushed out.

Successive coats should be applied by cross hatching the Previous Coat In brushing of the solvent base coatings, care must be taken so that no lifting of formers coats occur.

During application of each coat, all areas such as corners, edges, welds, Small brackets, bolts, nuts, and interstices shall receive additional coating material toensure that these areas have at Least the minimum specified film thickness and to ensure continuity of the coating.

Inspection Hold Points Visual Inspection Enclosed areas Inside Corners Inside / Outside Edges Weld seams (Stripe Coat) Large Horizontal Surface Large Vertical Surface Around Fittings Sagging / Over spray Masked Off Areas

House Keeping

House Keeping Work Area Storage Area Mixing utensils & containers Wet Coating Safe Grades

Painting Defects Sagging & Curtaining

Orange Peel Effect

Wrinkling or Lifting

Rough Surface Finish

Pin Holing

Thin Areas

Over Spray

Sagging

Figure 1. First cutFigure 2. Second cutFigure 3. Remove debris by brushFigure 4. Apply tapeFigure 5. Remove tape at 60 or 180

SurfaceDescriptionI S OA S T M5B 14B 23B 32B 41B 50B

The edges of the cuts are completely smooth; none of the squares of the lattice is detached 0

Detachment of flakes of the coating at the intersections of the cuts. A cross cut area not signifanctly greater than 5% is effected

Detachment of flakes of the coating at the intersections of the cuts. A cross cut area not signifanctly greater than 5% is effected

Detachment of flakes of the coating at the intersections of the cuts. A cross cut area not signifanctly greater than 5% is effected

Detachment of flakes of the coating at the intersections of the cuts. A cross cut area not significantly greater than 5% is effected

The coating has flaked along the edges and/or at the intersections of the cuts. A cross cut area not signifanctly greater than 5% but not significantly greater than 15% is effected

The coating has flaked along the edges of the cuts partly or wholly in large ribbons, and/or it has flaked partly or wholly on different parts of the squares. A cross cut area Significantly greater than 15%, but not significantly greater than 35%, is affected.

The coating has flaked along the edges of the cuts in large ribbons and/or some squares have detached partly or wholly. A cross cut area significantly greater than 35%, but not significantly greater than 65%, is affected.

Any degree of flaking that cannot be classified even by classification 4 (1B).

Any degree of flaking that cannot be classified even by classification 4 (1B).

Procedure Material Inspection Homogeneous Mixing Thinning Material Wastage Control

Coating Application

Spray EquipmentSpray Gun and Tip (Reversible) Airless Pump Fluid Hoses Air Hoses

Filter & Strainers Water Separators Pressure Gauges

Spray Equipment

Coating Inspection

Proper Application

Runs & Sages

Wet Film Thickness

Dry Film Thickness

Holiday Detection

Wet Film Thickness

Dry Film Thickness Gauge

Holiday Detector

Holiday Detector is a portable quality control inspection instrument used to electrically locate defects in protective coatings up to 30 mils applied to metallic or concrete structures. The detector converts low voltage direct current (rechargeable batteries) into regulated high voltage pulses. Output voltage is selectable from 1,000 to 3,000 volts in 10 settings. This versatile unit can be used to inspect protective coatings applied to pipelines, tanks, pilings or any similar conductive surface. The solid state capacitor discharge circuit provides genuine regulated output voltages that ensure unchanged inspection voltages regardless of weather conditions, type or size of exploring electrode or structure.Holiday Detector

Coating specification. Manufacturers data sheet. Blasting and coating equipment check list. Inspection Report. Anchor pattern measurement device. (Profile Gauge) Dial indicator. Press o film. Wet film thickness gauge (Comb) Dry film thickness gauge. Magnetic gauges, Elcometer. High intensity battery powered light. White coverall. Gloves lint free. Rubber soled shoes.Thermometer. For air temperature.Humidity gauge. Or sling psycho meter.Contact thermometer. Metal temperature gauge.Sharp knife.Hypodermic needle pressure gauge.COATING INSPECTORS KIT

Date: ______________Project: ____________Contractor/Maintenance crew Leader.____________________ Job Location ________Compressor Size-cfm.____ Manifold outlet size. __ Gauges. __No. of outlets. ___ Oil Leaks ____General Condition. ______________________________________________________________Remarks: ______________________________________________________________________Dead man, Handle and hoses fitted / not fitted. ________________________________________Remarks: Air Hood. Air hoses, purifiers type _____ size______ condition. __________________Blasting Nozzle size. _______condition._______ Type. ________. Remarks.Blast Pots. Quantity. Type. _____ Size. _______ Condition. ___Moisture Trap. ________Air Hoses,_____ size.________ Condition_______Remarks. Air less spray pump. Type.___ Ratio. ___No. of spare filters.___ Mesh size._________ Hand set. _____ Condition. ______Liquid line size. ______coupling ________________gauges. ______ Tip Size. ______ Reversible tip condition. __________________________No of machines on site. ________ Spare Hand set. ________ Spare Tips. ____Tools. Remarks. ___________________________________________________________________Paint mixer type _______________________ size _______________________Inspectors Name ____________________ Signature. _____________________________Contractors Representative Name _________________________Signature._________________CONTRACTORS EQUIPMENT CHECK LIST

PLANT #___________________ PLANT NAME ___________________________________Previous Coating _______________ Shop /field applied ___________________________

Contractor/Coating Crew Name _______________ Reg. #____________ Phone # ___________________Work Started at ___________am/pmwork completed at _____________________am/pm

BLAST CLEANING / HAND TOOL / POWER TOOLNACE / Sa _______ Profile Depth ________Started ________________am/pm Date _________Finished ____ am/pm Date ___________Compressor size ____cfm, Nozzle Pressure ___ psi, Nozzle Size_____ Air Hose Size _____ Length _____ Blast Hose Size ______Length _______

COATING SPECIFICATIONPrimer Prod # _________________ Top Coat Prod # ___________________________Mfg. Date ____________________Mfg. Date ________________________________Expire Date ___________________Expire Date ______________________________Batch #_______________________Batch # __________________________________Color # ______________________Color # __________________________________Stock # ______________________ Stock # __________________________________Amount at site ________________ Amount at site _____________________________

COATING APPLIED BY (Brush, Airless or conventional)Date____________1st Coat ____________am/pm Air Temp ________ Metal Temp______Date __________ 2nd Coat ____________am/pm Air Temp ________ Metal Temp______Date ___________ 3rd Coat ____________ am/pm Air Temp _______Metal Temp ______ W.F.T. 1st Coat _____________ 2nd Coat ____________ 3rd Coat ___________________ D.F.T. 1st Coat _____________ 2nd Coat _____________ 3rd Coat ___________________Remarks______________________________________________________________________ Inspector: NAME --------------------------------------------------- SIG ---------------- INSPECTION & TEST REPROT: PAINTS & COATING

Steps for SandblastingDead man with remote control

No loose dress + safety shoes Air Fed Face Shield

Leather Gloves

Trained & Skilled workforce

Lighting Explosion Proof In Confined Space

Scaffolding (if required)

Communication

Provide dead man or remote control valve fitted at the blasting nozzle for safety. Adequate grounding for static should be provided. Provide sufficient number of dust evacuators, and provide canvas screen around the work area.

2. Provide air-fed head shield for blast nozzle operators, which must be in GoodOperating condition. No blasting should be allowed without this device.

3. Always use respirators in dusty atmosphere, especially when silica sand is in useFor surface preparation. Always check the wind direction and never allow theworker to sit in dusty environment. Properly trained, certified, physically fit, andalert blast cleaning equipment operators and support personnel must be used.

4. Unnecessary peoples should keep away of the blasting area.

5. Adequate lighting (Explosion Proof) should be provided especially for blasting inside of the tanks and vessels. Battery operated flash light (24 V DC) should beused. Two men as stand by should be used at entrance to vessel.

6. Secure and adequate scaffolding should be placed to assure the inspectorAnd the blasting equipment operator sufficient vantage point from which tooperate.

Sand Blasting.

Always follow the Occupational Health and Safety Act. (OHSA). Acute Silicosis is a lung disease that develops rapidly.

3. This occurs through inhalation of small airborne particles of silica dust, mainly in the range of 0.5 which are not expelled from the lung when inhaled. Instead, they remain in the lung and are deposited in lymph nodes, where over time, calcium can deposit in those nodes and settle along the rim of lymph node.

4. The condition is known as egg-shell classification. In some cases, silica particles are carried into the lungs where a scar may form around the particles. Over time, the hardened scars gradually start to show up on the chest x-ray as fibrosis of the lung.

Sand Blasting Equipment

Coating Application No Careless move with spray gun Keep Clear Area Never Point the gun toward any one Never Put Finger in front of gun Use apron Eye & Ear Protection Never Leave the Gun un-attendant Never Exceed the Air Pressure Never Clean the Tip with Pressure Never Flush Thinner in the Direct Sun Always use Low Pressure

What are the implementations for Sandblasting & Coating? Coating Specification Contractor Selection

Job Scheduling Coating Job Progressive Inspection

Coating Specification 2.1 MATERIALS 2.2 PAINT APPROVAL 2.3 PAINTING CONTRACTORManufacturer. 3. SURFACE PREPARATION3.1 GENERAL3.2 SURFACE PREPARATION BY BLAST CLEANING3.2.1 General3.2.2 Blast cleaning equipment3.2.3 Abrasives3.2.4 Grades of surface finish3.2.5 Performance and application conditions3.3 SURFACE PREPARATION BY HAND AND POWER TOOL CLEANING4. PAINT APPLICATION4.1 GENERAL4.2 PAINT APPLICATION REQUIREMENTS4.2.1 Spray application4.2.2 Brush application4.2.3 Roller application5. PAINTING SCHEDULES AND PAINT SYSTEMS5.1 GENERAL

5.2 GENERIC PAINT CHARACTERISTICS6. INSPECTION AND TESTING

Contractor SelectionThe painting Contractor shall be responsible for:

The quality of workmanship, which shall be performed in accordance with this DEP and all other relevant documents such as site regulations, safety rules, referred standards and codes, etc.

Obtaining the Principal's assurance that the equipment is certified safe and available and that all appropriate tests are completed before starting any painting work.

The protection of all equipment, structures and any other areas from mechanical damage, environmental damage, damage caused by abrasives during blast cleaning, paint droppings, or overspray.

The earthling of electrical equipment.

Taking all necessary precautions to avoid interference with the execution of work of other contractors

Maintenance of the paint work until completion of the contract. This shall include the repair of any damages caused by third parties.

The characteristics of the paints and paint materials obtained from the paint

Job SchedulingPAINTING SCHEDULESTable 1-1 PIPING, VESSELS, COLUMNS, EXCHANGERS, REACTORS, STRUCTURAL STEEL AND FIRE-FIGHTING SYSTEMS ITEM OPERATING TEMP (C) SUBSTRATE PAINT SYS NUMBERTable 1-2 TANKS AND LPG STORAGE ITEM OPERATING TEMP (C) SUBSTRATE PAINT SYS NUMBER(see Appendix CRUDE OIL TANKS STORAGE TANKS Table 1-3FURNACES, STACKS, FLARE STACKS, FLUE DUCTS, OFFSHORE STRUCTURES, TOPSIDE FACILITIESITEM OPERATING TEMP (C) SUBSTRATE PAINT SYS NUMBER(see Appendix 2)APPENDIX 2 PAINT SYSTEMSSYSTEM NUMBERSURFACE PR PAINT SYSTEM Primer Inter-coat Top coat PrimerInter-coatTop coat

Code and StandardsS I SSwedish Institute of Standards.A N S I American National Institute of Standards.J I S Japan Institute of Standards.B S I British Institute of StandardsS S P C Steel Structure Painting CouncilN A C E National Association of Corrosive EngineeringA S M E American Standard for Mechanical EngineeringA W W AAmerican Water Works AssociationSSPC Vol 1 & 2. Specification of SSPCNACE RP 0178-95 Fabrication details, Surface finish requirements and proper design considerations for Tanks and Vessels to be lined for immersion.SSPC SP-!-91 Solvent cleaning (SSPC Manual Chapter 2 Surface Preparation Specification.SIS 055 900 Surface Preparation Standard for Painting Steel Structure.ISO 9000 2000. Quality System

Acid Having a pH of less than 7; turns blue litmus paper redAlkaline Having a pH of more than 7; turns red litmus paper blue Binder The non-volatile part of a medium Blistering Isolated convex deformation of a paint film in the form of blisters arising from the detachment of one or more of the coats Drier A compound, usually organic-metallic and soluble in organic solvents and binders, which is added to paint to accelerate drying by catalytic oxidation Dry film Thickness (DFT) The thickness of a coating after all the solvent has evaporated and the coating has cured Evaporate To convert from a liquid into vapor Filler A composition used for filling fine cracks and indentations to obtain a smooth finish preparatory to paintingGloss The visual impression created by the reflecting properties of a surfaceHardener A cross-linking agent used to cure a resin or paint systemHolidays Defects characterized by a film having areas of insufficient thickness, even to the point where parts of the surface may remain uncoatedInhibitor A material used in small proportion to slow a chemical reactionOrange Peel The pock-marked appearance of a sprayed film due to its failure to flow out to a level surface

Overspray Sprayed paint which misses the surface to be coatedPigment A substance, generally in fine powder form, which is practically insoluble in media and which is physically dispersed in the binder to impart specific physical and chemical properties (optical, protective, decorative, etc.)Pinholes Minute holes in a dry film which form during application and drying of paintPolymer A chemical compound or mixture of compounds formed by polymerizationPrimer The first coat of a painting system that helps bind subsequent coats to the and which may inhibit its deteriorationResin A natural or synthetic material used to bind pigments together and to the substrateSpreading Rate Refers to the area, in square feet, which can be covered by one gallon of coating at a given Wet Film Thickness (WFT)Solvent liquid, single or blended, which is volatile under normal drying conditions and in which the binder will dissolve completelyTeardrops Drops of paint which collect on the bottom edges of items painted by dippingThinner A volatile liquid, single or blended, added to paint to facilitate application by lowering the viscosityVehicle The total sum of the constituents of the liquid phase of the paintWet Film Thickness (WFT) The thickness of a coating immediately after application, before any solvent has evaporated

Pre-treatrment1.Salt Contamination Meter1. Salt Contamination MeterPaint can be divided into two main groups according to their solidification or film formation which may be either a physical or a chemical process.In chemically curing paints the film is formed by chemical reactions in the binder. By definition the reactions do not include oxygen uptake. Ordinarily, the paint is delivered in two parts to be mixed prior to use. The best known types are epoxy and urethane. 5. Surface Temp Max 70 C5. Always use rubber gloves before performing the test.