STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

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1 STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING SPECIFICATION FOR PAINTING PAGE: 1 of 10

2 STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING 1.0 GENERAL 1.1 These technical specifications shall be applicable for the work covered by the Contract. It is understood that Contractor shall complete the work in all respects with best quality materials and workmanship, best engineering practice, Manufacturer recommendations, ITP and instructions of HPCL. 1.2 All the items covered in this specification are required to be supplied by the Contractor only. 2.0 SCOPE Scope of work covered in this specification shall include but not limited to the following: 1. Surface preparation for all components of A/G product storage tanks covered in this Contract. 2. Selection, procurement and application of primers, paints and other materials on various metallic surfaces including providing all requisite scaffolding, spray equipment, compressors, applicators, brushes, etc. 3. Lettering, marking as per HPCL requirements. 3.0 CODES AND STANDARDS 3.1 REFERENCE STANDARDS IS : 5 IS : 101 ASTM STANDARDS 3.2 SURFACE PREPARATION STANDARDS SWEDISH STANDARD : SIS /ISO THIS STANDARD CONTAINS PHOTOGRAPHS OF THE VARIOUS STANDARDS ON FOUR DIFFERENT DEGREES OF RUSTED STEEL. MANUFACTURER S BROCHURES AND INSTRUCTIONS WITH RESPECT TO STORAGE, SURFACE PREPARATION, MIXING AND THINNING, APPLICATION SPECIFICATION FOR PAINTING PAGE: 2 of 10

3 AND CURING INTERVALS. 4.0 EQUIPMENT All tools, brushes, rollers, spray guns, abrasive materials, sand, hand/ power tools for cleaning, scaffolding materials, air compressors, instrument for measuring humidity, profilemeter etc required for the works shall be supplied by the Contractor. 5.0 SURFACE PREPARATION, COATING APPLICATION AND DOCUMENTATION 5.1 GENERAL In order to achieve the maximum durability, copper slag cleaning shall be followed Mill scale, rust, rust scale, etc. shall be fully removed by copper slag blast cleaning to SA 2 ½ or equivalent as per SWEDISH STANDARD: IS /ISO Copper slag Blast cleaning shall not be performed where dust can contaminate surfaces undergoing such cleaning or in conditions where the humidity exceeds 85% The first coat of primer must be applied on dry surface immediately and in any case within 4 hrs of cleaning of surface Blasting and painting shall in general be avoided during unfavorable weather conditions. 5.2 PROCEDURE FOR SURFACE PREPARATION COPPER SLAG BLAST CLEANING SPECIFICATIONS FOR COPPER SLAG BLASTING : 1. The surface shall be cleaned of all dust and heavier layers of rust by copper slag blasting the entire internal surface to photographic standard SIS: The consumption rate of copper slag is 1.6 Kg/Sqm of the blasted area. This has to be ensured strictly. 3. All tools, equipments, base material, hand and power tools for cleaning, including scaffolding material, copper slag blasting equipment, air compressor etc. shall be arranged by the contractor at site in sufficient quantity. SPECIFICATION FOR PAINTING PAGE: 3 of 10

4 4. The compressor used shall be of size enough to produce displacement of 5.6 to 7.0 Cum/Min of air at a pressure of 7 Kg/sqcm. Standard blasting equipment, hoppers, hoses nozzles and attachments shall be used to obtain best test results and to maintain safety standards. The rate of cleaning shall be about 15 sq.mt. per hour at a pressure of 7 kg/sq.cm. 5. The abrasive used shall be of the physical properties as mentioned below and shall be free from oil, loan and mud etc. 6. The blast cleaned surface shall be blasted with dry compressed air before applying primer. This should be done even if the surface appears very clean and white in colour. The white colour may be due to deposition of silicon and reflection of light on the surface. 7. Proper earthing and bonding arrangements shall be made to prevent any damage by sparks produced by static electricity. Bonding shall be done between tank and blast nozzles and hopper and air compressor also. The bonding conductor should not be less than 16 SWG single strand copper cable. 8. The time gap between blast cleaning and application of primer shall not be more than THREE hours. Blast cleaning work shall, commence from top to bottom. 9. The blast cleaning operation shall be carried out keeping the nozzle at an angle of 30 degree to the vertical in order to prevent rebounding abrasive from showing down the abrasives emerging from nozzle and from under cutting the material to be removed. A blast cleaning, the percentage of bare metal obtained shall be between 95% to 100% of each of sq.cm. of the blasted area corresponding to photographic visual standards of SA 2 ½ of the Swedish standard referred above. 10. Arrangements for inspection of various stages of the job shall be made available by the Contractor so that the entire copper slag blasted area is available for inspection. Any defective work noticed shall be immediately rectified and even reblasting shall be done if necessary. Physical Properties of Copper Slag : Colour : Black. Grain shape : Granulated, Angular multifaceted. Hardness : 5 to 7 Moh s scale. Sp. Gravity : 3.2 to 3.7 SPECIFICATION FOR PAINTING PAGE: 4 of 10

5 Bulk Density : 1.87 Kg/ltr. Moisture Content : less than 1 % Sieve Analysis of copper slag : Sieve Size ( mm ) Range (%) -4.0 to to 4-3 to to to to 55-1 to to to to below 0.2 to COATING PROCEDURE AND APPLICATION Copper Slag blasted surface upon inspection and clearance by HPCL shall be coated with one complete application of primer as soon as practicable and in no case later than 4 hrs on the same day. Applied paint shall have the required Dry Film Thickness (DFT) after drying which shall be measured and recorded by the contractor and should be submitted to HPCL Each coat shall be in a proper state of cure or dryness before the application of succeeding coat. Manufacturer s instructions shall be followed for intercoat interval The type of application may be Airspray or Airless spray or Brush application as per manufacturer recommendation and HPCL instructions for getting satisfactory results For each coat, the painter should know the WFT corresponding to the specified DFT and standardize the paint application technique accordingly. This has to be ensured in a qualification trial by Contractor. 5.4 SCAFFOLDING Double pipe scaffolding shall be used and all the painters shall be provided with Safety belts for ensuring accident free working. SPECIFICATION FOR PAINTING PAGE: 5 of 10

6 5.5 DOCUMENTATION 1. A written quality Plan with procedure for qualification trials and for actual work. 2. Daily progress Report with details of humidity, surface preparation, surface profile, Dry film thickness particulars of applications, number of coats applied, type of materials used, methodology-air or Airless or Brush, progress of work vs programme. 3. Code and Batch numbers of primers and paint materials used. 4. Type of testing equipments and their calibration. 5. Elcometer and Profilemeter readings for the various components jointly recorded with HPCL. 6. Paint consumption statement along with the Theoretical consumption requirements. 6.0 RECOMMENDED MANUFACTURERS ASIAN PAINTS BERGER PAINTS GOODLASS NEROLAC JENSON AND NICHOLSON SHALIMAR PAINTS BOMBAY PAINTS 7.0 HPCL LOGO AND LETTERING HPCL will provide their LOGO with sizing, Flow, coloring and same is to be provided to the Tanks. HPCL will also convey to the Contractor in writing details of the lettering for product and tank details along with the desired color-coding and same has to be arranged by the Contractor. 8.0 INSPECTION AND TESTING 8.1 All painting materials including primers and thinners brought to site by the Contractor for application shall be directly procured from Approved manufacturers as per specifications and shall be accompanied by Manufacturer Test Certificates. SPECIFICATION FOR PAINTING PAGE: 6 of 10

7 8.2 HPCL may call for tests for the primers and paints including verification of batchwise tests for physical and chemical analysis. The Contractor shall carry out the same at his own cost and provide the results to HPCL. 8.3 The painting work shall be subjected to inspection by HPCL at all times. Stages of inspection are as follows: 1) Surface preparation 2) Primer application 3) Each coat of paint All records of inspection shall be maintained in Registers and jointly signed by HPCL and Contractor. Any defect noticed during the various stages of inspection shall be rectified by the Contractor to the satisfaction of HPCL before proceeding further. Irrespective of the inspection, repair and approval at intermediate stages of work, Contractor shall be fully responsible for making good any defects found during Final inspection or during the Defect Liability period. DFT shall be checked and wherever shot same shall be made up with additional coats. 8.4 The shades of successive coats should be slightly different in colour in order to ensure application of individual coats in consultation with manufacturer. 8.5 Calibrated Digital Elcometers, surface profile gauges (calibrated Profilemeter) and any other inspection instrument required by HPCL shall be provided by the contractor at site. 8.6 The contractor shall arrange expert technical support at site by paint Manufacturer who will cross verify independently regarding surface preparation and DFT and quality and provide a report to HPCL. 9.0 PRIMERS AND FINISH COATS DESIGNATIONS PRIMERS P-6 : EPOXY ZINC PHOSPHATE PRIMER FINSIH COATS/ PAINTS F-2 : ACRYLIC POLYURETHANE FINISH F-6 : HIGH BUILD MIO FINISH COATING F-7 : HIGH BUILD COAL TAR EPOXY COATING SPECIFICATION FOR PAINTING PAGE: 7 of 10

8 F-9 : INORGANIC ZINC SILICATE PRIMER PAINTING FOR PIPING SL.NO. TYPE OF PIPING 1 FIRE WATER SURFACE PAINT SYSTEM PREPARATION FIELD PRIMER SA 2 1/2 1 COAT OF DFT/ COAT + ) 2 FOAM SA 2 1/2 1 COAT OF DFT/ COAT + PRODCT PIPING SA 2 1/2 1 COAT OF DFT/ COAT + ) FINISH PAINT 1 COAT OF F COAT OF 40 ( =180) 1 COAT OF F COAT OF 40 ( =140) 1 COAT OF F COAT OF 40 ( =180) SHADE P-6 AS STRIPE COAT (RED SHADE); F-6 (GREY) AND F-2 (FIRE RED; IS:536) or as directed by EIC P-6 AS STRIPE COAT (RED SHADE); F-6 (GREY) AND F-2 (GOLDEN YELLOW; IS:356) or as directed by EIC As directed by EIC ALL WELD JOINTS SHALL BE BUFFED AND COATED WITH STRIPE COAT OF EPOXY ZINC PHOSPHATE PRIMER PRIOR TO TAKING UP F-6 SPECIFICATION FOR PAINTING PAGE: 8 of 10

9 PAINTING FOR FLOATING ROOF TANKS: INTERNAL SL.NO. COMPONENT 1 Underside of Floating roof deck and pontoon bottom, product side of annular and sketch bottom plate, inside surface of shell upto 1m ht from bottom, outer surface of still well from bottom to max. Liquid level, structural steel roof ladders, ladder on still well, roof supports upto long leg ht, datum plate, inside face of all shell nozzles and trough. SURFACE PREPARATION SA 2 1/2 PAINT SYSTEM FIELD PRIMER 1 COAT OF DFT/ COAT 2 Inside pontoon SA 2 1/2 1 COAT OF DFT/ COAT FINISH PAINT 3 COAT OF F-6(AMINE 100 (300) 2 COAT OF F-6(amine 80 (80x2=160) TOTAL DFT IN F-6 (GREY) Total=365 microns F-6 (GREY) Total=225 microns ALL WELD JOINTS SHALL BE BUFFED AND COATED WITH STRIPE COAT OF EPOXY ZINC PHOSPHATE PRIMER PRIOR TO TAKING UP F-6. PAINTING FOR FLOATING ROOF TANKS: EXTERNAL SL.NO. COMPONENT SURFACE PREPARATION 1 Soil side of bottom plates PAINT SYSTEM FIELD PRIMER SA 2 1/2 1 COAT OF DFT/ COAT FINISH PAINT 3 COATs OF 100 (300) TOTAL DFT IN Total=365 microns 1 coat-black shade; 2 nd coat: tanned brown and 3 rd coat: black) 2 External shell, wind girders, WG supports, Floating roof topside with associated structurals, roof supports above roof, rolling ladder, spiral stairway incldg. SA 2 1/2 1 COAT OF DFT/ COAT + 1 COAT OF 40 (65+40=105) 1 COAT OF F-6(AMIDE CURED)@ COATS OF 40 (100+2 X40=180) F-6(Grey) Total=285microns) SPECIFICATION FOR PAINTING PAGE: 9 of 10

10 Gratings, chequered plates, kerb angle, foam dam, hatches, covers, pontoon top, sides and deck top 3 Inside surface of shell from top edge to Max. design liquid level(that is, 1.50m above Max. liquid level) SA 2 1/2 1 COAT OF DFT/ COAT + 1 COAT OF 40 (65+40=105) 1 COAT OF F-6(AMIDE CURED)@ COATS OF 40 (100+2 X40=180) F-6(Grey) Total=285microns) 4 All still well pipes above max. liquid level SA 2 1/2 1 COAT OF DFT/ COAT + 1 COAT OF 40 (65+40=105) 1 COAT OF F-6(AMIDE CURED)@ COATS OF 40 (100+2 X40=180) F-6(Grey) Total=285microns) ALL WELD JOINTS SHALL BE BUFFED AND COATED WITH STRIPE COAT OF EPOXY ZINC PHOSPHATE PRIMER PRIOR TO TAKING UP F-6. PAINTING FOR FIXED CONE ROOF OF INTERNAL FLOATING ROOF TANKS: EXTERNAL SL.NO. COMPONENT SURFACE PREPARATION 1 EXTERNAL SURFACE OF FIXED CONE ROOF OF INTERNAL FLOATING ROOF PAINT SYSTEM FIELD PRIMER SA 2 1/2 1 COAT OF DFT/ COAT + 1 COAT OF 40 (65+40=105) FINISH PAINT 1 COAT OF F-6(AMIDE CURED)@ COATS OF 40 (100+2 X40=180) TOTAL DFT IN F-6(Grey) Total=285microns) ALL WELD JOINTS SHALL BE BUFFED AND COATED WITH STRIPE COAT OF EPOXY ZINC PHOSPHATE PRIMER PRIOR TO TAKING UP F-6. SPECIFICATION FOR PAINTING PAGE: 10 of 10

11 SPECIFICATION FOR PAINTING PAGE: 11 of 10

South African Qualification and Certification Committee (Corrosion Protection) SYLLABUS MODULE PS PAINTING SUPERVISORS COURSE

1/8 South African Qualification and Certification Committee (Corrosion Protection) APPENDIX SYLLABUS MODULE PAINTING COURSE DURATION: The planned duration is a minimum 5 day course and the theory and practical