( Soft Copy of Procedure for Surface Preparation ) BD1253AA-MBAB-Q-PRO-0005

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





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





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





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”





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.





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





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.





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





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





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





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





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.





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





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.





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





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





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





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





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.







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





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.






6. Smoking/source of ignition not permitted in vicinity of spray area.

Format for Surface preparation and Painting Report


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
