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TECHNICAL REVISIONAugust 2006
Process Industry PracticesCoatings
PIP CTSL1000Application of Internal Linings
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PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES
In an effort to minimize the cost of process industry facilities, this Practice has been prepared from the technical requirements in the existing standards of major
industrial users, contractors, or standards organizations. By harmonizing these technical
requirements into a single set of Practices, administrative, application, and engineering
costs to both the purchaser and the manufacturer should be reduced. While this Practice
is expected to incorporate the majority of requirements of most users, individual
applications may involve requirements that will be appended to and take precedence
over this Practice. Determinations concerning fitness for purpose and particular matters
or application of the Practice to particular project or engineering situations should not
be made solely on information contained in these materials. The use of trade names
from time to time should not be viewed as an expression of preference but rather
recognized as normal usage in the trade. Other brands having the same specifications
are equally correct and may be substituted for those named. All Practices or guidelines
are intended to be consistent with applicable laws and regulations including OSHA
requirements. To the extent these Practices or guidelines should conflict with OSHA orother applicable laws or regulations, such laws or regulations must be followed.
Consult an appropriate professional before applying or acting on any material
contained in or suggested by the Practice.
This Practice is subject to revision at any time.
Process Industry Practices (PIP), Construction Industry Institute, The
University of Texas at Austin, 3925 West Braker Lane (R4500), Austin,
Texas 78759. PIP member companies and subscribers may copy this Practice
for their internal use. Changes, overlays, addenda, or modifications of any
kind are not permitted within any PIP Practice without the express written
authorization of PIP.
PRINTING HISTORY
August 2003 Issued August 2006 Technical Revision
Not printed with State funds
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TECHNICAL REVISIONAugust 2006
Process Industry Practices Page 1 of 13
Process Industry PracticesCoatings
PIP CTSL1000Application of Internal Linings
Table of Contents
1. Introduction.................................21.1 Purpose............................................ 21.2 Scope.................... ........................... 2
2. References ..................................22.1 Process Industry Practices .............. 22.2 Industry Codes and Standards ........ 22.3 Other References.............................3
3. Definitions...................................3
4. Requirements..............................34.1 Project Scope................................... 34.2 Selection Requirements and Internal
Lining Systems................................. 34.3 General ............................................ 3
4.4 Climatic Condition Control ............... 44.5 Surface Preparation......................... 64.6 Application ....................................... 64.7 Inspection....................................... 104.8 Documentation............................... 104.9 Shipping, Handling, and Storage... 10
Appendix A - Figures.....................12
Data Forms
CTSL1000-D1 DocumentationRequirements
The following data forms shall be part of
this practice only if indicated on the
purchaser's completed Documentation
Requirements Sheet.
CTSL1000-D2 Selection CriteriaSheet
CTSL1000-D3 Application ofInternal Linings
CTSL1000-F Daily InspectionReport
CTSL1000-T Inspection andTesting Requirements Sheet
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Page 2 of 13 Process Industry Practices
1. Introduction
1.1 Purpose
This Practice provides requirements for contractors installing industrial linings.
1.2 Scope
This Practice describes the general requirements for surface preparation,environmental control, and the installation and inspection of liquid-applied internal
linings to metal substrates. Sheet linings and application to piping are not included.
2. References
Applicable parts of the following Practices, industry codes and standards, and references shall
be considered an integral part of this Practice. The edition in effect on the date of contract
awards shall be used, except as otherwise noted. Short titles are used herein where
appropriate.
2.1 Process Industry Practices (PIP)
PIP VESV1003 Fabrication Requirements for Welded Vessels and Tanks tobe Lined
2.2 Industry Codes and Standards
American Society for Testing and Materials (ASTM)
ASTM D3359 Standard Test Methods for Measuring Adhesion by Tape Test
ASTM D4285 Standard Test Methods for Indicating Oil or Water inCompressed Air
ASTM D4417 Standard Test Methods for Field Measurement of Surface
Profile of Blast Cleaned Steel
ASTM D4541 Standard Test Methods for Pull-Off Strength of CoatingsUsing Portable Adhesion Testers
ASTM E337 Standard Test Method for Measuring Humidity with a
Psychrometer (the Measurement of Wet- and Dry-Bulb Temperatures)
Steel Structures Painting Council (SSPC)
SSPC-AB1 Mineral and Slag Abrasives
SSPC-PA2 Measurement of Dry Paint Thickness with Magnetic Gages
Measurement of Dry Coating Thickness with Magnetic Gages
SSPC-PA Guide 3 A Guide to Safety in Paint Application
SSPC-SP1 Solvent Cleaning
SSPC-SP2 Hand Tool Cleaning
SSPC-SP5/NACE No. 1 White Metal Blast Cleaning
SSPC-SP7/NACE No. 4 Brush-Off Blast Cleaning
SSPC-VIS 1-89 Visual Standard for Abrasive Blast Cleaned Steel(StandardReference Photographs)
Deleted: covers
Deleted: PIP CTCL1000 Interna
Lining System Selection Criteria and Sy
Data Sheet
Deleted:
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2.3 Other References
National Institute of Occupational Safety and Health (NIOSH)
NIOSH Publication No. 92-102 NIOSH Alert: Request for Assistance in
Preventing Silicosis and Deaths from Sandblasting
3. DefinitionsCS: Carbon and low-alloy steel
SS: Austenitic stainless steel
contractor: The party responsible for furnishing and/or installing the lining system
nonferrous: Copper, aluminum, and nickel base alloys
owner: The principal end user
purchaser: The owner or the owners agent
inspector: The owner or the owners authorized agent
4. Requirements
4.1 Project Scope
4.1.1 Documents required to define the scope of the work are listed on Purchasers
Data SheetPIP CTSL1000-D1.
4.1.2 Systems requiring additional coating specifications beyond this practice and
referenced data sheets shall be covered by purchasers documentation.
4.2 Selection Requirements and Internal Lining Systems
4.2.1 Internal lining system selection criteria data sheet,PIP CTSL1000-D2, shallbe used for selecting the appropriate coating.
4.2.2 Internal lining system data sheet, CTSL1000-D3, shall be used to define
specific requirements for each lining system.
4.3 General
4.3.1 Condition of Surfaces to be Lined
4.3.1.1 PIP VESV1003 defines the details to be followed in fabricating avessel that is to be lined.
4.3.1.2 The inspector shall verify that the vessel surfaces to be lined comply
with the requirements ofPIP VESV1003.
Formatted: Bullets and Numb
Formatted: Font: Italic
Formatted: Font: Italic
Formatted: PIP Head 1.1 gra
Indent: Left: 1", Hanging: 0.5
Formatted: Font: Italic
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4.3.2 Conflicts, Exceptions, and Deviations
4.3.2.1 All conflicts between the referenced documents and this Practice
shall be submitted in writing to the purchaser for clarification and
resolution before proceeding with the lining application.
4.3.2.2 All exceptions, deviations, and substitutions to the requirements
specified herein and in referenced documents shall be approved by
the purchaser.
4.3.3 Regulations and Material Safety Data Sheets
4.3.3.1 Protective linings shall comply with all applicable federal, state, and
local codes and regulations on surface preparation, lining
application, storage, handling, safety, and environmental
requirements, including the recommendations ofSSPC-PA Guide 3.
4.3.3.2 The latest issue of the lining manufacturers product data sheets,
application instructions, and Material Safety Data Sheets (MSDSs)
shall be available at the lining site and complied with during lining
operations.
4.3.4 Surfaces not Lined
4.3.4.1 The following surfaces shall not be lined, unless otherwise specified:
a. Nonferrous metals
b. Galvanized or metallized surfaces
c. Nonmetallic
4.3.4.2 The following surfaces shall not be lined and shall be protected from
surface preparation and lining activity in the area:
a. Sacrificial anodes
b. Resilient seal materials
4.3.5 Precautions for Stainless Steel and Nonferrous Metals
4.3.5.1 All SS and nonferrous metals shall be protected from blasting,
overspray, and linings intended for CS, especially linings that
contain zinc.4.3.5.2 Abrasives for use on SS shall comply with SSPC-AB1 and shall be
free of metals.
4.3.5.3 Linings and solvents for use on SS and nonferrous metals shall be
free of substances such as chlorides, sulfur, halogens, or metallic
pigments that can harmfully affect SS or nonferrous metals.
4.4 Climatic Condition Control
4.4.1 Factors Affecting Application
4.4.1.1 Temperature
Unless otherwise specified by the lining manufacturer, linings shall
not be applied if:
Deleted:
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a. Temperature of steel or lining material is below 50F (10C).
b. Air temperature is below 50F (10C) or above 120F (49C).
c. Surface temperature is expected to drop to 50F (10C) before
lining has cured if low temperature will be detrimental to the
lining.
4.4.1.2 Moisture
a. Linings shall not be applied in rain, snow, fog, or mist.
b. Linings shall not be applied if steel surface temperature is less
than 5F (3C) above the dew point.
c. Linings shall not be applied to surfaces that show visible traces
of moisture as condensation or precipitation.
4.4.1.3 Humidity
The manufacturer's instructions shall be followed regarding
acceptable humidity range for application and curing of moisture-
cured linings.
4.4.1.4 Measure of Ambient Conditions
a. Measurements of temperature, humidity, and dew point shall be
taken inside the equipment to be lined at the beginning of eachworkday and every 4 hours thereafter, or sooner if weather
conditions appear to be changing.
b. Dew point temperature shall be determined by sling
psychrometer in accordance with ASTM E337, at the location
where work is being performed.
c. A record of these measurements shall be kept, indicating the
wet- and dry-bulb temperature, relative humidity, dew point,
and surface temperature of the metal of items lined.
4.4.2 Dehumidification
4.4.2.1 Dehumidification equipment shall, as a minimum, have the capacity
to:
a. Depress the air dew point in the equipment being lined to 10F
(6C) below ambient temperature within 20 minutes.
b. Affect an air change rate of three times per hour, unless particle
loading is unusually high (see SSPC-PA Guide 3 forregulation).
4.4.2.2 If the selected dehumidifier can reduce air dew point by more than
10F (6C), the air change rate can be reduced. If the dehumidifier
cannot reduce the dew point by at least 10F (6C), more air shall be
used.
4.4.2.3 The following critical measurements shall be taken on a regular basis
at a frequency to be determined by the purchaser:
Deleted: 2
Deleted: b
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a. Ambient dew point (air entering the dehumidifier)
b. Dew point of air leaving the humidifier
c. Dew point of air inside the tank near metal surface
d. Surface temperature of the substrate
4.5 Surface Preparation
4.5.1 Precleaning
4.5.1.1 Before blasting, oil, tar, grease, salt, and other contaminants shall be
removed from the surfaces to be lined.
4.5.1.2 Hydrocarbon removal shall be accomplished by solvent cleaning
(SSPC SP1), power brush (SSPC SP2) high-pressure water, or steamcleaning using proper chemicals.
4.5.1.3 Cleaning shall be followed by a freshwater rinse to ensure complete
removal of soluble salts and cleaning chemicals.
4.5.1.4 If the entire tank is to be lined, all rafters, supports, and
superstructure shall be included in the cleaning process.
4.5.1.5 A black light shall be used to locate hydrocarbon contaminants.
4.5.1.6 If lining the bottom of a floating roof tank, before blasting begins,
the underside of the roof and 7-feet up the tank wall shall receive a
brush blast (SSPC-SP7/NACE No. 4) to remove contaminants andloose scale.
4.5.2 Abrasive Blast Cleaning
4.5.2.1 Compressed air supply used for blasting shall be free of water and
oil. Adequate separators and traps shall be provided and kept empty.
4.5.2.2 Abrasive shall be selected to produce a necessary profile or anchor
pattern for lining to be applied. Abrasive shall be free of
contaminants, such as water-soluble salts, dirt, clay, oil, and grease.
4.5.2.3 Silica or other abrasive substances containing more than 1 percent
crystalline silica shall not be used as an abrasive blasting material.
Refer toNIOSH Publication No. 92-102.
4.5.2.4 Blasting shall not be allowed if metal surfaces are less than 5F
(3C) above the dew point.
4.5.2.5 Abrasive blast cleaning shall be to a white metal finish and comply
with SSPC-SP5/NACE No. 1.
4.6 Application
4.6.1 General
4.6.1.1 Lining materials and thicknesses shall be as listed in
PIPCTSL1000-D3, Internal Lining System.
Deleted: 3
Deleted: 4
Deleted: CTCL1000
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4.6.1.2 Lining materials shall be furnished in the manufacturers unopened
containers, shall be clearly marked, and shall be kept covered, clean,
and protected.
4.6.1.3 Blasted surfaces shall be absolutely clean and dry before the
application of the first coat.
4.6.1.4 Spent blast media shall either be removed or adequately covered
before lining to prevent contamination of the surface to be lined.
4.6.1.5 Workers shall take precautions (changing or dusting shoes and
removing abrasive from pant cuffs) to ensure that cleanliness is
maintained throughout the entire lining operation.
4.6.1.6 If the prepared surface becomes dirty or rusty before the first prime
coat is applied, the surface shall be recleaned to a degree that was
initially specified.
4.6.1.7 When required, welds and edges shall be striped with primer by
brush application before the application of the first prime coat.
4.6.1.8 Before the application of any coat, damage to the previous coat shall
be repaired with a corresponding specified material.
4.6.1.9 Lined surfaces, including striping and repair, shall be thoroughly
dry and clean before the application of subsequent coats inaccordance with the manufacturers recommendation for recoat
time.
4.6.1.10 Unless otherwise specified, the allowable dry-film thickness range
shall be as specified by the lining manufacturer on the product data
sheet.
4.6.1.11 The recoat time between coats shall be that recommended by the
manufacturer for any given temperature.
4.6.1.12 Thinning shall not exceed the maximum allowable volatile organic
compound (VOC) level for the lining involved.
4.6.2 Preparation of Lining Materials
4.6.2.1 Lining materials shall be stirred or mechanically agitated to ensure
that pigments, vehicles, and activators are thoroughly mixed. Whenrequired by the manufacturer, linings shall be continuously stirred by
mechanical agitators.
4.6.2.2 Lining materials shall be thinned only with thinner that is
recommended by the manufacturer and in quantities that do not
exceed the manufacturers recommendation.
4.6.2.3 All mixing shall be done in clean containers that are free from traces
of grease, paints, and other contaminants. After mixing, the
containers shall be kept covered to prevent contamination.
4.6.2.4 The mixing of partial kits is not allowed.
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4.6.2.5 Inorganic zinc primers and all pigmented lining materials shall be
strained before the application in accordance with the lining
manufacturers written instructions.
4.6.2.6 Tinting for color contrast of the primer and midcoat is not allowed.
4.6.2.7 Pot life shall not exceed the limits specified by the manufacturer.
4.6.2.8 Materials that have exceeded the lining manufacturers
recommended shelf life shall not be used.
4.6.3 Thick Film Reinforced Systems
4.6.3.1 Putty/Caulking Application
1. Application may be by spray or putty knife and shall includechine, bottom plate seams, the bottom of sumps, and along the
column bases.
2. Putty used shall be compatible with the resin system asrecommended by the manufacturer.
3. Large projections and lap joints on welded plates to be linedshall be filled with putty to smooth out the surface and permit
complete contact with the laminate system. See Figure 1 and
Figure 5 in Appendix A.
4. Chine or bottom angle shall be filled with putty and covered to asmooth 3-inch (75-mm) radius to permit contact with the
laminate system. See Figure 3 in Appendix A.
5. Riveted seams, lap joints, and chine angle plates shall be filledwith putty and smoothed out to obtain complete contact with the
laminate system. See Figure 2 and Figure 4 in Appendix A.
4.6.3.2 Columns, Support Legs, Sumps, Etc.
1. For tanks on which the column base is not fixed or attached to
the bottom by welds, a striker plate and resin laminate patch
shall be placed under the column base as follows:
a. Plates shall be installed under fixed roof tanks one at a time.
No fixed roof support shall be raised while another is on the
jack.
b. Tack welds and/or guides shall be removed to free the
column base and to provide a smooth tank bottom.
c. The column base shall be jacked up in accordance with
instructions that are detailed in Figure 5, Figure 6, and
Figure 7 in Appendix A.
d. If a lining system is used without reinforcing, the lining
system shall be inserted into Step 6 instead of reinforced
laminate in Figure 5 in Appendix A.
2. Striker plate for support legs on floating roof tanks shall be
placed as follows:
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a. Tanks normally have a stationary striker plate with a
circumferential fillet weld as part of the original
construction. See Figure 5, Figure 6, and Figure 7 in
Appendix A. If this stationary plate is not a part of the
design, Step 5 and Step 6 shall be eliminated, and
reinforced laminate (or lining system) shall be applied
directly to the blasted and primed steel bottom, ensuring
that it extends 12 inches (300 mm) onto the floor. Stepsshown in Figure 7 in Appendix A shall then be continued.
b. The auxiliary striker plate shall be blasted, primed, and
placed into wet laminate. Support legs shall be lowered
onto the auxiliary striker plate when the resin starts to gel.
c. Hollow legs shall be wrapped with plastic, secured to
prevent dripping during the transfer to a temporary support,
and then raised.
d. Reinforced laminate (or lining system) shall extend at least
12 inches (300 mm) in all directions from the striker plate
such that there is a 3-inch (75-mm) overlap when the lay-up
operation is continued across the floor.
3. Sumps shall receive a reinforcement layer across the bottom, upsides, and 6 inches (150 mm) to 12 inches (300 mm) onto the
floor.
4. Additional layers of laminate shall be installed onto the tank
bottom as follows:
a. Under the gage hatch (4-foot by 4-foot [1.2-M by 1.2-M]
area).
b. Fill line outlet (4-foot by 4-foot [1.2-M by 1.2-M] area).
c. Swing the line arresting chain of floating roof tanks (3-foot
by 12-foot [1-M by 4-M] area).
4.6.4 Repair of Linings
4.4.4.1 If, after inspection, the lining thickness is deemed to be insufficient,
necessary additional lining to achieve the required film thicknessshall be applied. If the lining is too thick and detrimental to the
integrity of the system, the excess lining shall be sanded off to the
required film thickness.
4.6.4.2 If abrasive or other contaminants have contaminated the lining, the
lining shall be repaired in accordance with the lining manufacturers
written recommendation.
4.6.4.3 If improperly mixed linings (e.g., wrong catalyst or no catalyst) are
applied, the lining shall be removed and the surface restored to the
originally specified condition.
4.6.4.4 Holidays shall be repaired in accordance with the lining
manufacturers recommended procedure.
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4.7 Inspection
4.7.1 General
4.7.1.1 Inspections and tests shall be performed in accordance with
purchasers Inspection and Testing Requirements Sheet,
PIPCTSL000-T, to ensure that the surface preparation and liningapplication comply with the requirements of this Practice.
4.7.1.2 The lining shall be holiday free unless otherwise specified on
purchasers Inspection and Testing Requirements Sheet,
PIPCTSL1000-T.
4.7.2 Inspection Hold Points
4.7.2.1 Hold Point (H)
1. A hold point (H) is the notification that a shop process is ready
for purchasers inspection and to hold any furtherapplication
until inspection has occurred.
2. Hold points shall be provided in accordance with purchasersInspection and Testing Requirements Sheet,PIPCTSL1000-T.
4.7.2.2. Witness Point (W)
1. A witness point (W) is an observation by purchasersinspector(s) of the actual test as it is being performed.
Application may proceed if purchasers inspector(s) is not
present and was given proper notification.
2. Witness points shall be provided in accordance with purchasers
Inspection and Testing Requirements Sheet,PIPCTSL1000-T.
4.8 Documentation
4.8.1 A Daily Inspection Report,PIPCTSL1000-F, shall be completed for eachwork shift.
4.8.2 The contractors forms may be used with prior approval from the purchaser.
4.8.3 A log shall be maintained of all reports, inspections, and tests (including
date, time, and results of instrument calibrations).
4.9 Shipping, Handling, and Storage
4.9.1 Lined items shall not be handled or moved until all linings have been
properly dried or cured as required in the lining manufacturers instructions.
4.9.2 Lined items shall be handled with equipment such as wide belt slings, web
belts, and wide padded skids that are selected to prevent damage to the
lining. Handling equipment that is likely to cause damage to the lining shall
not be used. Items such as chains, cables, hooks, tongs, metal bars, and
narrow skids shall not be permitted to come in contact with the lining.
4.9.3 Lined items shall be loaded, padded, and secured for transport in a manner
such that the lining will not be damaged in transit.
Deleted: CTSL1001
Deleted: CTSL1001
Deleted: fabrication
Deleted: CTSL1001
Deleted: Fabrication
Deleted: CTSL1001
Deleted: CTSL1002
Deleted: Dragging or skidding of line
shall not be permitted.
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4.9.4 HDPE flange protectors shall be used to protect lined flange faces. The
protectors shall be attached by bolts.
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Appendix A - Figures
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