Method of Painting Works

LAHOUD ENGINEERING COMETHOD STATEMENT

ADCO

North East Phase I Development Project,

Rumaitha

LEC Doc. No.: DATE:13/ 10/ 04

Page 1 / 43LEC/F257/ MS- 001 Rev. 3

METHOD STATEMENT FOR

PAINTING WORKS

ADCO

Project : North East Bab (NEB) Phase-1 Development Project

SUBCONTRACTOR DOCUMENT REVIEW

1. Revise and re-submit

Client : Abu Dhabi Company for Onshore Oil Operations (ADCO)

2. To be issued as final. Provided comments are incorporated.

3. No comments – Final issue

4. For information only (Internal use)

Item: UO: TECHNIP

Sr. Doc. Code By: Date:

3 13/10/04

PROJECT NO. CS Prefix No. Class Code Serial No. Rev. No. Date

Document Class Code

3 13/10/04RESUBMITAL

INCOPORATING COMMENTS

S. MOHAN DASDANY

ABOUJAOUDEGHASSAN BERBARI



S. MOHAN DASDANY




S. MOHAN DASDANY


0 20/07/04 FIRST ISSUEJEH

(CAPE)DANY


Rev. Date Status Written By Checked By Approved ByTECHNIPApproval

OTHERSApproval

DOCUMENT REVISIONS


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INDEX

1.0 SCOPE

2.0 DEFINITIONS

3.0 REFERENCES

4.0 RESPONSIBILITIES

5.0 SPECIAL TOOLS & EQUIPMENT

6.0 SAFETY

7.0 ENVIRONMENT

8.0 WORK INSTRUCTIONS

9.0 PROCEDURES

10.0 FINAL ACCEPTANCE

11.0 SPECIFICATION CONTROL

12.0 APPENDIX - 1

APPENDIX – 2 (JOB HAZARD ANALYSIS)

1.0 SCOPE


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1.1 This document covers the requirements and procedures to be complied with for the Painting Works related to North East BAB Phase I Development Project for ADCO, Rumaitha Oilfield at Bab, Abu Dhabi, United Arab Emirates.

1.2 The purpose of this document is to:-

- Define the procedures for the above works.

- Set correct practices for the painting works, through the general and specific procedures contained herein.

2.0 DEFINITIONS

Project Title : North East BAB Phase I Development ProjectOwner : ADCOMain Contractor : TECHNIPSub-Contractor : LAHOUD ENGINEERING CO. LIMITED. (LEC) Vendor : CAPE EAST LIMITED (CAPE)

3.0 REFERENCES

The painting works will be executed in strict accordance with the following Project Specifications:-

3.1 Shell (Design Engineering Practice) DEP 30.48.00.31 – Gen. Dated December 1995

3.2 ADCO Doc. No. 30.99.37.003 Amendments to Shell DEP 30.48.00.31 Rev. 5 Oct. 2002

3.3 Quality Control Plan LEC/ F257/CAPE QCP-001, Rev. 1 Dated 19.08.04


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3.4 Cape Procedures for Surface Preparations and the Application of Protective Coating in appendix 1 of the present document.

3.5 Paint manufacturer’s data sheets & applicable instructions.

3.6 SSPC - Steel Structures Painting Council – Manual Volumes 1 & 2

3.7 ISO 8501-1 Preparation of Steel substrates before application of paint - visual assessment of surface cleanliness.

To also comply with QHSE Following Documents:

3.8 7046J-000-JSD-6200-001 Environment job specification.3.9 30.99.90.2302 Construction HSE plan.3.10 30.99.90.2003 Environmental Construction & Pre-commissioning Plan3.11 30.99.90.2005 Waste Management Plan for Construction & Pre-

commissioning

4.0 RESPONSIBILITIES

4.1 All scaffoldings, platforms and safe access to carry out the painting works will be as per above project specifications & requirements.

4.2 Responsibility for particular personnel shall be as follows:-

a) The Project Manager will be the overall responsible for painting works.

b) The Project Supervisors will be responsible for day to day painting activities and for the quality of works.

c) The Painting Supervisor will be responsible for forward planning requirements associated with the painting works and the submission of all related planning reports.

d) The QA/QC Representative will be responsible to verify compliance to the specification and approved procedures and reporting to the QA/QCleader


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e) The Safety Officer will be responsible for the monitoring of site safety rules and regulations.

5.0 SPECIALISED TOOLS AND EQUIPMENT

5.1 Mechanical and Hand Tools

a) Air Compressors 750 CFM

b) Air Compressors 300 CFM

c) Grit Blasting Units with complete accessories.

d) Grit Re-cycling Unit

e) Airless Spray Pump including hoses, spray guns and tips.

f) Conventional Spray Machines

g) Hand Tools as required.

5.2 Electrical

a) Junction Boxes and Electrical Leads

b) Floodlights

5.3 Testing Equipment

a) Hygrometer

b) Wet Film Gauge

c) Dry Film Micrometer

d) Profile Meter

e) Testex tape

f) Thermometer


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g) Dew point calculator

h) Holiday tester ( whenever required )

6.0 SAFETY

6.1 All installation/construction work will be undertaken in accordance with Project Safety Rules and Regulations.

6.2 Work release will be obtained from erection department prior to any work being carried out and work will commence only after completion of prerequisite works.

6.3 All necessary personal protective equipment will be provided and worn.

6.4 The work area will be kept in a clean and tidy condition.

7.0 Environment

7.1 Particular care shall be taken to maintain a clean/ safe working environment.

7.2 Housekeeping shall be continuously conducted and all wooden. timber/ scrap/ packing material removed from site.

7.3 Equipment shall be regularly maintained and any fluid/oil leakages corrected.

7.4 Empty paint containers, can, tins shall not be punctured prior to disposal.

7.5 Empty paint can & tins, aerosol spray cans, waste paint, contaminated rags & PPE, paint filters & solvents will be collected & disposed in the Hazardous waste skip and kept separate from other waste streams.

8.0 WORK INSTRUCTIONS

8.1 The painting works shall be carried out strictly in accordance with the Project Specifications as per Item 3. REFERENCES.

8.2 Relevant construction drawings.


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9.0 PROCEDURES

These procedures shall be carried out and read in conjunction with the referenced project specification.

1. A separate area should be provided for painting Stainless Steel materials (if required) at a suitable distance to avoid ingress of airborne contaminants from the nearby carbon steel blasting / painting operations.

2. Potable water supply to be provided at the blasting / painting yard for cleaning if required.

The blasting / painting yard will be set-up and divided into two (2). Parts A & B.

Sequence of work to be carried out as follows:-

a. First lot of work released will be blasted/ primed on Yard A.

b. Second lot of work released will be blasted/ primed on Yard B.

c. Upon completion of blasting on Yard B, painting crew will be assigned to Yard A to carry out intermediate coats on primed spools to avoid any contamination on the intermediate coats.

d. Upon completion of intermediate coats of spools at Yard A shall be inspected and released for shifting to site.

e. After removal of painted spools, another release shall be shifted to Yard A for blasting and priming.

f. Upon completion of blasting on Yard A, painting crew will be assigned to Yard B to carry out intermediate coats on primed spools to avoid any contamination on the intermediate coats.

The above sequence of work shall be followed in both yards to avoid any contamination on coating.


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9.1 Surface Preparation

9.1.1 Specific surface preparation method shall be as specified for each individual coating, Recycled Garnet from blasting area will be used. Garnet will be recycled twice provided it achieves the required profile. After recycling of Garnet, surface profile shall be checked by using profile gauge daily. The use of recycled garnet shall be discontinued if the required surface profile is not met

.9.1.2 Abrasive for blast cleaning shall be clean, dry, free of any

constituent part that could be detrimental to long term coating performance, and shall be selected to provide the proper surface profile for the coating to be applied.

9.1.3 Surface preparation shall be subject to inspection before the prime coat is applied to ensure all traces of dust and foreign matter have been removed by brushing or blowing with clean compressed air.

9.1.4 All blasting operations shall be scheduled in a manner to give the painting crew ample time to complete all painting operations during daylight hours and before any flash rusting occurs.

9.1.5 Adequate traps to be provided to avoid oil / water in the compressed air to come in contact with the blasted / painted surface.

9.1.6 Before the start of any blast cleaning operation any oil, grease, chloride contamination shall be removed by a suitable means.

9.2 Preparation for Painting

9.2.1 Storing, thinning, mixing and handling of paint materials shall be in accordance with materials data sheets and manufacturer’s instruction and recommendations.


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9.2.2 Inspection and Testing shall be as per clause 3.1 DEP31.38.01.31-Gen.Pressure testing may be performed on fully painted piping spools(including welds) provided that:--The welds consist of at least two layers(root and fill run) for stainless steels, and three layers for all other materials, in accordance with a approved WPS for the application.-The test is not considered to be a sensitive leak test as specified in ANSI/ASME B31.3.-The piping spool has been fully inspected(Visual examination, on-Destructive examination and positive material identification where specified)and released for Pressure test.

9.2.3 Unless otherwise recommended by the Manufacturer, coating shall not be applied when:

a. The ambient temperature is less than 4oC.

b. The relative humidity is more than 85 percent.

c. The surface temperature is less than 3oC above dew point.

d. The metal temperature is higher than recommended by the Manufacturer for application. Temperature limit shall be as per Paint manufacturer Data sheet.

e. Surface preparation has not been completed or oil, grease and dust are present on the substrate to be painted.

f. Poor weather conditions for painting exist or are expected within two hours of application such as blowing sand, fog or rain.

g. Where the deposition of moisture in the form of rain, condensation, frost, etc. on the surface.

h. Where the available light is less than 500 lux.

9.3 Painting Application


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9.3.1 Surface shall be painted with the paint system as specified on the ADCO - SHELL DEP 30.48.00.31 – Gen., Appendix 2 Paint System.

9.3.2 Paint shall be applied to dry, clean, prepared surface under favorable conditions and in accordance with manufacturer’s instruction and recommendations.

9.3.3 Pigmented and catalyzed materials shall be mixed before being applied.

9.3.4 Pot life and mixing ration shall be strictly in accordance with manufacturer’s recommendation and instructions.

9.3.5 Continuous agitation type spray pots shall be used when applying metal pigmented coatings such as zinc or aluminum loaded coatings.

9.3.6 A mist coat shall be applied over inorganic zinc primer to avoid surface defects. The Applicator shall exercise necessary care to ensure a smooth and uniform coating is applied over inorganic zinc primer.

9.3.7 Extra coats of paint shall be applied on areas where shape and/or plane of application results in thinly applied coating; e.g., at edges, welds, corners, etc. To compensate for these effects, a stripe coat of paint shall be brush applied before applying the finish coat.

9.3.8 All coating shall be uniformly applied without runs, sags, solvent blisters, dry spray or other blemishes. All blemishes and other irregularities shall be repaired or completely removed and recoated. Special attention shall be paid to crevices, corners, edges, weld lines, bolt heads, nuts and small brackets, to apply the specified minimum thickness by brush application if spray will not completely cover all surfaces.


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9.3.9 Paint shall not be applied within 50 mm of edges which will be welded later. Such weld areas shall be taped for a distance of 50 mm either side of the weld.

9.3.10 Mechanical mixers shall be provided for mixing of paints to properly disperse / mix any component that may have settled at the bottom of the paint drum.

9.3.11 Paint shades to be selected to have contrasting colours to distinguish the preceding coats and good coverage

9.3.12 Powder based Zinc primers shall be checked for the degree of curing prior to the application of the intermediate coat by an approved method, i.e. solvent rub test.

9.4 Painting Systems

The painting works shall be carried out strictly in accordance with the Paint Systems specified on the Shell DEP 30.48.00.31 – Gen., dated December 1985 under Appendix 2 for each individual scope of work.

The applicable Paint Systems No. 1 up to 15 shall be followed.

9.5 Material Safety Data

9.5.1 Storage

Observe safe storage practices by separating resin from hardeners, by keeping solvents and hardeners in a cool area free of source of ignition, and by observing a special warning on labeled products.

9.5.2 Work Site

Work area should be well ventilated to protect workers from fumes of cleaning solvents, liquid, resins and hardener. Air movement must be designed to ensure turnover in work area and adjacent areas to avoid build-up of heavy vapours.


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Eliminate sources of ignition from empty containers with product residues.

10. FINAL ACCEPTANCE

Stage inspection will be carried out by CAPE, LEC and TECHNIP representatives. Cape QC Representative will issue necessary Inspection Control Sheet.

11. SPECIFICATION CONTROL

11.1 At all times Cape Key personnel will have access to:-

- Task Methodology, Inspection and Test Plan- Quality Documents- Project Specifications- Cape/main Contractor HSE Policy

11.2 All Cape employees, when in doubt will approach the supervisor for assistance in clarifying work requirements.

12. APPENDIX - 1

- Cape Procedures for Surface Preparation and the Application of Protective Coating.

APPENDIX – 2

- Job Hazard Analysis


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Appendix - 1

Cape Procedures for Surface Preparations and the Application of Protective Coating.


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I N D E X

Section 1 - General Application Procedure Surface Preparation.

Section 2 - General Application Procedure Painting.

Section 3 - Procedure for the Application of Coating System.

Section 4 - Control of Thickness of Paint Coating.


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Section 1- General Application Procedure Surface Preparation


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1. Purpose

1.1The purpose of this procedure is to ensure a control of the surface preparation prior to application of protective coatings.

2. Scope

2.1The scope of this procedure is for the surface preparation prior to application of protective coatings and should be read in conjunction with the relevant paint system application procedure.

2.2This procedure should always be read and interpreted in accordance with ADCO Painting Specification.

3. Responsibilities

3.1The QA/QC representative shall be responsible to the QC leader and to the project management for ensuring the correct application of this procedure.

4. General

4.1 Surface preparation is perhaps the single most important stage in the application of a protective coating system. There is a very close relationship between the performance of a coating system and the


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quality of the surface over which it is applied. The adhesion of most coatings is adversely affected when application is carried out over surface, which have deposits of oil, grease, dirt, loose material or similar forms of contamination on them.

Prior to commencement of surface preparation factors that may affect the integrity of this operation must be considered and carefully monitored. In addition to this, the sequence of events that must be accomplished to complete the protective coating system must be considered and programmed to take place in logical order to conclude with high quality product.Consideration must be given at this point as to the effect of the proposed method of surface preparation on:

(a) The metallurgical properties of the substrate;

(b) The physical characteristic of the substrate;

(c) The chemical and physical properties of the coating substrate (In the case of remedial or maintenance work);

(d) Surface which may be damaged or do not require treatment;

(e) The ultimate performance of the protective coating system.

4.2 Standard of Surface Preparation

Surface Preparation shall be conducted in accordance with the Technical Specification and with reference to the appropriate standards.

Blast cleaning shall be carried out to the appropriate pictorials standard of SIS.0559.00 when read in conjunction with the descriptive standard of together with the requirements of the ADCO Painting Specification.

The grades of surface finish applicable are:

Class 1 – Light Blast Cleaning

This degree approximates Standards SA1 of SIS.0055900.


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Class 2 – Medium Blast Cleaning


Class 2.5 – Near White Metal Blast Cleaning

This degree approximates Standards SA2.5 of SIS.0055900.

Class 3 – White Metal Blast Cleaning


4.3 Manual Cleaning

Where manual cleaning of exposed metal surfaces is used, mechanical cleaning tool, such as brushes etc. shall be used. Where permitted, the grade of surface finish achieved shall be ST-3 in accordance with SIS.0055900.

Power tool cleaning which may result in polished shall be avoided.

Removal of corrosion residue (dust etc.) after power tool cleaning shall be ensured.

4.3.1 Degreasing

Degreasing is a surface cleaning procedure that will be employed prior to blast cleaning and prior to other accepted forms of surface preparation for painting. The procedure may also be used for the removal of other soluble forms of surface contamination, which may occur on the surface of a coating.

Deposits of oil, grease, drilling and cutting compounds, weld flux etc. shall be removed by means of a suitable solvent.

High-pressure water washing or steam cleaning, incorporating in alkaline cleaning agent are alternative method of degreasing, providing chloride


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content of the water is within acceptable limit when used on stainless steel. Thorough washing with clean, good quality water alone is acceptable for the removal of light industrial and atmospheric, water-soluble contamination.

Solvent used in cleaning stainless steel surfaces shall be organic free of metallic elements and have less than 50ppm chloride content.

Solvent used for cleaning of coated surfaces shall be oil-less and compatible with the coating, which it is applied (e.g. M.E.K. – Methyl Ethyl Ketone).

4.3.2 Removal of Rust and Scale

The removal of heavy rust scale may be carried out by the use of impact cleaning tools (e.g. needle guns). On steelwork it will be necessary to inspect the surface of the base metal after the removal of heavy corrosion products to ensure properties of the structure have not been adversely affected by pitting.

4.4 Abrasive Blast Cleaning

Abrasive blast cleaning is the most effective form of surface preparation when used in conjunction with the correct preabrasive blast cleaning and postabrasive blast cleaning procedures. The type of equipment, the type of abrasive and the techniques employed by the operator are just some of the factors that contribute towards the effectiveness of the blasting operation. The correct preparation of the surface before the blasting process and the preservation of the cleaned surface after the blasting process both ensure the production of high quality surface finish that will provide long term durability of the protective coatings.

4.4.1 Techniques and Restrictions

When abrasive blast cleaning is employed the requirements of the Painting Specifications as endorsed in this Manual shall be met, i.e.:(1) To prevent moisture deposition on the surfaces: Abrasive blast

cleaning shall not be conducted when the temperature of the


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substrate is less than 3 degrees centigrade above the dew point of the surrounding air or when Relative Humidity exceeds 85%.

(2) To Prevent dust and abrasive contamination: Abrasive blast cleaning shall not be carried out in open areas close to painting operations or wet coated surfaces.

(3) To improved effectiveness and uniformity: Abrasive blasting will be performed by the operation in small sections or “block” shall be completed before moving to the next.

(4) To Improved paint adhesion on cured coatings: Light abrasive blasting may be used to provide a mechanical bond for subsequent. On areas exposing bare metal, blast cleaning shall overlap any adjacent coated areas by a minimum of 50mm.

(5) To prevent galvanic contamination of austenitic stainless steel and aluminum: Abrasive used shall be a suitable type such as aluminum oxide or inert aluminum silicate.

(6) To assist maintenance of nozzle pressure and particle velocity: Nozzles shall be discarded and replaced when orifice wear reaches 50%.

Blast cleaning operation shall be conducted at a suitable distance from painting operation so that components are not contaminated with abrasive or dust.

4.4.2 Types of Abrasive

The painting specification lists the type of abrasive medium that are suitable for use in the plant. The abrasive types and their intended use by CAPE on this project are detailed as follows:

Garnet shall be used as the abrasive medium for all carbon steel. Inside plant only. Abrasive shall be washed, dried, clean and free from other contaminants. The abrasive particle size shall be such as to produce surface amplitude of 50 to 70 microns on achieving a Class 2.5 blast on carbon steel.


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4.5 The Effect of Particle Size on Profile

The maximum particle size shall be no larger then that passing through the appropriate mesh screen size to suit the centre line profile height requirements as typified in SIS 0055900. The maximum profile height required will be in accordance with the paint manufacturers recommendations for the particular coating type and thickness specified. In addition to particle size, surface profile height is also influenced by factors such as the angle and velocity of particle, cleanliness of the abrasive, shape of particle and the properties and characteristics of the surface being cleaned. Consequently, the profile height can be expected to vary over a fairly wide range during a production run.

The general recommendation by paint manufacturers is that the maximum profile height should not exceed 75 microns with rogue peaks of 100 microns allowance. When blasting with oxides on stainless steel and aluminum the surface shall be blasted such that a suitable key for paint application is produced.

As mentioned in the previous section, the abrasive types intended for use by CAPE can be expected to produce a surface profile in the range of 50 to 75 microns.

4.6 Blasting Cleaning Equipment and Facilities.

Abrasive Blasting Facilities

Equipment used for extensive abrasive blasting is capable of accommodating one manual blast nozzle and is fully self-contained.

The medium-capacity equipment described hereto shall be supplemented by smaller portable mini blast machine as when required.

Air shall be provided by portable compressors, which will deliver good quality air free of oil and water at a pressure adequate to produce the standards of surface preparations required.

In-line oil and water separators shall provide additional assurance that clean, dry air is being delivered to the painting equipment and blast nozzles. Blasting hood air shall be cooled and regulated by devices.


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Section 2 - General Application Procedure Painting


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1. Purpose

1.1 The purpose of this procedure is to ensure a control of the application of protective coating system.

2. Scope

2.1 The purpose of this procedure is for the application of protective coatings being applied and should be read in conjunction with the relevant paint system application procedures.

2.2 This procedure should always be read and interpreted in accordance with ADCO Painting Specification.

3. Responsibilities

3.1 The QA/QC representative shall be responsible for ensuring the correct application of this procedure.

3.2 The QA/QC representative shall be responsible to the Project Supervisor for the correct implementation of the procedure.

4. General

4.1 Coating inspectors shall be certified to British Gas or NACE to appropriate levels and copy of their CV’S and certifications shall be reviewed by ADCO. Competent & experienced personnel only shall be


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employed in the application of protective coatings. The applicator shall be instructed on the use of the materials he shall be applying and will be conversant with the procedures described in this manual, which are applicable to his function. He shall also be appreciative of his responsibilities to conduct his work in a diligent and conscientious manner and to notify his superiors of any observation he has made may impair his objectives.

4.2 Spray Application

The operator of spray equipment shall be experienced in its use and shall be responsible for maintaining it in good working order.

Material hoses and container shall be thoroughly cleaned before thedifferent materials are introduced. During the application of protective coating the spray pots, material line and the spray gun shall be kept at approximately the same elevation, The spray gun shall be held no closer than 200mm or further than 600mm from the surface to be coated and shall always be held at the right angels to the surface.

Large surfaces shall receive two passes at right angels to each other (cross-hatching) and, in all instances; each spray pass shall overlap the previous pass by approximately 50%. Edge of pipe flanges and structural components, welds, irregular or recessed surfaces shall be given special attention and shall receive spray coats to ensure adequate film thickness has been applied.

At regular intervals during the course of coating application the applicator is to conduct wet film check to ensure that the desired coating thickness is being achieved. Care shall be taken to minimize excessive wet film build as runs, sags, or in the case of inorganic Zinc primers, “mud cracking” may result. When excessive coating has been applied excess materials shall be brushed out immediately.

4.3 Brush Application

The application of coatings by brush shall be strictly controlled and restricted to the following uses:


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(1) When areas cannot be properly coated, by spraying for any reasons.

(2) Stripe coating for every coat on edges, rat holes, welds, etc.

(3) For touch up or repairs to localized damage.

(4) For brushing out excessive and incorrectly applied materials.

(5) Where spray application is not practicable for any reason, e.g. where Control of over spray is not possible.

Brush application of coating shall be performed in such a manner as to ensure that a smooth and uniform coating is applied. The finish surface shall be devoid of any deep or detrimental brush marks.

4.4 Other Methods of Application

Method of application other than spray or brush shall only be employed with prior consent of the client.

4.5 Surface Finish

The surface finish of the completed protective coating system shall be of a uniform luster and shall not contains runs, sags, brush marks, pinholes, blisters, laminations, misses or extraneous materials. Where localized repair work only has been carried out, however, appearance will lack uniformity.

4.6 Identification of Areas Requiring Special Treatment

The applicator of protective coating materials shall be instructed in the identification of areas of components, which will require special treatment during the application process. Particular attention shall be paid to areas of difficult access, e.g. pipe saddles, internal surface of trunnions, joining faces of flanges and contact surfaces.


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Included in his instruction shall be identification of weld defects such as undercut, porosity, sharp edges void and weld spatter, so that corrective action may be taken prior to coating of these areas.

As the coating applicator usually the last person to see the substrate before it is coated, he shall be required to observe the surface of minor defects that may have escaped the attention of others. Such defects include arc strikes, sharp edges and laminations in the metal. His observation and responsibilities shall extend to the condition of coasted surfaces prior to over coating to ensure minor damage or defective areas are not covered without the appropriate procedures being employed.

4.7 Other General Requirements of the Painting Specification

In addition to the foregoing requirements of the Painting Specification, there are a number of requirements which must be strictly complied withduring execution of the coating application procedure.

(1) All surfaces to be painted or coated shall have been adequately prepared, in accordance with the Specification, and shall be clean, dry and free of any surface contamination. Abrasive particles and dust shall be brushed or blown from blasted surfaces before any coatings are applied.

(2) The first coat of paints shall be applied to ferrous surfaces within two hours of completion of surfaces preparation or before flash rusting or contaminations occur.

(3) Paints shall not be applied under the following conditions:

(a) When the temperature of the surface is greater than 50 deg. C or the surrounding air temperature is less than 4 deg. C.

(b) When the temperature of the surface is less than 3 deg. C above the dew point of the surrounding air.

(c) When the ambient of he relative humidity is higher than 85%.


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(d) When there is a likelihood of an unfavorable change in weather conditions within two hours after coating.

(e) Between sundown and sun-up (unless special approval is granted).

(f) Where there is any deposition of moisture of the surface.

(4) The pot life of catalyzed materials shall not be exceeded. In the event of pot life limit being reached, the material shall be discarded and the equipment cleaned before replenishment with new material.

(5) Zinc pigmented primers and two packed materials containing heavy metallic pigments shall be kept in continuous agitation during application to prevent setting of pigments.

(6) Manufacturer’s recommended minimum and maximum recoat intervals shall be complied with.

(7) Coated surfaces shall be handled with due respect during coating and process, and completed coating shall be allowed sufficient time to attain full cure prior to major handling being undertaken.

(8) Surfaces, which may become inaccessible after assembly or erection shall be cleaned and coated to Specification requirements before assembly or erection.

(9) Surfaces, which do not require painting, shall be protected in the appropriate manner prior to painting being conducted.

(10) The following items do not require painting:

(a) Any equipment furnished completely painted by the manufacturer, unless colour coding or repair of coating damage be specifically required as an addition to the contract scope of work.

(b) Hot dipped galvanized steel (except for fire system pipe work), weathering steel, brass, copper and aluminum.

(c) Name Plates and identification plates.


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(d) Non-metallic surfaces.

(e) Insulation weather proofing material or sheeting.

(f) Screwed items of valves, gaskets surfaces, finished machine parts of equipment, valve stem and packing units of valves, control spring rods and shafts, sliding or wearing surfaces of turbines, engines, motor and similar equipments.

(g) Cable trays, electrical conduits and supports.

(11) Paint colours, or structural steel, piping and equipment shall be in accordance with specifications.

Accordingly, the finish colour for main pipework, exposed structural and vessels, columns, exchangers and tanks shall be as above.

4.8 Spray Equipment

Equipment used for spray application of coatings shall be of a type that is suitable for the type of materials being sprayed. The paint manufacturer’s recommendations shall be used as a guide to equipment selection.

Spray guns, lines and pressure pots shall be maintained in a clean condition and in good working order. Each spray unit shall be supplied with dry, filtered air, free from oil and moisture contamination and of sufficient capacity to obtain the required pot pressure and atomized pressure.

Conventional spray pressure pots shall be equipped with air pressure regulators. Spray equipment shall be equipped with fluid tips, needles and air caps consistent with the paint manufacturer’s recommendations for the material being sprayed. Airless sprayed. Airless spray equipment shall be equipped with the recommended tip size that shall provide optimum atomization and fan width for the type of material and the type of surface being sprayed.


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5. General Working Conditions

5.1 The condition is which the works is conducted include both the micro and macro- environments. The microenvironments include the factors which directly affects the properties and performance of the coating e.g. surface and ambient conditions. The macro-environment includes those elements, which directly influence the effectiveness of the application of the coating and indirectly effect performance or integrity of the coating, e.g. site conditions and safety aspects.

5.2 Temperature

The temperature of both the substrate and surrounding air is an important factor at the stage surface preparation and coating application. Substrate temperature must be in a minimum of 3 deg. C above dew point temperature to ensure that moisture contained in surrounding air does not condense on the surface before coating are applied. The temperature of the surrounding air must also above 4 deg. C in order for the coating to be able to achieve curing.

As the temperature of the surface to be painted exceed 50 deg. C, painting shall not proceed unless special dispensation for application at higher temperatures is given by the Client.

To overcome material problems associated with high surface temperatures summer grades catalysts may be used with two-pack materials and, if necessary, solvent types may be notified to retard the curing process.

5.3 Relative Humidity

The relative humidity of the surrounding air gives us an indication of how close the atmosphere is to saturation. The instrument that shall be used for measuring R.H. is the whirling hygrometer. This apparatus consists of a wet and dry bulb thermometer, and works on the basis that the drier the air the more rapidly the evaporation take place from the moistened wick on the end of the wet bulb, and the lower will it’s temperature. A percentage value of Relative Humidity is determined from the difference between the wet and dry bulb temperatures.


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Surface preparation or application of protective coating shall not proceed when Relative Humidity exceeds 90% where epoxies coating are used.

5.4 External Conditions

Painting shall not be carried out when there is the likelihood of a change in the weather conditions, which may result in the deposition of moisture on the surface within two hours of coating. Where freshly applied coatings may possibly affect by rain temporary weatherproof shelter may be erected over these areas.

Painting shall also be suspended when prevailing weather conditions may result in the deposition of dust or other extraneous materials the wet film. In windy conditions temporary screens may be erected to prevent ingress of windborne contaminants as well as serving to minimize paint overspray to other areas of the site.

5.5 Contamination of Prepared Surfaces and Uncured Film

Particular care shall be exercised to prevent contamination or deterioration of prepared surfaces and wet film. Cleaned surfaces of ferrous components shall never be left unprotected overnight and, in any case, shall not remain uncoated for longer than 2 hours or before discoloration of the surface occurs. Painting shall be conducted in a location where there is minimal risk of contamination from either abrasive or windborne particles.

Contamination shall be removed from prepared and/ or coated surfaces by either or a combination of the following methods:

(a) Re-blasting

(b) Solvent Cleaning

(c) Light Sanding

(d) Fresh Water Washing


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6 General Notes:

- Ambient conditions shall be noted 4 times a day.

- Blast profile shall be measured and recorded twice a day (before starting the primer / paint application).

- DFT shall be taken a minimum of 5 readings in each area.

- The protected / marked surfaces for painting shall be cleared after painting.

- The minimum spray nozzle distance shall be 200mm from the surface to be painted.

- In case of conflict the requirements of ADCO Painting Specification shall prevail.

- All inspection tools and instruments shall have valid certification.

- All tools and equipment shall be safe to use.


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Section 3 - Procedure for the Application of Coating System


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1. Purpose

1.1The purpose of this procedure is to ensure a detailed control of the application of protective coating systems.

2. Scope

2.1The scope of this procedure is for the application of protective coating systems for ADCO – North East BAB Phase I Development Project at Rumaitha Oilfield, Abu Dhabi, United Arab Emirates.

2.2This procedure should always be read and interpreted in accordance with the ADCO Painting Specifications.

3. Responsibilities

3.1The QA/QC representative shall be responsible for ensuring the correct application of this procedure.

3.2The QA/QC representative shall be responsible to the Project Supervisor for the correct implementation of the procedure.

3.3The QA/QC representative shall be responsible for achieving the stage acceptance of the Quality Control and Inspection Plan.


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3.4The actions described in this procedure may be delegated to personnel with sufficient training and experience to complete the task. RESPONSIBILITIES SHALL NOT BE DELEGATED.

4. Material Requisition

4.1 It shall be the responsibility of the appropriate Project Supervisor to authorize the requisition of materials required for the coating application which shall consist of:

Blasting - as per medium required by specification.

Primer - as per paint requirement in specification.

Intermediate Coat as per paint requirement in specification.Top as per paint requirement in specification.Solvent/thinner as per paint manufacturer.

5. Equipment

5.1 Airless Spray -Inspected and passed by CAPE QA/QC.Conventional Pumps

5.2 Blasting Equipment -Inspected and passed by CAPE QA/QC.

6. Quality Control

6.1 It shall be the responsibility of the Painting Inspector to monitor ambient conditions, preparation and application of coating system.

7 Surface Preparation

7.1 It shall be the responsibility of the Project Supervisor to ensure the surface is carried out correctly.

7.2 Ensure area is released for surface preparation. Mask of all areas not requiring paint application, area is clean and free of obstacles and debris.


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7.3 Removal soluble contaminants using oil free solvent. Check ambient conditions are within specification requirements. Abrasive blast clean area to near white metal in accordance with visual standard SA 2.5 or SA3 of SIS 0055900 as required by the specification system.

8 Coating Application

8.1 It shall be the responsibility of the Project Supervisor to ensure the correct application of the coating system.

8.2Ensure area is released for the application of the coating system. Surfaces are clean & dry and have been air cleaned to remove all traces of contamination. Ensure primer application occurs within 2hours of completion of surface preparation or before any sign of rash rusting.

8.3Material shall be positively identified and checked for specification compliance. Check shelf life expiry date. Record batch no. and coating type.

8.4Paint shall be mixed thoroughly prior to use and where two parts shall be mixed in accordance with manufacturer’s instructions. Pot life shall not be exceeded during application.

8.5Check and record ambient condition 4 times a day and note commencement time of painting to ensure manufacturer’s recommended over-coating intervals are being complied with.

8.6Coating shall be applied by airless spray, brush application shall be limited to stripe-coating of edges and small areas to touch – up, and in accordance with manufacturer’s recommendations.

8.7Apply primer coat to achieve minimum D.F.T. as per specification.

Apply intermediate coat (where required) to achieve a minimum D.F.T as per specification.


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8.8Ensure all coated surfaces have been thoroughly cleaned as per specification before application of next coat and all coats are free of defects such as runs, sages, pinholes & surface contamination.

8.9After a minimum overnight curing, check dry film thickness. Total minimum dry film thickness of completed shall be as per system requirements.

9 Repairs

9.1 Inspect all surfaces to determine extent of damage, where area is minor and blast cleaning cannot be carried out, power tool clean the area to visual standard ST-3 (SIS 0055900) and only with prior approval from the client, larger areas shall be abrasive blast cleaned as per 7.3.

9.2 Surface preparation shall overlap adjacent coated surfaces by

minimum of 500mm. Damaged coating where steel has not been exposed shall be suitably abraded with garnet paper in preparation for primer/intermediate/top coat application.

9.3 Coated edges around damaged area shall be chamfered to a smooth finish.

9.4 Apply relevant coat as per Section 8.

9.5 Ensure repair coating overlap around coatings by minimum of 50mm and are free of defects.

10 Final Acceptance

Upon final acceptance of the paint coating system the CAPE QA/QC Dept. shall issue an Inspection & Test Status form completed for the relevant work package.


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11 Quality Control Plan

Client Specification: Painting Specification as per Item 2.2 above

Manufacturer’s Data Sheets.

Section 4 - Control of Thickness of Paint Coating


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1. Scope

1.1 The procedure defines the system of controlling the thickness of paint coating.

2.2 This procedure should always be read and interpreted in accordance with ADCO Painting Specification.

2. Control of thickness of Painting Coating

2.1 General

The required Dry Film Thickness (D.F.T.) and corresponding Wet Film Thickness (W.F.T.) for each respective coating in the protective coating system has been nominated in the ADCO Painting Specification.

It is to be noted that a wide range of coating thickness and finishes are expected to be encountered on existing coatings throughout the site-painting contract. The diversity of methods and conditions under which shop painting has been conducted by various contractors cannot be expected to consistently produce the same uniform result. Consequently, variations in film thickness exceeding specification parameters are to be expected.

Whilst maximum values have been given for D.F.T.’s, as specified, it must be impressed that it is not always practicable to maintain coating thickness within the given limits. Instances where, during application,


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coating thickness may unavoidably exceed the maximum limits specified are:

(a) When the configuration or surface irregularities of the component are being coated dictates that the spray pattern cannot be uniform, with a resultant inconsistency in film build.

(b) When D.F.T.’s test indicate that the existing coating is below the required minimum and the properties of the coating type used for building up dictates that the maximum limit imposed by the Specification may be exceeded.

(c) When repair work is carried out to coatings the areas where the repair coating overlaps existing coating, by the requirements of the Specification shall exceed maximum limits.

In cases when maximum limits are exceeded, the Coating Manufacturer shall be consulted as to the effect of the excessive film build on the integrity of the coating and the coating system. Potential adverse effects shall initiate either a change in application method or a change in coating system, or a combination of these two:The cohesive strength of organic zinc silicate coating decreases when excessively thick or when double coated, which may result in sheering or splitting of the zinc film even when subjected to only moderate physical stress. When cohesive strength of the inorganic zinc film is questionable the results of the standard adhesion test as described in this document shall constitute the criteria of acceptance.

The principal method of controlling the thickness of paint coatings shall be by frequent monitoring of wet film thickness during the application of the coating.

2.2 Determination of Wet Film Thickness

The Wet Film Thickness (W.F.T.) required to achieve a given D.F.T. can be determined from the percentage Volume Solids contained in the paint material. The solids content forms the dried paint film after application


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and after the volatile content has evaporated. For example, a paint containing 50% Volume Solids will require a W.F.T. of 100 microns to achieve a D.F.T. of 50 microns.

Recommended Wet Film Thickness of Products intended for use on the project are given in the relevant specification data sheet and CAPE Application Procedure.

2.3 Effect of Thinning

It is important to note that the additional of thinners to the paint material effectively reduces the % Volume Solids stated by the manufactures, and the W.F.T. of the applied coating shall have to be increased accordingly.

In addition to the effect on film thickness, thinning when used excessively can detrimentally affect the chemical properties and integrity of the paint film. Thinning, therefore, is to be avoided wherever possible and only to be done with the prior approval of the manufacturer.

2.4 Monitoring of Wet Film Thickness

Wet Film Thickness shall be constantly during the course of coating application. The measurement shall be conducted on flat surfaces and before the coating has set or lost an appreciable proportion of its solvent.The device used for measuring of W.F.T. shall be the metallic graduated comb type. The gauge shall be capable of measuring the range of thickness appropriate to the particular coating or system being used.

2.5 Monitoring of Dry Film Thickness

Dry Film Thickness (D.F.T.) test shall be conducted by field personnel only after the coating film has attained sufficient hardness to enable the gauge to be placed on the surface without risk of sticking or indentation. Magnetic type gauge, such as the Mikrotest or Elcometer, shall be used to determine dry film thickness.

If the Painting Specification does not specify the frequency of measurements to be taken, a guide of approximately: 5 determinations


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per 9 sq.m. of surface area shall be used. Components having surface area of: Less than 9 sq.m. shall receive 3 determinations.

The average of these separate gauge readings shall constitute each thickness determination. Each reading shall be spaced evenly over the entire coated surface of the component.

The average D.F.T. determination recorded on the Q.C. Report shall be the average of the thickness determinations calculated for the particular components being tested. The maximum and minimum values recorded on the Q.C. Report shall be the maximum and minimum values of individual measurements taken.

JOB HAZARD ANALYSIS FOR BLASTING & PAINTING YARD SR. NO. STEP HAZARD CAUSE PREVENTIVE

MEASURES

1. Blasting Personal Injury Improper equipment and incompetent operator

Obtain work permit (if required)

All hoses and equipment must be certified by Third Party.

Warning sign board shall be installed.

Only trained operators shall carry out the blasting activity.

Deadman handle shall be auto.

Exhaust spark arrestor, chalwyn valve and explosion proof battery isolator shall be installed.


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Fire Hazard

Electrical shock

Fire with Compressor

Proper earthing shall be provided.

DCP Fire Extinguisher shall be available near to compressor.Standby man available with compressor.

Maintain proper housekeeping.

Tripping Improper laying of hoses.

Hoses shall be laid straight as possible from blast pot up to the blasting point.

Lung Injury

Respiratory problem

Inhalation of dust.

Polluted breathing air supply.

Covering protection shall be installed at least 3 meter height.

Warning signs shall be installed.

Blaster shall wear blasting hood with purified air supply and complete PPE.

2. Painting Personal Injury Improper equipment and incompetent operator.

Obtain work permit (if required)

All hoses and equipment must be certified by Third Party.

Warning sign board


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Breathing Problem

Skin Irritation

Fire Hazard

Toxic atmosphere

Open body parts

Paint fumes

Fire with Compressor

shall be installed.

Only trained operators shall carry out the painting activity.

Use respirator or airline mask.

Face and body protection

DCP Fire Extinguisher shall be available near to painting area.

No smoking in painting area.

Standby man available with compressor.

Maintain proper housekeeping.

Tripping Improper laying of hoses.

Hoses shall be laid straight as possible from spray pump up to the coating point.

Method of Painting Works

Documents

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north east bab neb phase

present document