0 ISSUE STIN OFFS STIN 11-96

REV. DESCRIPTION COMP. VERIF. APPR. DATE

Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato
This document is CONFIDENTIAL and the sole property of AGIP . It shall neither be shown to third parties nor used for purposes other than those for which it has been sent.
FUNCTIONAL SPECIFICATION
PROTECTIVE TREATMENTS OF METAL STRUCTURES
BY METAL COATINGS
20004.VAR.PAI.FUN.
Rev 0
May 1996
20004.VAR.PAI.FUN
Rev. 0 May 1996
Sheet 2

Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato
This document is CONFIDENTIAL and the sole property of AGIP . It shall neither be shown to third parties nor used for purposes other than those for which it has been sent.
FOREWORD
Rev. 0 Total Number of Sheets: 17
May 1996
This Specification was issued in agreement to E.E.C. Directives.
20004.VAR.PAI.FUN
Rev. 0 May 1996
Sheet 3

Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato
This document is CONFIDENTIAL and the sole property of AGIP . It shall neither be shown to third parties nor used for purposes other than those for which it has been sent.
CONTENTS
1. GENERAL
1.1 Scope
1.2 Normative References
1.2.1 European Normative References
1.2.2 Normative References of ISO, IEC and national organizations
1.2.3 Normative References of other Organizations
1.2.4 Legislation
2. FUNCTIONAL NORMATIVE REQUIREMENTS
2.1 Operative environment
2.2 Functional requirements
2.2.1 Coating
2.2.2 Material properties
2.2.3 Coating thickness
2.2.4 Surface preparation
2.2.5 Spray metallizing processes
2.2.6 Sealer application
2.3 Safety
2.4 Ergonomics
2.5 Requirements for Quality Management and Quality Assurance
2.6 Additional Requirements for Review
2.6.1 Assistance by the Supplier of coating products
2.6.2 Reception of the coating materials
2.6.3 Production process control
2.6.4 Checks, inspections and testing
2.6.5 Warranties and final acceptance
20004.VAR.PAI.FUN
Rev. 0 May 1996
Sheet 4

Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato
This document is CONFIDENTIAL and the sole property of AGIP . It shall neither be shown to third parties nor used for purposes other than those for which it has been sent.
2.7 Documentation
2.7.1 Documents to be submitted at the start of work
2.7.2 Documents to be submitted during work progress
2.7.3 Documents to be submitted at the completion of work
20004.VAR.PAI.FUN
Rev. 0 May 1996
Sheet 5

Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato
This document is CONFIDENTIAL and the sole property of AGIP . It shall neither be shown to third parties nor used for purposes other than those for which it has been sent.
1. GENERAL
1.1 Scope
This Specification defines the functional requirements of metal coatings applied
to offshore structures, onshore and offshore production plants, machinery and
packages.
1.2 Normative References
1.2.1 European Normative References
At the time this Specification was issued no European Standards or Directives
applicable to the matter were available.
1.2.2 Normative References of ISO, IEC and national organizations
UNI-ISO 2063 Rivestimenti metallici ed altri rivestimenti inorganici,
metallizzazione termica a spruzzo, zinco, alluminio e loro
leghe (tape method).
ISO 8502-4 Preparation of steel substrates before application of paint and
related products. Tests for the assessment of surface
cleanliness. Part 4: Guide on the estimation of the probability
of condensation prior to paint application.
ISO 8503-1 Preparation of steel substrates before application of paint and
related products. Surface roughness characteristics of blast-
cleaned steel substrates.
Part 1: Specifications and definitions for ISO surface profile
comparators for the assessement of abrasive blast-cleaned
surfaces.
ISO 8503-2 Preparation of steel substrates before application of paint and
related products. Surface roughness characteristics of blast-
cleaned steel substrates.
Part 2: Method for the calibration of ISO surface profile
comparators and for the determination of surface profile.
Comparator procedure.
20004.VAR.PAI.FUN
Rev. 0 May 1996
Sheet 6

Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato
This document is CONFIDENTIAL and the sole property of AGIP . It shall neither be shown to third parties nor used for purposes other than those for which it has been sent.
ISO 8503-4 Preparation of steel substrates before application of paint and
related products. Surface roughness characteristics of blast-
cleaned steel substrates.
Part 4: Method for the calibration of ISO surface profile
comparators and the determination of surface profile.- Stylus
instrument procedure.
ISO 8504-1 Preparation of steel substrates before application of paint and
related products. Surface preparation methods. Part 1: General
principles.
ISO 8504-2 Preparation of steel substrates before application of paint and
related products. Surface preparation methods. Part 2:
Abrasive blast cleaning.
ISO 8504-3 Preparation of steel substrates before application of paint and
related products. Surface preparation methods. Part 3: Hand
and power-tool cleaning.
ISO 2409 Paints and varnishes - Cross-cut test.
ISO 9227 Corrosion tests in artificial atmospheres - salt spray tests.
UNI 9852 Prodotti vernicianti.- Determinazione del grado di
reticolazione.
BS 729 Specification for hot dip galvanized iron and steel articles.
DIN 8566 Metals for thermal spraying.
1.2.3 Normative References of other organizations
ASTM D 4587 Practice for conducting test on paint and related coatings and
materials using a fluorescent UV-condensation light-and-water
exposure apparatus.
AICC N. 11 Associazione Italiana Coil Coating - Prove di durezza
1.2.4 Legislation
D.P.R. del 27 Aprile 1955, N. 547 Norme per la prevenzione degli infortuni
sul lavoro.
D.P.R. del 19 Marzo 1956, N. 303 Norme generali per ligiene del lavoro.
Legge del 29 Maggio 1974, N. 256 Classificazione e disciplina
dellimballaggio e delletichettatura delle sostanze e dei preparati pericolosi.
20004.VAR.PAI.FUN
Rev. 0 May 1996
Sheet 7

Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato
This document is CONFIDENTIAL and the sole property of AGIP . It shall neither be shown to third parties nor used for purposes other than those for which it has been sent.
Ministero della Sanit - Decreto N. 50 del 16 Febbraio 1993.
In Countries other than Italy these regulations may be complemented,
integrated or substituted by applicable local Laws and regulations.
20004.VAR.PAI.FUN
Rev. 0 May 1996
Sheet 8

Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato
This document is CONFIDENTIAL and the sole property of AGIP . It shall neither be shown to third parties nor used for purposes other than those for which it has been sent.
2. FUNCTIONAL NORMATIVE REQUIREMENTS
2.1 Operative environment
Components protected according to the requirements of this specification can
be subjected to quite different environmental service conditions.
The environment conditions in which coating operations will take place are
however a determining factor for a satisfactory outcome of these operations; to
this purpose the Contractor is requred to keep climatic conditions under careful
control while coating operations are going on. The conditions for application
specified in the Supplier's technical sheet shall be always observed.
This specifications refers to the usual conditions that can be found in site yards,
in shops and anyway in the typical premises of an oil producing enterprise.
2.2 Functional requirements
Spray metal coating of metal structures shall be performed in accordance to the
requirements specified in the data sheets and in the documentation specific to
the individual job.
2.2.1 Coating
Metal coating is performed using metals exhibiting anodic behaviour in respect
to Iron. These sacrificial anodic coatings offer to the substrate an active
protection of electrochemical nature. Zinc and Aluminium are commonly used.
Aluminium is usually more resistant than Zinc in marine environment, and is
preferable for industrial areas where the atmosphere contains high levels of
Sulphur or of Sulphur compounds; Zinc is to be used for protective coatings
where the atmosphere contains alkaline corrosive agents (pH 7 12) or is of a
rural type, or is dry and warm.
The metal coating shall be sealed with fluoro-polymer based paints, having a
minimum of 16% Fluorine in respect to the dry base paint.
2.2.2 Material properties
2.2.2.1 Aluminium
The following aluminium alloys may be used:
20004.VAR.PAI.FUN
Rev. 0 May 1996
Sheet 9

Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato
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1) 99.9% aluminium alloys
2) 90% aluminium and 10% alumina alloys (in order to improve surface wear
resistance).
Other alloys may be used, however only if complying with the requirements of
DIN 8566 Standard.
2.2.2.2 Zinc
99.9% pure zinc alloy, complying with the requirements of BS 729 Std.
2.2.2.3 Sealer
The sealing material shall have the following properties:
1) Fluoro-polymer based enamel, two-component, having a minimum of 16%
Fluorine in respect to the dry base paint.
2) Physical properties:
Adhesion (on 1 sq.mm) - (ISO 2409) Grade zero
Pencil hardness - (AICC N 11) H
Curing degreee - (UNI 9852) >100
60 gloss 80 - 100 gloss
3) Resistance to accelerated ageing
QUV 1000 H (cycle 4 + 4 - after rinsing)
(ASTM D-4587)
60 gloss variation
<10%
Weather-o-meter 4000 hours 60 gloss variation
<10%
Salt fog (ISO 9227) After 4000 hours, 1
mm max blistering on
scribe marks.
60 gloss variation
<10%
20004.VAR.PAI.FUN
Rev. 0 May 1996
Sheet 10

Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato
This document is CONFIDENTIAL and the sole property of AGIP . It shall neither be shown to third parties nor used for purposes other than those for which it has been sent.
2.2.3 Coating thickness
Zinc coating Minimum thickness 250 m
Aluminium coating Minimum thickness 200 m
Sealer Minimum thickness 30 m
2.2.4 Surface preparation
All steel surfaces to be metal coated shall be cleaned until a substrate is
obtained complying with the requirements of the coating process.
To this purpose the surfaces shall be abrasive blast cleaned in accordance to
ISO 8504-2 and to the following requirements:
- only dry abrasive shall be used
- silica abrasives shall not be used.
Subject to the Company's approval, limited surfaces may be cleaned by
mechanical or hand brushing in accordance to ISO 8504-3. Welding slag and
spatter, residual flux, and any other foreign body not removed at the previous
fabrication stage and found before or during blast cleaning shall be eliminated
using an appropriate mechanical tool; sharp corners shall be rounded off.
Blast cleaning may not be carried out in night time unless as preliminary
cleaning or when performed inside factory buildings.
All blast cleaned surfaces shall be coated within four hours from the blast
cleaning.
Blast cleaning shall be extended for a distance of 2.5 cm (1 in) on the nearby
surfaces alreay coated. Acids, detergents in solution, or solvents may not be
used to wash the blast cleaned surfaces. This also applies to rust inhibitors.
No blast cleaning may be carried out on wet or damp surfaces nor on surfaces
that may become damp before the coating is applied.
20004.VAR.PAI.FUN
Rev. 0 May 1996
Sheet 11

Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato
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2.2.5 Spray metallizing processes
The different spraying techniques are listed here and a comparison is given.
2.2.5.1 Flame spraying
The material to be sprayed is brought into a flame which burns compressed gas
and oxygen. Particles are accelerated by an air jet.
2.2.5.2 Gas-explosion spraying
The material to be sprayed is placed with oxygen and acetylene into a gun
where an explosion takes place at intervals. The particles are thus heated and
projected onto the substrate.
The process is applicable to powders of any material. The temperature
obtainable is relatively low (4700 K), but spraying speed is very high, well in
excess of the one obtainable by the other spraying methods. The coatings show
good adhesion and density values.
2.2.5.3 Arc spraying
The material to be deposited is supplied as metal wires that constitute two
electrodes between which an arc is struck. Particles are accelerated by a gas jet.
This process is suitable only for metallic materials, electrically conductive.
A 6000 K temperature is obtained, overheating the particles and a strong gas
absorption may take place. Problems may arise due to difference in
temperature between the cathode (hotter, producing smaller particles) and the
anode (colder, producing larger particles). This process is the most economical
one.
2.2.5.4 Plasma spraying
The material to be sprayed is brought as powder into a plasma jet. The particles
are accelerated and melted by the jet thrust and temperature. Very high
temperatures are obtained (up to 15000 K) allowing the spraying of refractory
materials. It is anyway necessary that the evaporation temperature of the
material be at least 300 K higher than its fusion one, in order to avoid particle
vaporization. The substrate can be kept at low temperature (even below
100C), thus allowing deposition also on polymers. The wide difference in
temperature of the particles (fused or almost fused) and of the substrate causes
fast cooling (10
3
10
7
K/s) allowing metastable phases to form.
20004.VAR.PAI.FUN
Rev. 0 May 1996
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Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato
This document is CONFIDENTIAL and the sole property of AGIP . It shall neither be shown to third parties nor used for purposes other than those for which it has been sent.
2.2.6 Sealer application
All the surfaces must be perfectly clean and free from oil, grease and/or
residues.
Paints and solvents shall be supplied in their original containers accompanied
by the Supplier's Technical Data Sheets.
The Supplier's indications shall be observed, giving special attention to :
- choice of solvents
- mixing instructions
- time required for the paint to dry before another coat layer can be applied
- equipment required for paint application.
Once the time limit for application is reached, the spraying equipment shall be
emptied, the leftover material scrapped, the equipment cleaned and filled with
new product.
All paint spraying equipment shall be inspected and approved by the Customer
before any application work is started.
Filters shall always keep oil or water from entering the air circuit.
Paints containing heavy or metallic pigments that tend to settle shall have these
kept in suspension by a mechanical mixer acting within the pressurized tank.
The spray gun shall be kept at a distance of 45 cm min and 60 cm max from the
surface to be painted, and always at a right angle to the surface. Spraying
passes shall be uniform and parallel.
Each pass shall overlap the preceding one by approx. 50%.
All drippings and overspraying shall be removed at once using a brush, the
paint shall be removed and the surface repainted.
2.3 Safety
It is the Contractor's duty to observe the regulations on safety and health
preservation applicable to his premises. Special consideration is to be given to
the following:
- painting products mixing and handling shall be performed in areas where air
can circulate freely and that are distant from zones of danger;
20004.VAR.PAI.FUN
Rev. 0 May 1996
Sheet 13

Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato
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- the abrasives for blast cleaning shall be chosen among those not harmful to
operators' health.
The paints storerooms shall be appropriately ventilated and complying with
applicable law provisions on safety and fire prevention.
All paints, solvents, fluidizers, catalysts, etc. shall bear on their container the
data required by the Decreto Ministero della Sanit (Health Ministry Decree)
N 50 of 16 February 1993, and/or be accompanied by the relevant safety data
sheets mentioned in that Decree.
In Countries other than Italy, these regulations may be complemented,
integrated or substituted by applicable local Laws and regulations .
2.4 Ergonomics
Not applicable.
2.5 Requirements for Quality Management and Quality Assurance
The additional requirements for Quality Management and/or Quality Assurance
are contained in the applicable Quality and Execution Requirements
Specification attached to the Invitation to Bid.
2.6 Additional Requirements for Review
2.6.1 Assistance by the Supplier of coating products
The Supplier of coating materials shall provide assistance to the job, and:
- shall check and certify that the surfaces of components were correctly
prepared;
- shall supervise coating application and certify its correctness.
In connection to this, the Supplier, acting jointly with the Contractor, shall
appoint, subject to the Companys agreement, an independent third Party as
Supervisor of all operations.
20004.VAR.PAI.FUN
Rev. 0 May 1996
Sheet 14

Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato
This document is CONFIDENTIAL and the sole property of AGIP . It shall neither be shown to third parties nor used for purposes other than those for which it has been sent.
2.6.2 Reception of the coating materials
The Contractor shall ensure that purchased products comply with the
requirements specified.
The Contractor shall purchase the products to be used for coating from
Suppliers qualified by the Company.
The Contractor shall file and retain all the technical and administrative
documents related to the purchase, both those issued by himself and by the
Supplier, for at least 3 years.
All coating materials shall be delivered on the job site in their original factory
containers with intact labels and seals. The containers shall be provided with
identifying documents or inscriptions, stating clearly their content and its
validity expiry date.
The containers shall be stored in a closed, well ventilated storeroom, observing
the range of allowable temperatures recommended by the Supplier.
2.6.3 Production process control
The Contractor shall possess an appropriate organization able to perform the
following functions:
- prepare written work instructions describing how operations are to be
performed, the proper equipment to be used, the adequate work
environment, and the compliance with reference Standards and codes and
with the Companys requirements.
- monitoring and checking of specific characteristics of the process and of
application.
2.6.4 Checks, inspections and testing
2.6.4.1 Preliminary tests
Upon arrival of a load of coating materials, the Contractor shall provide to
verify:
- the integrity of the containers;
- the date of expiry of validity for the materials;
- correspondence of the shipping documents with the identification of the
containers.
20004.VAR.PAI.FUN
Rev. 0 May 1996
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Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato
This document is CONFIDENTIAL and the sole property of AGIP . It shall neither be shown to third parties nor used for purposes other than those for which it has been sent.
The storeroom where the materials will be placed shall be checked to ensure a
constant temperature of +20C (5 C) and adequate air flow.
2.6.4.2 Inspection and tests during work progress
The Contractor shall perform at the start, middle, and end of every work shift a
check of ambient temperature and relative humidity using appropriate
instruments, and calculate the probability of moisture condensation according
to ISO 8502-4 Standard; the values shall all be recorded in the relevant work
log book section.
When surface preparation is completed, appropriate checks must be carried out
in order to ensure that the substrate is adequate for the subsequent coating
operations:
- visual check: shall be performed in accordance to ISO 8501 - 1 Std.; the
substrate finish shall be as specified in the Suppliers Technical Data Sheets.
- dust level check: shall be performed in accordance to ISO 8502-3 Std., the
number of checks shall be established by agreement with the Company,
depending on the surface and homogeneousness of the component
examined; acceptance level per class 1.
- surface roughness test: shall be performed according to ISO 8503-1 and
8503-2 Standards, using the "comparator method; the number of tests shall
be established by agreement with the Company, depending on the surface
and on the homogeneousness of the component; the acceptance level shall
be the "medium" one. As alternative, the "stylus method" of ISO 8503-4
Std. may be used.
- check of welding flux removal: when requested by the Company, the pH
value of the surface near the welded joints shall be checked, wetting the area
and applying litmus paper; acceptance level is neutral pH.
The following tests and checks must be performed before and during
application of the coating:
- check of the wet paint thickness; while paint coats are being applied, the
Contractor shall sistematically check the wet paint thickness using a "comb
type" (Rosemann) or a "wheel type" (Gardner and Erichsen) measuring
instrument.
2.6.4.3 Final Inspection
Once the coating application is completed, and the film has fully hardened, the
following checks shall be performed:
20004.VAR.PAI.FUN
Rev. 0 May 1996
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Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato
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- thickness check: groups of 20 measurements shall be carried out on surface
parts, their number to be agreed with the Company depending on the surface
and the homogeneousness of the component; the average value, obtained
discarding the highest and lowest value measured shall not be less than the
design thickness value;
- visual check: the coated surface shall be 100% inspected visually; for
acceptance it is required that no paint runs, foreign bodies, orange peel,
oxidized or deteriorated areas are present.
2.6.5 Warranties and final acceptance
Final acceptance of the coating is given upon satisfactory result of a visual
check that will take place one year after completion of the coating. The
Supplier shall give joint warranty with the Contractor to this purpose.
The acceptance criterion is the absence of traces of corrosion or of deterioration
of the coated component, that can be attributed to defects in the coating or to a
defective application of it. Any exfoliation, whatever small, is equivalent to a
deterioration.
No deterioration is acceptable; the Contractor is invited to ascertain the ones
found and to provide for repair as soon as possible.
2.7 Documentation
2.7.1 Documents to be submitted at the start of work
Prior to starting activity the Contractor shall submit to the Company the
following documents:
- plan and schedule of operations for surface preparation and coating;
- characteristics and location of the place where coating materials will be
stored;
- planning of controls to be performed before, during and at the end of
operations;
- type of products to be used.
20004.VAR.PAI.FUN
Rev. 0 May 1996
Sheet 17

Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato
This document is CONFIDENTIAL and the sole property of AGIP . It shall neither be shown to third parties nor used for purposes other than those for which it has been sent.
2.7.2 Documents to be submitted during work progress
While work is in progress the Contractor shall keep a Work Data Log, that shall
be available at all times to the Company, and record in it all the following
information:
- temperature, humidity and dew point measurements performed at the start,
middle and end of every work shift;
- tests performed during operations and their results;
- order progress status.
Technical data sheets of coating materials also shall be always available.
2.7.3 Documents to be submitted at the completion of work
When work on the order is completed the Contractor shall prepare a final report
including in it:
- surface preparation characteristics;
- trade name and characteristics of the paints used;
- quality certificates of the paint materials, divided by manufacturing batches;
- number of coating layers applied;
- atmospheric conditions;
- inspections and tests performed and the relevant results, inclusive of the final
acceptance tests;
- if and what repairs were made.