PROJECT REPORT

PREPARED BY : ANAS HAKIMI BIN KORI

MATRIC NUMBER : 9431
WEEK NO : 19

DATE BRIEF DESCRIPTION OF ACTIVITY

4/10/2009 – 5/10/2009  To learn about painting. The painting is applied at equipment G2-101A
(Feed Gas Filter - sweating surface) and G2-301B (Mercury Removal Filter
– dry surface)

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 DETAIL REPORT

PREPARED BY: ANAS HAKIMI BIN KORI WEEK NO: 19

Objective(s) of the activities:

1. To learn some basics of painting, on the dry and wet equipment’s surface.
Contents:
To Learn Some Basics On Painting Used in Oil & Gas Industries (Small Scope: PGB POD)
This is a special project given by INSA Manager, Mr Abu Bakar to all the practical students in INSA. The
objective is for the interns to learn some basics of painting used in Oil & Gas Industries. This project is in
accordance with the painting activity that is running at GPP-2 at equipment G2-101A, M2-351, G2-301A
and M2-301.

In every activity, the most important document is the Code & Standards which is needed for engineering
reference. In painting activity, these three documents are mandatory:
a) PTS 30.48.00.31 – PETRONAS Technical Standards for Protective Coatings and Linings
b) SSPC – Steel Structures Painting Councils’ Specification
c) NACE – National Association of Corrosion Engineers
Generally, painting activity will involved surface preparation, painting application and inspection
activities. The procedure is prepared by contractor and approved by owner (PGB). Before proceed further,
I would like to introduce some basic terms and the apparatus used throughout the painting procedure.

TERMS:
a) Surface Profile – The shape of a cross-sectioned power-tool-cleaning finish
b) DFT – Dry film thickness – The thickness of dried painting film
c) WFT – Wet film thickness – The thickness of wet painting film
d) RH – Relative humidity – A term used to describe the amount of water vapor exists in a gaseous
mixture of air and water
e) DP – Dew point – The temperature of metal surface that will be sweating
f) Wet Bulb Temperature – Lowest temperature that can be reached by the evaporation of water only
g) Dry Bulb Temperature – Normal air temperature

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APPARATUS:
a) Power Brush (grinding machine)
b) Paint Thickness Gauge
c) Hygrometer (Relative Humidity Gauge)
d) Paint Brush
e) The Paint

Paint Thickness Gauge Hygrometer

G2-301B MERCURY REMOVAL FILTER

Referring to the attached drawings, the location of pipe to be painted is inside the G2-301B skirt. Here is
the details of equipment:
a) Material: SA-234 and SA-106-B
b) Design temperature: 50oF (10oC)

Painting
How do select painting process? How do we determine whether it is SSPC-SP3 or SSPC-SP2?
1) The painting is applied at the external side of pipe, we shall use PTS 30.48.00.31 Section 6.2,
Painting and Coating System Schedules For External Application.
2) Check the material of the surface that will be painted. In this case, the material is SA-234 and SA-
106-B. Referring to ASME VIII Division 1, Table UCS-23 (Carbon and Low Alloy Steel) these
2 materials are carbon and low alloy steel. (please see drawing)
3) Check the insulation. The pipe is non insulated.

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 4) Check the design temperature. The design temperature is 50oF (10oC). Now the only scope left is
PTS 30.48.00.31 Section 6.2.1, Carbon Steel Design Temperature < 110 oC NON
INSULATED in the Atmospheric Zone. (please see drawing)
5) Check whether this painting is the initial or maintenance painting. This is the maintenance
painting.
6) Check the compatibility of the surface preparation. Since blast cleaning is not compatible in the
plant, we shall choose PTS 30.48.00.31 Section 6.2.1.3 Coating System No. 1C: Maintenance
Painting for Power Tool Cleaned Surface.

Table 19.1: Coating system No.1C, as per PTS 30.48.00.31

COAT DESCRIPTION PRODUCT COLOUR VOLUME DFT OVER THINNER

TYPE NAME GROUP SOLID (µ) COATING
(VS) % INTERVAL AT
40OC MIN-MAX
1st coat Surface Tolerant Interseal Grey 82 125 6Hr – Ext International
Epoxy 670HS GTA220
2nd coat Surface Tolerant Interseal Grey 82 125 4Hr –2Wk International
Epoxy 670HS GTA220
3rd coat Polyurethane Interthane Color 57 50 3Hr-Ext International
990 Range GTA713
Total 300

Table 19.2: Contractor’s detail of painting at G2-301B

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 G2-301B, before cleaning G2-301B, during cleaning

G2-301B, after cleaning G2-301B, after painting

G2-101A FEED GAS FILTER

Referring to the attached drawings, the location of pipe to be painted is inside the G2-301B skirt. Here is
the details of equipment:
a) Material: SA-106-C
b) Design temperature: 50oF (10oC)

This painting project requires special coating as the part that will be painted is sweating line. Proper
coating type as well as adequate ventilation is needed to achieve the desired DFT. This equipment is using

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modified epoxy. The product use is Interzone 954. The DFT that shall be achieved is 400µ. The
specification is as below:
COAT DESCRIPTION PRODUCT COLOUR VOLUME DFT OVER THINNER
TYPE NAME GROUP SOLID (µ) COATING
(VS) % INTERVAL AT
40OC MIN-MAX
Full coat Modified epoxy Interzone Pearl Grey 85 400 3Hr – 5D International
954 GTA220

Table 19.3: Contractor’s detail of painting at G2-101A

As mentioned by the Manufacturer, Interzone 954 has the specialty to cure when immersed in water.
Surface preparation is as SSPC-SP2. The surface to be coated is cleaned and freed from contamination.
Also, the application of painting is done 2 days as the painting work is using paint brush. As mentioned
by Manufacturer;
a) When applied by paint brush, typically 100µ to 150µ of DFT is achieved
b) When applying Interzone 954 by brush or roller, it may be necessary to apply multiple coas to
achieve the total specified DFT.
However, practically, it will depend on the calculation of the Painting Inspector. In this case,
minimum DFT 400µ had been achieved after painting work is carried out twice.

G2-101A, before cleaning G2-101A, after power brushed

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 G2-101A, after painting

As per PTS 30.48.00.31 Section 5.2, painting is not permissible to be applied when the following
conditions occur unless recommended by Manufacturer and accepted by Owner:
a) The surface temperature is less than 3oC above the dew point
b) The surface temperature is below 5oC
c) When the relative humidity is above 85%
d) The metal surface temperature is higher than that recommended by Manufacturer
e) Surface preparation has not been completed
f) Poor weather condition for painting exist within 2 hours of application

INSPECTION:
As per PTS 30.48.00.31 Section 8.2.2, Painting Inspector is the one that is responsible to ensure the
quality of all aspects of painting is in accordance with the painting specification. Painting Inspector is
responsible to witness, verify, and document the various inspection points:
a) Pre-surface preparation inspection
b) Measurement of environmental conditions
c) Evaluation of compressor and surface preparation equipment
d) Determination of surface preparation cleanliness and profile
e) Inspection of application equipment
f) Witnessing paint mixing
g) Determination of wet film thickness (WFT)
h) Determination of dry film thickness (DFT)

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 i) Evaluating cleanliness between coats
j) Pinhole and holiday testing
k) Adhesion testing
l) Evaluating the curing of applied paints
m) Any other coating related activities

Surface Preparation Inspection

As mentioned earlier, surface preparation method depends on the painting procedure as mentioned in the
PTS 30.48.00.31. For this project, for G2-301B, SSPC-SP3 is applied (SSPC-SP3 is the same as ISO
8501-1 ST3). SSPC-SP3 is thorough hand and power tool cleaning. When viewed without magnification,
the surface shall be free from visible oil, grease and dirt, and from poorly adhering mill scale, rust, paint
coatings, and foreign matter. The surface also has to give a metallic sheen arising from the metallic
substrate.

Dew Point and Relative Humidity Measurement

What is Dew Point? Dew Point is the temperature that the metal surface will start to sweat. That is why
the code said that the surface temperature should be 3oC above the sweating temperature (dew
point).

To determine the Dew Point and the percentage of Relative Humidity, the steps are as below:
1) Using Hygrometer, measure the dry bulb and wet bulb temperature.
2) After getting both reading, find the difference to get wet-bulb depression.
3) Using Psychrometric Chart to get the RH and DP.

For example:
Surface Temperature = 26oC

Wet Bulb Temperature = 22oC

Dry Bulb Temperature = 26oC
Wet Bulb Depression = DBT – WBT
= 4oC

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Referring to the Psychrometric Chart, the value of RH=71% and DP=20oC
Therefore, the minimum surface temperature allowed to be painted is 20oC + 3oC = 24oC
The RH is 71%, which is less than 85%

“The surface temperature not is below 5oC”  ACCEPTED

“The surface temperature is not less than 3oC above the dew point”  ACCEPTED
“When the relative humidity is not above 85%”  ACCEPTED

.: Therefore, the surface is accepted to be painted

Dry Film Thickness Measurement

To determine DFT, Painting Inspector need to determine the WFT of the painting once after the painting
work is finished and after the determined drying time is up. The measurement is by using Paint Thickness
Gauge (namely, the common tool used is called Elcometer). The difference between wet film thicknesses
is the Dry Film Thickness.

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Table 19.4: Table UCS-23 – Carbon and Low Alloy Steel, extracted from ASME VIII, Division 1 (2007)

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Table 19.5: Psychrometric Chart

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Verified by (Plant Supervisor): SHAHRULLIZAM SHAHID

Initial:

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