INTEGRATED GAS SURFACE FACILITIES FOR RDG FIELD

Document QCP PAINTING ON METAL SURFACES (SHOP & FIELD) APPLICATION

Title:
Total No of pages: Purchase Order Number:
- 22 JI2041/24-002

Supplier Own Document Number Rev Date Supplier approval name & signature
NPES/RDG/PRO-0001 A2 25-09-2019

SUBMITTED FOR:
Supplier Name: NAPTUNE POWERTECH ENERGY
INFO REVIEW SERVICES

Review does not constitute acceptance of Package Description: STRUCTRAL,MECHANICAL & PIPING
design details, calculations, test methods or INSTALLATION WORKS
materials developed or selected by supplier, nor
does it relieve supplier from full Compliance Package Code: R272PFCL30B
with contractual or other obligations.
Tag Nos: N/A

Model
Type Nos: N/A

Cairn Document Number: Rev

R272PFCL30B-RDG-Q-PRO-0001 A2

Petrofac
Status Approval Code Description
Code
APPROVED MAY PROCEED FOR CONSTRUCTION / FABRICATION /
 1 IMPLEMENTATION.
REVISE AND RESUBMIT FOR REVIEW / APPROVAL MAY PROCEED FOR
 2 CONSTRUCTION / FABRICATION / IMPLEMENTATION.
 3 REJECTED, REVISE AND RESUBMIT FOR REVIEW / APPROVAL.

 4 FOR INFORMATION ONLY

 V VOID

Reviewing Engineer’s Full Name (IN BLOCK LETTERS), Sign and Date
Name: Sign: Disp.: Date:

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Doc. No: R272PFCM32-RRX-M-PRO-0001
R272PFCL30B-RDG-Q-ITP-0001Rev A2

QCP for PAINTING ON METAL SURFACES (SHOP & FIELD) APPLICATION

1.0 PURPOSE ...................................................................................................................................................... 4

2.0 SCOPE ........................................................................................................................................................... 4
3.0 DEFINITIONS / ABBREVIATIONS................................................................................................................. 4
4.0 REFERENCES ............................................................................................................................................... 5
RESPONSIBILITY & AUTHORITY ...................................................................................................................... 5
Painting Supervisor ......................................................................................................................................... 5
QC Inspector (QCI) ......................................................................................................................................... 5
Storekeeper .................................................................................................................................................... 5
DESCRIPTION OF ACTIVITIES .......................................................................................................................... 5
General ........................................................................................................................................................... 6
Safety ............................................................................................................................................................. 6
Material Approval ............................................................................................................................................ 7
Storage of Materials ........................................................................................................................................ 7
Surface Preparation ........................................................................................................................................ 8
Blast Cleaning Standards ............................................................................................................................. 10
White Metal Blast (SSPC SP5): ................................................................................................................ 10
Near White Metal Blast (SSPC SP10): ..................................................................................................... 10
Commercial Blast (SSPC SP6) ................................................................................................................ 10
Brush off Blast (SSPC SP7): .................................................................................................................... 12
Power Tool Cleaning (SSPC SP3)............................................................................................................ 12
Hand Tool Cleaning (SSPC SP2) ............................................................................................................. 12
Solvent Cleaning (SSPC SP1) .................................................................................................................. 12
Paint Mixing .................................................................................................................................................. 12
Weather Conditions ...................................................................................................................................... 13
Masking......................................................................................................................................................... 14
Pre-coating Checks ...................................................................................................................................... 15
Painting ......................................................................................................................................................... 15
Primer Coat Application ................................................................................................................................ 16
Intermediate & Top Coat Application ............................................................................................................ 16
Tape Wrapping ............................................................................................................................................. 18

CONTENTS

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 ENGINEERING

INTEGRATED GAS SURFACE FACILITIES FOR RDG FIELD

PROJECT
Doc. No: R272PFCL30B-RDG-Q-ITP-0001
R272PFCM32-RRX-M-PRO-0001 Rev A2

QCP for PAINTING ON METAL SURFACES (SHOP & FIELD) APPLICATION

Coating of Tank Internal Surfaces ................................................................................................................ 18

Repair of Damaged Coating ......................................................................................................................... 19
Identification Marking – Job Stencil .............................................................................................................. 19
Storage and Transportation of Painted Pipes/Spools ................................................................................... 20
Testing and measuring equipment ............................................................................................................... 20
7.0 RECORDS ................................................................................................................................................... 21
8.0 APPENDICES .............................................................................................................................................. 22

Notes:

This document and referenced ITRs shall be applied to Construction/Inspection & Test activities
carried out on E&C Project Sites.

This document is based on widely used international codes, standards and good engineering practice
that is applied in Oil & Gas Projects and is intended to highlight the minimum tests and inspections
that ensure quality requirements are fulfilled within the scope of the document.

This document and referenced ITRs are generated to provide guidelines to PetrofacE&C Project
teams including their sub-contractors during preparation of project specific QCPs/ITRs and shall be
customized to meet specific requirements based on applicable project specifications and/or other
statutory and regulatory requirements. It may also be utilized at bidding/proposals stage.

In case of any conflict between this document and the Project specification, drawings and applicable
codes, the project specification shall take precedence over this QCP and applicable ITRs.

The referenced Inspection and Test Records (ITRs) are controlled independently. Therefore, the
latest revision of these ITRs, at the time of initiation, shall be utilized.

ITR number suffixed with letter “X” are classified as in-process Site/Field Quality Records and will not
be part of the Turnover System Process where as ITR number suffixed with letter “A” are part of the
Turnover Process and Turnover Records.

When filling ITRs do not leave any blanks. If an item/activity is not applicable, denote as N/A.

Use of Blanco, Tipp-ex etc. on ITR is forbidden.

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R272PFCM32-RRX-M-PRO-0001 Rev A2
R272PFCL30B-RDG-Q-ITP-0001

QCP for PAINTING ON METAL SURFACES (SHOP & FIELD) APPLICATION

1.0 PURPOSE
The purpose of this procedure is to define the coating application methodology, the associated
inspection and documentation requirements for underground and above ground shop and field
coating works. This procedure provides general guidelines. The coating application is more
specifically governed by project specifications and paint manufacturer recommendations. In
case of conflict between the requirements of this procedure and project specifications, the
project specifications shall prevail.

2.0 SCOPE
This procedure covers the Quality Control requirements for coating applications on metallic
surfaces that constitute permanent works for the project and shall be implemented by Sub
Contractor and their sub -contractor(s) if any and are applicable to underground and above
ground coating activities carried out at the painting-yard and field. This procedure does not
cover painting on concrete surfaces/structures.

3.0 DEFINITIONS / ABBREVIATIONS

Company : Vedanta Limited

PMC : Worley Parsons India Ltd

Contractor: Petrofac International UAE LLC

SC or Subcontractor Naptune Powertech Energy Services

Project : Integrated Gas Surface Facilities for RDG Field Project

QCP : Quality control procedure

ITP : Inspection and test plan

ITR : Inspection and test record

QCI : Quality control inspector

DFT : Dry film thickness

WFT : Wet film thickness

MSDS : Material safety data sheet

PDS : Product data sheet

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R272PFCM32-RRX-M-PRO-0001
Doc. No: Rev A2
R272PFCL30B-RDG-Q-ITP-0001

QCP for PAINTING ON METAL SURFACES (SHOP & FIELD) APPLICATION

4.0 REFERENCES
R272PFC-RRX-MT-SP-0001 : Spec for External Paint
R272PFC-RRX-MT-SP-0003: Spec for Internal Lining
CAIRN-TSG-L-SP-0005 : Specification for Painting (Piping & Structural)
CAIRN-TSG-L-SP-0014 : Specification for Coating and Wrapping of Underground
Piping with Operating Temperature upto 120°C

SSPC : Steel Structures Painting Council

RESPONSIBILITY & AUTHORITY

Painting Supervisor
The Painting Supervisor shall be responsible for ensuring preparation of surfaces to be
coated correctly, application of paint in accordance with the project specifications, this
procedure, approved Method Statements and the paint manufacturer’s recommendations.
Furthermore, the Painting Supervisor shall complete the painting forms as indicated in the
attached forms and ensure that they are endorsed by the responsible party, some of the
inspection activities shall be carried out by Painting Supervisor/QCI at the appropriate stages
of the in- process paint inspection activities.

QC Inspector (QCI)
QCI shall ensure through monitoring and surveillance that all painting works are executed in
accordance with the Project specifications and are inspected accordingly. QCI shall also
ensure through surveillance that storage conditions for paint material are being maintained as
per manufacturers’ recommendations by the respective in-charge personnel. QCI shall also
be responsible for reporting non-conformances if any and in consultation with QC Engineer
shall raise a NCR if required. Extra vigilance is required that no underground piping is buried
under backfill prior to inspection and subsequent release.
Storekeeper
Storekeeper shall be responsible for ensuring that all paint materials are stored safely and all
manufacturers’ recommendations are followed. Expired paint material shall not be allowed to
be kept in the stores premises. A wall mounted thermometer shall be available in the stores
premises to constantly monitor and ensure that temperature and humidity conditions are
acceptable per manufacturers’ standards.
DESCRIPTION OF ACTIVITIES

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QCP for PAINTING ON METAL SURFACES (SHOP & FIELD) APPLICATION

General
a. The applicable coating system for a given application is identified in the Coating Schedule
as per Project Specification. The painting supervisor shall ensure the correct coating
system is selected for the intended purpose.

b. For underground coating works, it is recommended that the coating manufacturer's

technical representative witness the demonstration application of each coating system
prior to start of production work.

c. Manufacturer instructions shall be followed for application of tape wrapping on joints,

flanges, etc on buried piping and on pipe spools that penetrate through concrete
structures. Wrapping shall be carried out after application of coating. Proper overlapping
shall be ensured and voids, gaps are not acceptable.

d. The general guidelines indicated here are applicable to the lining works on tank internal
surfaces as well. Approved coating manufacturer’s instructions and approved product
data sheet requirements shall be duly adhered to.

e. For lining/coatings such as Fusion Bonded Epoxy (FBE), 3-Layer Polyethylene Coating
(3LPE), etc that requires a special technique/process, manufacturer/vendor instructions
shall be implemented. The application is usually carried out by qualified personnel under
the supervision of manufacturer/vendor representative.

f. Painting personnel must have previous experience in the use of the specified blasting and
painting tools and equipment. They shall also be well acquainted with the technique of
measuring WFT & DFT during their routine work. The painting supervisor/s shall work
closely with other disciplines such as piping, insulation and civil in order to achieve
smooth functioning and avoid costly rework necessitated by poor inter-departmental
coordination efforts. Only skilled painting technicians shall be deployed on site.

g. QCI shall be competent, experienced and certified personnel.

Safety
a. All works shall be carried out in accordance with MSDS, manufacturer(s)
recommendations and project safety requirements.

b. Personal Protective Equipment (PPE) shall be worn at all times. A protective hood with a
positive fresh air supply shall be used during blast cleaning operations.

c. A filter type dust mask shall be used during hand tool or power tool cleaning operations in
enclosed areas or in other situations where excessive concentrations of dust are
produced.

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d. Protective clothing such as gloves, goggles, and aprons should be worn during solvent
cleaning operations. Hands should be cleaned with a waterless hand cleaner after
exposure to solvents. Clothing or protective equipment that is wet with solvents or paint
should be promptly removed and laundered before re use.

e. Particular care must be exercised when working in close or confined spaces, especially
when spraying. It shall be ascertained that all necessary tests have been made for
oxygen sufficiency and hydrogen sulfide. The threshold limit value (TLV) prescribed by
OSHA for the particular solvent vapor in the air shall not be exceeded unless fresh air
masks are supplied to workmen. When volatile solvents are flammable, the concentration
in the air shall be kept to one quarter or less of the lower explosive limit (LEL) by
adequate exhaust or ventilation facilities. All blast cleaning equipment shall be maintained
in good working order and shall be inspected regularly.

f. All operators shall receive adequate training and be fully competent in the use of
equipment for surface preparation, as well as airless spray application devices, before
being allowed to operate such equipment.

Material Approval
a. The abrasive material (shot, grit, garnet, etc) to be used shall be approved prior to usage
in production. Prior to start of production blasting operations, Sub-contractor shall
demonstrate to the satisfaction of Contractor that the selected abrasive provides the
specified anchor profile and surface cleanliness. This shall be done by blasting a
representative piece of steel and measuring the anchor profile, in accordance with ASTM
D4417 Method C and/or comparing the surface cleanliness to the appropriate visual
standard. Any changes in the abrasives or grit size shall qualify in the same way prior to
usage. The test shall be witnessed by Contractor.

b. Caution should be used while selecting abrasives, since some contain trace quantities of
undesirable materials. A non-toxic or low toxicity abrasive should be used.

c. Only paint and painting materials approved by COMPANY shall be used. These materials
shall be delivered to the job site in sealed and labeled containers. The label of each can
of paint shall include batch number, expiry date, shelf life, and color code.

d. If considered necessary, the presence of paint manufacturer’s representative shall be

arranged for demonstration and first time application.

Storage of Materials

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QCP for PAINTING ON METAL SURFACES (SHOP & FIELD) APPLICATION

a. All blasting materials shall be kept dry. With the exception of expendable abrasives,
blasting abrasives may be reclaimed and used after approval and as per the
manufacturer’s procedure and in accordance with project specifications.

b. Different abrasive materials shall not be allowed to mingle and shall be stored separately.

c. The paint containers shall be stored in a location that is protected from the elements, well
ventilated and free from excessive heat, open flame, or other sources of ignition. Paint
materials susceptible to freezing shall be stored in a heated area.

d. The date of manufacture shall be clearly marked on each paint container, and paints that
have exceeded their shelf life shall be discarded. The same shall be monitored on a
regular basis in conjunction with the paint manufacturer instructions.

e. Paints and thinners shall be stored in areas that are well ventilated, and as specified by
the paint manufacturer.

f. Coating materials shall be used on “First in-First out Basis” and no coating materials shall
be used after expiry of shelf life.

g. Paints that show signs of leakage or have gelled shall be discarded and any skins that
have formed shall be cut and removed prior to application.

h. Discarded paint, empty paint buckets, thinners, or any rags, cloths etc., shall be
discarded into containers and hauled off to an approved dumping site.

i. Each batch of paint or thinner used shall be accompanied by a material certificate from
the respective manufacturer. Any paint or thinner arriving on site without material
certificate shall not be used until such time certification has been obtained.

j. For underground painting materials, storage conditions should be in accordance with

manufacturer(s) recommendations and as specified by Project specification.

Surface Preparation
a. Steel surfaces shall not be blasted when the surface temperature is less than 3°C (5°F)
above the dew point, relative humidity is greater than 85 percent, or there is a possibility
that the blasted surface will be subject to wetting before the first coat of primer can be
applied. Surfaces shall be blown, wiped, or vacuumed free of blasting abrasive and dust
before they are primed.

b. Abrasive blast cleaning is the preferred method of surface preparation; it shall be used
except in hazardous areas where blast cleaning is not permitted.

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c. Since freshly blasted surfaces are subject to immediate corrosion, particularly in areas of
high humidity or salt atmospheres such as marine environments, no more surfaces shall
be blast cleaned than can be prime coated before visible or detrimental re-rusting occurs.

d. A 300 mm (12 in.) wide strip of uncoated, blasted surface shall be left between primed
and un-blasted surfaces to prevent damage to the newly dried coating when additional
blasting is done. When blast cleaning is resumed, the 300 mm strip of previously blasted
surface shall require only a light brush blast to remove any rust that may remain.
Cleaning shall be accomplished by directing the cleaning nozzle away from the coated
surface.

e. Blast cleaning equipment shall be checked regularly to ensure that the air pressure is
adequate and that the air is free from oil or water contamination. Traps and filters shall
also be checked and cleaned regularly.

f. Wet blasting may be used when air pollution problems preclude the use of dry blasting.
The blasted surface shall be treated with a corrosion inhibitor to minimize re-rusting. The
compatibility between a corrosion inhibitor and a particular paint product shall be
confirmed with the paint manufacturer.

g. Prior to painting, all surfaces shall be thoroughly cleaned of any material that may result
in premature failure of the coating. The method of surface preparation used shall be
compatible with the priming coat of paint and shall be one, or a combination, of the
methods described in this procedure. For general surface preparation procedures and
requirements, the SSPC Steel Structures Painting Manual (Volumes 1 and 2) shall be
used as a reference.

h. The area where blast cleaning is to be done should be barricaded to keep out
unauthorized personnel. Silica sand shall not be used due to the possible personnel
health hazard from ingested silica dust.

i. Visible oil and grease and soil shall be removed by solvent cleaning. The area shall be
washed in chloride-free, clean fresh water and allowed to dry before conventional (air
blast) cleaning, automatic (wheel blast) or hand/power cleaning. QCI shall perform
surveillance to ensure cleaning is performed adequately and in accordance with the paint
manufacturer’s requirements.

j. The surface shall be prepared prior to application of primer or paint by abrasive blasting
(paint shop application) or by hand tool/abrasive blasting (field application). The method
of surface preparation shall be recorded on the applicable inspection record.

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QCP for PAINTING ON METAL SURFACES (SHOP & FIELD) APPLICATION

k. The type of abrasive is determined by the profile required and the type of material to be
blasted. The use of steel shot or steel grit is not permitted for blasting of stainless steel.

l. Sub-contractor QCI shall perform surveillance of pre-blast and blasting operations. Once
the blasting is completed for one batch, Subcontractor QCI shall use testex tape and
measure the profile and this shall be witnessed by Contractor QCI as per ITP
requirements. The result shall be recorded and the testex tape shall be attached to the
applicable inspection record.

m. After blast cleaning, the surfaces shall be kept free from oil, grease, dirt, etc. until the
coating has been applied. Surfaces shall be prime coated within 4 hours or before any
visible deterioration of the blasted surface has occurred. Surfaces not meeting the
blasting profile shall be re-blasted prior to coating. Presence of chlorides and iron salts
shall be determined using a salt contamination meter of type SCM-400 or equivalent or as
provided for by project specification.

n. Used abrasive shall be removed from external surfaces using a dry brush and blowing
down with clean dry compressed air.

o. Steel defects revealed during abrasive blasting (slivers, laminations, cracks, pitting etc.,)
shall be reported to Contractor for evaluation. Defects shall be repaired as directed by
Contractor.

p. Identification markings shall be transferred to inside the pipe spools before commencing
the blasting and painting operation. Transfer of markings shall be monitored/witnessed by
Contractor.

q. Pipe ends and fitting ends shall be left uncoated for a distance of 75 mm or as specified
by project specifications.

r. Surface preparation for field weld joints and damaged coating shall be carried out using
hand or power tools in accordance with specification requirements.

s. Stainless steel, high alloy and aluminum surfaces requiring painting shall be abrasive
blast cleaned per SSPC-SP7 performed with either garnet or aluminum oxide abrasive.

t. All carbon steel and low alloy (1 1/4 Cr through 9 Cr) materials shall be abrasive blast
cleaned in accordance with SSPC-SP10 performed with a sharp grade of abrasive. Blast-
cleaned surfaces are required for zinc rich epoxy system, inorganic zinc system and other
systems.

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QCP for PAINTING ON METAL SURFACES (SHOP & FIELD) APPLICATION

u. Abrasive blasting shall not be used on items which could be damaged by such an
operation. Power tool cleaning per SSPC-SP11 to produce an anchor profile of 25 m or
greater may be used for spot area surface preparation.

v. Spent abrasive shall not be re-used without specific permission from Contractor and may
be considered only on a case by case basis.

Blast Cleaning Standards

Blast cleaning involves the removal of mill scale, rust, rust scale, foreign material, or paint
from a surface by the use of abrasives propelled through nozzles or by centrifugal wheels or
by other mechanical means. Prior to blast cleaning, oil and similar matter shall be removed
with a solvent wash.

White Metal Blast (SSPC SP5):

After blasting, the surface shall be free of all dirt, mill scale, rust, corrosion products, oxides,
paint, or other foreign matter; shall have a gray white, uniform metallic color; and shall be
slightly roughened (profile pattern) to form an increased bonding area for coatings. SSPC
Vis 1 (Sa 3) and the equivalent Swedish standards provide a visual reference for
comparison.

Near White Metal Blast (SSPC SP10):

After blasting, the surface shall be free of oil, grease, dirt, mill scale, rust, corrosion products,
oxides, paint, or other foreign matter. Exceptions to this rule include light shadows or
streaks or slight discolorations caused by rust stain; mill scale; oxides; or thin, tight residues
of paint or coating that may remain.

At least 95 percent of the surface area shall be free of all visible residues; the remainder
shall be limited to the slight discolorations noted above. SSPC Vis 1 (Sa 2½) and the
equivalent Swedish standards provide a visual reference for comparison.

Commercial Blast (SSPC SP6):

After blasting, the surface shall be free of dirt, mill scale, weld flux, and foreign matter. Rust
shall have been removed. An irregular light red staining is acceptable, however, provided
wire brushing will not improve the condition. Rust that can be streaked with a brass tool or
popped from a cavity shall be removed. SSPC Vis 1 (Sa 2) and the equivalent Swedish
standards provide a visual reference for comparison.

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QCP for PAINTING ON METAL SURFACES (SHOP & FIELD) APPLICATION

Brush off Blast (SSPC SP7):

After blasting, the surface shall be free of all visible oil, grease, dirt, dust, loose mill scale,
loose rust, and loose paint. Tightly adherent mill scale, rust, and paint are considered tightly
adherent if they cannot be removed by lifting with a dull putty knife.

Power Tool Cleaning (SSPC SP3)

Power tool cleaning involves the removal of loose mill scale, rust, foreign material, or paint
from a surface by use of power operated wire brushes, impact tools, grinders, or sanders, or
a combination of these tools. SSPC Vis 1 (St 3) and the equivalent Swedish standards
provide a visual reference for comparison.

Prior to power tool cleaning, oil, grease, and salts shall be removed by solvent cleaning.
Care shall be exercised in the use of power tools to prevent excessive roughening of the
surface and the formation of ridges and burrs. Excessive power wire brushing of mill scale
produces a burnished, slick surface not suitable for coating.

Only power sanders shall be used when power cleaning of zinc rich primed surfaces is
required prior to application of top coats. Wire brushing produces a burnished surface
detrimental to top coating.

Hand Tool Cleaning (SSPC SP2)

Hand tool cleaning involves the removal of loose mill scale, rust, paint, and loosely adhering
material from a surface by hand brushing, sanding, scraping, or chipping; by the use of other
hand impact tools; or by a combination of these methods. SSPC Vis 1 (St 2) and the
equivalent Swedish standards provide a visual reference for comparison.

Prior to hand tool cleaning, oil, grease, and salts shall be removed by solvent cleaning. Care
shall be exercised to prevent excessive roughening of the surface and the formation of
ridges and burrs.

Solvent Cleaning (SSPC SP1)

The removal of foreign matter (oil, grease, soil, drawing and cutting compounds, and other
contaminants) from a surface by the use of solvents, emulsions, cleaning compounds, steam
cleaning, or similar materials and methods that involve a solvent or cleaning action.

Paint Mixing
Paint shall be mixed thoroughly immediately prior to application. Mixing ratio set by the paint
manufacturer shall be adhered to. Recommended mixers are mechanical stirrers, paddle
mixers, and can vibrators or shakers. If mechanical aids are not available, mixing by hand is
acceptable provided the following procedure is employed:

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QCP for PAINTING ON METAL SURFACES (SHOP & FIELD) APPLICATION

a. For Single Packaged, Ready Mixed Materials: Remove a portion of liquid from the top of
the container and transfer to a clean container. Mix the remaining portion with a clean,
broad, strong paddle. Use a lifting, whirling motion to thoroughly incorporate the heavier
liquid that has settled to the bottom. Replace the removed portion a little at a time,
mixing thoroughly each time a portion is added until the entire contents are of a uniform
consistency. A "boxing procedure" (pouring back and forth several times to clean
containers) will assist in thorough mixing.

b. For Multi-component Materials: Multi-component material shall be mixed in the volumes

provided by the coating manufacturer as “kits”. Kits shall not be “broken or split” without
the written approval of Contractor. Each component, if pigmented, shall be mixed
individually before combining them in the exact proportions specified. When metallic
powder is one of the components, add the powder slowly to the liquid base while mixing.
Continue mixing until the material is smooth and free of lumps. For spray application,
strain mixed materials through fabric or wire mesh.

c. If the paint cannot be mixed uniformly (thick sediments at the bottom etc.), it shall not be
used.

d. Metallic zinc or other dense pigment filled coatings shall be mechanically mixed
thoroughly prior to and during paint application. In field application, applicators must
constantly agitate the paint to obtain homogeneous mix.

e. The pot life of any paint that is indicated in the data sheets shall be carefully noted and
any mixed paint that has exceeded pot life must be discarded irrespective of its apparent
condition.

f. Paint shall be thinned in accordance with the manufacturer's instructions or as called for
in the project specifications. Only thinners of a type recommended by the paint
manufacturer shall be used. Thinners shall only be added under supervision and shall be
thoroughly mixed into the paint. The amount of thinner used shall be measured, not
estimated, and the percentage thinner used shall be calculated and recorded.

g. Improper thinning can result in poor paint or application, which will cause inadequate
paint performance. Also, improper use of thinners can result in increased emissions of
volatile organic compounds (VOCs).

Weather Conditions
a. The Painting Supervisor shall monitor the weather conditions and take measurements
for wet bulb temperature, surface temperature, dew point temperature (for Dew Point
calculations refer to attachment # 2). These, including weather conditions (windy, wet,
dry, and cloudy) shall be recorded on the daily inspection record by the Painting

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Supervisor at the start, during and at end of work. All measuring devices shall be
calibrated and shall bear valid calibration stickers.

b. Any significant changes to weather conditions which may adversely affect the quality of
the paint shall warrant additional readings as per above.

c. Blasting operations shall not commence if the surface temperature is not at least 3C
above dew point temperature. Priming/painting shall only be performed when the
weather conditions are within the requirements of Project specification. An ELCOMETER
disc type calculator or equivalent means should be used to determine the relative
humidity and dew point.

d. QCI shall perform surveillance inspection to ensure the data is collected and recorded
and to ensure blasting and painting operations are performed strictly in compliance with
the requirements of the project specifications.

e. For underground piping the painting subcontractor's supervisor shall verify that the liquid
coal tar epoxy coating has cured before exposure to rain, fog, condensation or dew or
ground wetness.

Masking
a. The bevel of each spool shall be masked to a distance of 50 mm from the bevel prior to
painting. This also applies to bevels in the field where the piping is painted prior to
completion of the welding. The masking of stainless steel requires special chloride free
tape.

b. The Painting Supervisor shall also ensure that the piping identification is maintained
prior to and after painting. This also applies to the straight run pipes.

c. Shop prefabricated spools shall be painted, including welds, except socket welds, seal
welds and Single pass fillet welds and in accordance in the project
specifications/requirements.

d. Welds performed in the field may be painted immediately upon release of the weld joint
for painting except socket welds, seal welds and single pass fillet welds and in
accordance with project specifications and requirements.

e. The Painting Supervisor shall ensure that there is no overspray onto previously painted
surfaces or beyond the application area. If there is danger of inorganic zinc primer
overspray contaminating stainless steel then the stainless steel shall be protected by
suitable means i.e. masking, covering with polythene etc.

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QCP for PAINTING ON METAL SURFACES (SHOP & FIELD) APPLICATION

f. After completion of painting all masking shall be removed and any overspray, dry spray
etc., removed.

g. The QCI shall perform surveillance inspection to ensure proper masking and protection
has been applied prior to start of painting.

h. Masking shall be applied before blasting and coating operations to protect the gasket
surfaces and the pipe or nozzle interior. Surfaces that will be inaccessible after assembly
including the surfaces of lap joint, flanges, nozzle necks, bolt holes shall receive the
complete painting system before being assembled, steel structure bolted connections
shall be primed unless otherwise noted.

i. The outer edge of ring groove flanges and raised face flanges will be blasted and coated
to the upper (outer) edge of the ring groove or the outside edge of the raised portion of
the flange. The entire groove area shall be protected.

j. In addition to the above, areas to be masked and not blasted/painted are: name plates,
couplings, shafts, valve spindles, level gauge glasses, small instruments,
instrumentation tubing, adjacent painted surfaces, interior of equipment, markings, etc.

k. Any paint spots or streaks that may have formed shall be removed on completion of
painting.

Pre-coating Checks
a. After the surface has been blasted and prior to application of any coating, the surface
shall be cleaned either by brushing or by air blowing. Used blasting material shall be
removed from external surfaces using a dry brush or by air blowing. Under no
circumstances shall surfaces that have been contaminated be coated before the surface
has been adequately cleaned.

b. All visible oil, grease and soil shall be removed with an approved solvent prior to coating.
Solvent, cleaning solutions, acid washes, inhibitors shall be approved materials. The
cleaned area shall then be washed in clean, chloride free potable water and allowed to
dry.

c. The compressed air supply shall be checked by the Painting Supervisor to ensure the air
is moisture and oil free. These checks are to be carried out at the start of each shift and
again after lunch (ASTM D4285). If necessary, a cooler shall be installed in the
compressed air line to ensure that compressed air is supplied at a temperature less than
110C. A Digital thermometer also may be used to check the air temperature at the hose
tip.

Painting

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QCP for PAINTING ON METAL SURFACES (SHOP & FIELD) APPLICATION

a. The representative of the paint manufacturer should visit the site at regular intervals to
provide technical support and shall submit a periodic report to Sub Contractor/Contractor
confirming that painting is being carried out in accordance with the requirements and
quality of work is acceptable. An adhesion test may be carried out if necessary.

b. The specific paint systems that shall be used are identified in the Project Specifications.
The application of cold spillage protection coatings shall be in accordance with the
manufacturer’s instructions and data sheets. Application of special coating systems like
glass flake linings, thermally sprayed aluminum, etc shall be in accordance with the
manufacturer’s instructions, MSDS, data sheets and project requirements.

Primer Coat Application

a. Primer coat application shall be as per Project specification and product manufacturer’s
recommendation/data sheets.

b. Prior to application of primer, all difficult to coat areas such as corners edges, and welds
shall be stripe coated with the specified primer.

c. When inorganic zinc primer is used, checks for surface zinc oxide formation shall be
made immediately prior to applying an epoxy topcoat. Any oxide formation shall be
removed either by high pressure cleaning with potable water, or hosing with potable
water and then scrubbing with a soft brush to remove all the zinc salts. The surface shall
be thoroughly dried before applying the top coat.

d. Dry film thickness readings will be taken and calculated as per Project specification and
shall be recorded on the inspection record. This applies to each individual coat. To
control the final thickness of the coats the QC Inspector may use WFT (Wet Film
Thickness) measurements as an indicator for final thickness.

Intermediate & Top Coat Application

a. The paint coats shall be applied as per Project specifications and product manufacturer’s
Recommendations/data sheets.

b. No mixing of different manufacturers coating in any system is permitted. Only approved

paint manufacturer products shall be applied.

c. Paint shall be applied by one, or a combination, of the following methods:

- Brushing.

- Roller coating.

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QCP for PAINTING ON METAL SURFACES (SHOP & FIELD) APPLICATION

- Air spraying.

- Airless spraying.

- Paint mitt (for small diameter piping and similar applications).

d. The method of application shall be governed by the paint manufacturer's

recommendation for the particular paint being applied. For general application
techniques, requirements, and precautions, SSPC PA1 shall be used as a reference. A
stripe coating, if required, is best applied by brush.

e. The method of application of coating shall also be governed by project specifications.

f. Each coat shall be checked for correct average DFT by the QCI or prior to application of
subsequent coat.

g. Surfaces shall not be recoated until the preceding coat has properly dried or cured. The
surface may be considered ready for recoating when the next coat can be applied
without the development of paint film irregularities, such as lifting or loss of adhesion of
the undercoat. However, the minimum or maximum drying or curing time specified by
the paint manufacturer shall be the acceptable recoat period. Paint shall not be force
dried so as to cause checking, wrinkling, blistering, pore formation, or any condition
detrimental to its appearance. Newly painted surfaces shall be protected to the fullest
extent feasible from rain, condensation, contamination, snow, and freezing until the
coating has dried.

h. Preferably, successive coats of paint should be of different colors. However, if they are
of the same color, alternate coats shall be tinted to produce sufficient contrast to ensure
complete coverage of the surface. The final (finish) coat shall not be tinted. Tinting
material shall be compatible with the paint and shall not be detrimental to its service life.

i. Where the specified dry film thickness is not achieved, additional coats shall be applied
until the required thickness is obtained. Application shall be such that the film thickness
will not affect the appearance or service life of the paint.

j. All paint shall be applied either by air spray or airless spray as specified by paint
manufacturers. The use of brushes is only allowed in the case of repairs or in difficult
areas where spray technique is not practical.

k. All paint shall be applied in a workmanlike manner. The finished application shall be
uniform in color, texture, and appearance. The work shall be free of sags, wrinkles, and
excessive brush or roller marks. Any deficiencies shall be corrected by Sub Contractor
at own expense.

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QCP for PAINTING ON METAL SURFACES (SHOP & FIELD) APPLICATION

l. After the completion of painting in the shop, all spools shall be cleaned to ensure that
spent abrasives are not present inside the pipe. Both ends shall be covered to avoid
ingress of sand after cleaning.

m. All welds, edges etc., shall be stripe coated to ensure full DFT in those areas. This
includes nuts and bolt heads.

n. For underground piping, each coat shall be checked for DFT in accordance with SSPC-
PA2.

Tape Wrapping
a. Tape wrapping is generally applied to welded and flanged joints on underground piping
and portions of pipe spools passing through a concrete wall, etc. It may also be applied
to the entire length of underground piping and other fittings as required by project
specification/requirements.

b. Surface preparation and primer application are carried out according to section 8.4 to
section 8.9.1.

c. An approved moldings putty of compatible grade is applied to the uneven surfaces such
as flanges, tees, valve bodies and other pipe fittings to form a smooth surface prior to
tape wrapping.

d. The edges of the applied molding putty shall be tapered to avoid formation of air pockets
when the tape is finally wrapped over it.

e. The primed surfaces and the surfaces where molding putty has b een applied shall then
be wrapped in spiral fashion with a minimum of 50-55% overlap that results in a
minimum of twice the tape thickness.

f. The end of each roll of tape shall overlap the end of the preceding roll by a minimum of
150 mm. The spiral angle shall be maintained for the entire pipe length where taping is
required.

g. When required by project specification and/or approved procedure, wrapping is carried

out in two stages. An outer layer of wrapping tape is applied over the inner layer and the
same wrapping technique as described above is deployed for the second layer also.

h. A dedicated and approved method statement/construction procedure describing the

correct activity sequence and related construction details shall be generated and
implemented accordingly.

Coating of Tank Internal Surfaces

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QCP for PAINTING ON METAL SURFACES (SHOP & FIELD) APPLICATION

a. Coating of tank internal surfaces generally requires the application of more than one
coating system. The tank floor and the lower portion of the wall (up to a specified height)
are lined with a specified coating material. The remaining portion of the inner walls
carries a separate coating system. During application, care should be taken to ensure
the required overlapping is achieved. A comprehensive and thorough coating inspection
shall be carried before the tank is boxed up.

b. A dedicated and approved method statement/construction procedure describing the

correct activity sequence shall be generated and implemented accordingly.

c. The requirements specified in Project specifications and coating manufacturer data

sheet(s) shall be implemented and inspection carried out accordingly

Repair of Damaged Coating

a. The damaged area shall be re-cleaned as originally specified for that item and the full
coating system re-applied in accordance with the manufacturer’s recommendations/data
sheet.

b. Any repair of damaged coating shall be cleaned by hand tools or power tools in
accordance with SSPC-SP11 or SP3.

c. All repair areas shall be feathered into the undamaged coating a minimum of 50 mm.
Repair shall be performed prior to the subsequent coat.

d. Repair of damaged area shall be performed prior to the next coat application. Coating of
weld joints shall be in accordance with original paint application as specified in Project
specification.

e. For items such as equipment already painted by Contractor’s supplier, Sub Contractor
shall use the same paint or an equivalent and compatible paint approved by Contractor.
Items supplied with the manufacturer's standard coating system shall be touched-up with
the same generic coating material or repainted.

f. Repair of damaged surfaces of zinc silicate primer shall be performed as detailed in the
Project specification/data sheet.

g. Any holidays, defects and unacceptable work shall be repaired in accordance with
manufacturer's recommendations. Holidays should be generally ground to bare metal
feathering the adjacent sound coating back a minimum of 25mm.

Identification Marking – Job Stencil

a. All spools and straight run pipe shall be identified clearly as per project requirements
specified in the applicable project document.

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QCP for PAINTING ON METAL SURFACES (SHOP & FIELD) APPLICATION

b. A job stencil shall be applied in the field in letters in a color which is in accordance with
Project specification. This shall only be applied on the final coat and shall contain the
required information.

c. Identification markings (e.g. heat numbers, spool number, weld details, etc) shall be
protected and transferred to the inside of the spool or tagged securely to spool, etc prior
to blasting. All spools and straight pipes shall be identified clearly as per procedure.
Special attention shall be paid to ensure the heat number is transferred /secured
properly and stays available for verification at all stages of work execution and later as
required.

Storage and Transportation of Painted Pipes/Spools

a. All painted pipes/spools shall be properly stored, clear from the ground. Pipe ends shall
be protected at both ends with end caps or plastic sheet wherever end caps are not
provided.

b. Method of storage shall protect coated pipes/spools from standing water, direct soil
contact, and sharp or hard objects.

c. Coated/painted pipes and spools shall be transferred by lifting and placement without
the use of hooks, ropes, cables, or other sharp handling devices.

Testing and measuring equipment

a. The inspection and measuring tools and equipment shall be calibrated and stickers shall
clearly indicate therein the date of expiry. Certificates shall also be available and
produced upon demand.

b. The inspection and test status shall be defined and controlled by the applicable
Inspection & Test Plan (ITP) and the respective Inspection Test Record (ITR). Inspection
activities shall be recorded progressively by QCI.

c. The QCI shall perform inspection as per relevant ITP on all painting activities, in addition
to profile measurements and DFT checks that shall be carried out during the course of
the coating application process. The QCI shall perform inspections on each batch and
each coat and the checks shall include but not be limited to the following:

Pinholes Dry Film Thickness

Blisters Orange Peel

Bubbling Mud Cracking

Fisheyes Dry Spray

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QCP for PAINTING ON METAL SURFACES (SHOP & FIELD) APPLICATION

Unmatched Colors Runs and Sags

Uniformity Mechanical Damage

Curing properties Holidays & missed areas

d. The inspection shall be witnessed and signed off by the Contractor QC and Company as
per relevant ITP on the applicable inspection record.

e. When a painting manufacturer is different between shop coating and field coating,
adhesion testing shall be done at randomly selected areas following the procedures of
ASTM D3359. Pulling off the adhesive strip should not peel off from the grid area more
than what is specified/confirmed in the project specification/requirements.

f. Adhesion of inorganic zinc coatings shall be tested by firmly scraping the coated
surfaces with the edge of a coin. A zinc film, which is properly dried and hard, will polish
to bright metal without powdering or loss of material.

g. For underground piping, the inspection on site shall be carried out using a holiday
detector after the pipe is lowered in the final position and after tape wrapping the joints
and in accordance with ITP and Project Specifications. Results shall be recorded in the
applicable inspection record.

h. Glass Flake lining on internal surfaces of tanks and piping spools shall be finally checked
for holidays and pin holes after completion of all internal work activities and man-entry
operations.

7.0 RECORDS

The painting inspection records for the paint yard and field painting activities shall be generated
as per the requirements of the applicable ITP. Daily monitoring of weather conditions at the
location shall be carried out and recorded at the location where blasting/painting is carried out.
This record shall be completed by the Painting Supervisor and QCI.

Should there be items that are not released for further painting these items shall be listed as
“Items on hold and release after repair”. These items shall be signed off by Sub Contractor QCI
upon repair.

The ITP shall include in-process inspection activities and a particular item shall be accepted
only after completion of all relevant activities and acceptance of final inspection.

List of Verifying Documents (ITR):

No. QMS Ref No. ITR No. Description

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QCP for PAINTING ON METAL SURFACES (SHOP & FIELD) APPLICATION

1 PEC-QU-ITR-X-11118 ITR-V-0101X Spool Release Report

2 PEC-QU-ITR-X-11119 ITR-V-0102X Painting Inspection Report

3 PEC-QU-ITR-X-11120 ITR-V-0103A Holiday Test Inspection Report

4 PEC-QU-ITR-X-11121 ITR-V-0104A Final coating Inspection Report

8.0 APPENDICES

None