TITTLE:

PAINTING SURFACE PROCEDURE

LINE NO:25-SA-4820-70551-1C127DA-N

Spool No:SA-4820M00350-70551-11A

CLIENT:

UTILITIES & FACILITIES

(UF)
 Aug 01,
00 IFR – Issued For Review Mohd As shahiddin
2019
REV DATE STATUS – REVISION MEMO PREPARED BY CHECKED BY APPROVED BY

PURPOSE
The purpose of this procedure is to provide a guide line for surface preparation e.g., manual blasting, power tool
cleaning for pipe spool as per highlighted mark at Reference Drawing (fabrication of pipe spool at PG-101-23
(20-S1102-1103(DS)). The maintenance painting will directly apply at site with the correct method of surface
preparation.
SCOPE
This painting procedure describe in detail method and step by step process which consist from surface
preparation until final coat application for any painting and surface preparation work.
CODE AND STANDARD/REFERENCE
ASTM: American Society for Testing & Materials
ANSI: American National Standard Institute
ISO: International Standard: ISO 8501-1
PTS 30:48:00:31: Protective Coating and Lining
NACE: Nace International Standards And Publications.

SURFACE PREPARATION
Treatment Prior to Surface Preparation
To obtain optimum paint coating performance, surfaces to be prepared shall be free from all weld spatters, flux,
rust, loose scale, dirt, grease, oil, mill scale and other foreign surface contamination on the surface prior to any
method of surface preparations. Paint to be applied before any corrosion/re contamination occurs. Paint to be
applied shall be less than 4 hours after surface preparation completed.
Execution of surface preparation
Surface preparation shall be carried out by dry blast cleaning using Natural Mineral Abrasive or Garnet and of
type and quality tested. Blast cleaning shall not only be limited to shop painting. Surface preparation standard at
site shall be in accordance to approved paint matrix. Prepared surface shall meet the nearest equivalent of the
surface preparation specifications as stipulated in Table below.

Table 1

NEAREST EQUIVALENTS OF THE MAIN SURFACE PREPARATION

SPECIFICATIONS
ABRASIVE BLAST CLEANING SSPC ISO 8501-1 NACE
Very Thorough. Near White Metal
SP 10 Sa 2.5 No 2
Blast.
TOOL CLEANING SSPC ISO 8501-1 NACE
Very Thorough. Power Tool
SP 3 St 3 -
Cleaning.

The restrictions concerning to surface preparation and protective measures are listed as below: -
Surface preparation should be carried out when surface temperature ≥ 5°C. In case of rain or bad weather,
surface preparation shall not be carried out.
When the subtract surface is wet, surface preparation shall not be carried out.
When surface temperature is < 3 °C above of dew point temp. (min) or relative humidity (RH) is 85% or higher,
surface preparation should not be carried out. When surface preparation is carried out in dark locations, fire-
proof lighting equipment shall be used by means of which the extent of rust removal from the surface can be
seen.

Surface Preparation by Blast Cleaning

When blast cleaning is to be carried out at the jobsite, appropriate protective measure shall be taken to ensure
prevention of adverse effect of dust on adjacent work or environmental pollution to the surrounding area.
Necessary approval is required prior to execution.
Compressed air supply shall be free from water and oil contamination. A Blotter test
to be conducted prior to commencement of surface preparation.
Abrasive blast cleaning equipment shall be in safe condition and equipped with a remote shut-off valve
triggered by the release of a dead man’s handle at the blasting nozzle.

4.4 Surface Preparation by Power Tool

(using mechanical/electric operated tools)

4.4.1 Surface preparation by hand or power tool to be prepared shall meet the required standards
comply with project specification and owner approval.

4.4.2 If surface being prepared lies adjacent to a coated surface which is not to be refurbished, abrade
with sand papering and overlap the coated surface by at least 25mm. The minimum requirement to apply
coating is SSPC-SP2 or SSPC-SP3 at the time of coating.

5.0 PAINT APPLICATION

5.1 Pre-Application

5.1.1 Material Handling

All painting material shall be stored in proper places as per manufacturing/owner

 requirement.

Mixing and Thinning

a) Paint material shall be prepared in accordance with paint manufacturer’s recommendation and
instructions. Mixing of coating material shall use solvent proof mechanical stirrer. Allow sufficient time in
agitating the coating of one or two packs paint so as to break lumps and bring the material to a uniform
consistency.

Thinner shall not be added to primer or paints unless necessary for proper application. If thinning is required,
type of thinner and percentage added shall in accordance to the paint manufacturer’s recommendation.

5.1.3 Surface Cleaning

Blast prepared surface shall be free from residues and other contaminants by blowing with clean and dry
compressed air. For Hand tool prepared surface, solvent wipe entire surface prior to paint application.

Continuous mechanical agitation type spray pots shall be used when applying heavily metal-pigmented paint
such as Zinc or aluminum loaded paint.

5.2 Application

5.2.1 Spray

Immediately after surface preparation, apply primer coat to minimum dry film thickness as specified in painting
and coating system schedule as per attachment. Wet Film Thickness gauge are used to check the wet coating
occasionally during application in assuring that the thickness required are achieved when the paint film is dry.

Prior to subsequent coat application, ensure primer coat has achieved required drying time as stipulated in
product data sheet and thickness of primer coat meets the minimum DFT requirement. Surface to be top coated
shall be free from defect such as dry spray, surface irregularities such as runs and sags and other surface
contaminants.
Edges of existing coating shall be feathered towards the substrate prior to top coating.
In case where the second coat is applied more than three days prior to application of the third coat or final coat,
the surface shall be prepared in accordance with paint manufacturer’s recommendation. This is to ensure
removal of surface contaminants and ensure good inter coat adhesion.

To avoid solvent trap, ensure previous coat achieved the minimum over coating interval as stipulated in the
paint technical data sheet or as per paint manufacturer’s recommendations.

Each spray pass shall overlap the previous spray by 50%. All runs and sags shall be brushed out immediately or
the coating shall be removed and the surface re-sprayed.

5.2.2 Brush/Roller

Brush or roller painting shall be used only as per paint manufacturer’s recommendation. Brushes shall be of
type and quality that will enable proper application. Multi coat application may be required to achieve specified
DFT.
Flanges, nozzles, clips, access way saddles and other attachments which protrude through insulation shall be
painted in accordance with the respective coating system.

Color coding, marking and lettering shall conform to PCESB requirement.

6.0 GENERAL REPAIR AND TOUCH-UP PROCEDURE

6.1 Before repair and touch-up paint to be applied, ensure all damage has been removed or
repaired.

6.2 Surface cleaning to be carry out on defectives areas at adjacent to unrepaired coat area.
Surface cleaning shall be feathered edge and overlap with existing sound coating by at
least 25mm.

6.3 Inorganic Zinc primer shall not overlap adjacent intermediate and finish coats.
 Area with inadequate coating thickness shall be thoroughly cleaned and if necessary
abraded and additional coats applied shall blend in with the final coating on adjoining
areas.

6.4 Apply painting repair as follow maintenance painting and touch-up paint system.

7.0 INSPECTION

7.1 Weather Condition

7.1.1 Painting cannot be carried out during rainy day or in bad weather condition. Surface temperature
shall be in range 5°C to 40°C.

7.2 Surface Preparation Check/Visual Inspection

7.2.1 Visual inspection shall be conducted at intervals of blasting and in between coats
(check cleanliness and blasting profile) as per approved ITP.

7.3 Wet Film Thickness (WFT)

7.3.1 This painting inspection is to check the wet coating occasionally during application in
assuring that the thickness required are achieved when the paint film is dry.

7.4 Dry Film Thickness (DFT)

7.4.1 Dry Film Thickness (DFT) of all coats shall be checked and logged in the painting
Inspection Report by QC Inspector as per QC Report.

7.4.2 A DFT gauge shall be use to check the paint film thickness and calibrated at
beginning of each day’s work.

7.4.3 Degree of curing for Inorganic Zinc coatings shall be determined using the method
 described in ASTM D 4752. The recommended minimum "pull-off" value for glassflake
coating system is 500 psi and all other coating systems, shall be minimum 300 psi.

7.5 Inspection Tools

7.5.1 Profile gauge - check blasting profile/surface preparation.

7.5.2 WFT gauge - check paint film thickness in wet condition.

7.5.3 DFT gauge - check paint film thickness after paint film are dry.

7.5.4 Whirling Hygrometer and Dew Point calculator - check microclimatic condition.

7.5.5 Surface Magnetic Dial gauge - measure steel or substrate temperature.

All inspection tools shall be calibrated and all the inspection shall be recorded in Painting Inspection Report by
Contractor's QA/QC.

8.0 RECORD
AND DOCUMENTATION

Prior to final acceptance of the paint work an inspection shall be made. STS QAQC inspectors and PCESB
representative shall both be represented and they shall sign an agreed inspection report.

This record shall include:

 8.1 General -
Names of the Contractor and the responsible personnel. - Dates when
work was carried out.
8.2 Materials preparation -
Equipment and techniques used. - Materials receipt
condition. (manufactures, brand & batch no) - Type and calibration of
instruments used.
8.3 Environmental conditions - Weather
and ambient conditions. - Painting periods

8.4 Surface preparation -

Condition of surface before preparation. - Tools and
methods used to prepare surface. - Condition after
preparation.
8.5 Paints and painting -
Information on systems being applied. - Mixing
and testing prior to application. - Paint application
techniques.
8.6 Testing -
Type of quality control checks carried out, and results. -
Compliance or otherwise with specification.
9.0 PAINTING AND COATING SYSTEM SCHEDULES FOR EXTERNAL APPLICATION.

Painting Specification 5A(1) / 5B (1)

Operating Condition INITIAL & MAINTENANCE PAINTING ( 172 C/200 C)
Surface
SP10 (Sa 2.5) SSPC SP3 (St 3)
Preparation
Coating Product Name DFT Product Name DFT
Inorganic Zinc
1st coat 75 Zinc Graphite 40
Silicate
Modified Modified
2nd coat Silicon 30 Silicon 30
Acrylics Acrylics
Modified Modified
3rd coat Silicon 30 Silicon 30
Acrylics Acrylics
Total DFT 135 Total DFT 100
PROCESS WORK FLOW FOR PAINTING AND SURFACE PREPARATION

Surface Preparation
-Rectification work if -Check temperature and humidity.
rejected

Reject

-performfor
Inspection visual inspection.
surface
prep

Accept

Primer application - Measurement of environmental

conditions.
Repair work if
rejected

Reject

-Visual inspection for condition.

Inspection

Accept
 Sub sequent -
Measurement of application environmental condition.
Repair work if
rejected
Reject

-Visual
inspection for condition. Inspection

Accept

-Painting report.
Reporting and
documentation