GREAT MADE MAN RIVER PROJECT

INSPECTION REPORT IDRECO TAZERBO WELLFIELD - LYBIA FROM NOVEMBER 23RD 2004 TO NOVEMBER 29TH 2004

IDR-001

Rev. 01

Date: 02/11/2004

Written by: Antonio Amati

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GREAT MADE MAN RIVER INSPECTION REPORT IN IDRECO TAZERBO WELLFIELD

TABLE OF CONTENT 1,0 2.0 3.0 4.0 5.0 6.0 7.0 RESUME REFERENCE DOCUMENTS AND STANDARDS DEFINITIONS DIARY INSPECTION CONCLUSIONS RACCOMANDATIONS 7.1 7.2 Coating applications Warranty

IDR-002

Rev. 01

Date: 18/12/2004

Written by: Antonio Amati

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GREAT MADE MAN RIVER INSPECTION REPORT IN IDRECO TAZERBO WELLFIELD

1.0

RESUME

IDRECO entrusted GRUPPO ISPAC to inspect painted surfaces of vessels and filters manufactured by Socomenin for IDRECO/GMRA Treatment Facilities East Project and installed in Tazerbo Libya, in order to evaluate damages occurred on the coating system applied by Socomenin using paints manufactured by International Peinture SA France. The expertise became necessary, after the technical report issued by ETSM (ETSM doc. No. TAZB-DAC-A001-RA3-REVG dated 12/10/04), commissioned by Socomenin and International Peinture SA France, has been considerate and discussed by GRUPPO ISPAC. Some vessels have been inspected, one of them was not filled up by water yet, others have been underwent to hydro test . The painted surface of filter which is not filled up by water , appeared in good conditions, and the adhesion is confirmed very good, holiday test by wet sponge device has been carried out. Any holiday have been found on the painted surface, except for welds, corners and edges. Following holiday test , the filter has been filled up by water and then empty after some hours; after then it has been inspected again without any appearance of rust on the shell and strainers plate. Only on welds some rust began to appear. The painted surface of filter and backwash which have been underwent to hydro test appeared rusty in many places, sometime in single spots far from each others, sometime like spreads pitting, very close from each others. All the surface was covered by these kinds of damages on the shell of the backwash and on the shell of the upper part of filters. The bottom part and the strainers plate of filters appeared in better condition. All the welds, edges and corners was rusty. Some specimens have been taken of and have to be analysed in laboratory to evaluate if damages occurred have been caused by solvent entrapment or salt contaminations of surface during sandblasting, or by other wrong application conditions of painting system.

IDR-002

Rev. 01

Date: 18/12/2004

Written by: Antonio Amati

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GREAT MADE MAN RIVER INSPECTION REPORT IN IDRECO TAZERBO WELLFIELD

2.0 -

REFERENCE DOCUMENTS AND STANDARD EMTS report No. TAZB-DAC-A001-RA3-REVG dated 12/10/2004 Paint inspection of filter vessels and backwash tanks manufactured by SOCOMENIN with INTERNATIONAL paint product on behalf of IDRECO. GMRA doc. No. 00240-A-530-00-SP-MT-3001-01 EXBIT B6 Standard specification for corrosion protection General coating. IDRECO doc No. 15650-S-300-50-SP-ME-0094-01 PTS for sand filters IDRECO doc No. 15650-S-300-50-SP-ME-0096-01 PTS for sand backwash tanks IDRCO doc No. 15650-S-100-00-PR-QA-0713-0A. Repair protective coating procedure SOCOMENIN doc. No. 15650-S-100-00-PR-QA-0464-01 Paint procedure for 165 sand filters and 54 backwash tanks. SOCOMENIN doc. No. 15650-S-100-00-PR-QA-0465-01 Paint inspection procedure for 165 sand filters and 54 backwash tanks. INTERNATIONAL Interline 982 Data sheet NTERNATIONAL Interline 925 Data sheet INTERNATIONAL Interline 925 Performance test data INTERNATIONAL Interline 925 Working procedure ISO 8501-3 ISO 8502-3 BS 5493 ASTM D4138 ISO 8502-6

IDR-002

Rev. 01

Date: 18/12/2004

Written by: Antonio Amati

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GREAT MADE MAN RIVER INSPECTION REPORT IN IDRECO TAZERBO WELLFIELD

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DEFINITIONS CORROSION PROTECTION inspectors book of reference FROSIO) GLOSSARY OF CORROSION RELATED TERMS edited by NACE INT.

All definitions below mentioned are taken from:

COATING SYSTEM The complete number and types of coats applied to a substrate in a predetermined order. (When used in a broader sense, surface preparation, pre-treatment, dry film thickness, and manner of application are included.) SOLVENT Solvents are volatile substances, this means that they evaporate from the paint film more or less quickly. Solvent in paint should rather be avoided. VOIDS A holiday, hole, or skip in a coating. Entrapped gas or solvent, often cause voids in coating, entrapped solvents may be caused by skin drying of the coating or to early recoating. The solvents are unable to evaporate sufficiently and will consequently remain in the coating. SALTS CONTAMINATIONS Contamination in the form of sea salt is common in marine atmosphere. If surfaces contaminated with sea salt are recoated and later immersed, humidity will penetrate the paint film to the contaminants. At first the contaminants attracts humidity, resulting in a strong saline solution. In order to thin the solution, more humidity will penetrate the coating until equilibrium has been reached. If the humidity has accumulated beneath a coating due to osmosis, the result will be a corrosion product. When the substrate start to corrode, the coating will begin to rupture, causing further breakdown. DFT Dry Film Thickness
Formattato

IDR-002

Rev. 01

Date: 18/12/2004

Written by: Antonio Amati

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GREAT MADE MAN RIVER INSPECTION REPORT IN IDRECO TAZERBO WELLFIELD

4.0

DIARY NOVEMBER 23-24, 2004 Trip from Milan to Tazerbo, Libya NOVEMBER 25, 2004 MORNING: inspection well nr 402, filter A Meeting whit IDRECO, GMRA, SOCOMENIN. AFTERNOON: inspection well nr 207, filter A; well nr 201, filter A NOVEMBER 26, 2004 MORNING: inspection well nr 206, filters A and B AFTERNOON: meeting with IDRECO, SOCOMENIN NOVEMBER 27, 2004 MORNING: inspection well nr 402, filter A; well nr 201, filters A, B AFTERNOON: inspection well 201, backwash. Meeting with IDRECO, SOCOMENIN. NOVEMBER 28-29, 2004 Trip from Tazerbo, Libya to Milan

5.0

INSPECTION 5.1 INSPECTION OF WELL 402, FILTER A Holiday test, low voltage wet sponge have been carried out. Any holiday have been found except on welds Visual appearance of film was quite good except on some areas where very bad orange peel was visible (a, b). On the strainers plate orange peel has bee treated with sand paper to allow gaskets to be adherent to the surface. (c) The thickness was from 250 and 800 micron. The filter has been filled up by water and after 24 hours has been get empty. Man holes have been opened to allow the hair to circulate. After these operations a new inspection was carried out, any evidence of rust has been found on the shell surface neither on the strainers plate. Some rust was found on welds and edges. The quite good appearance of surface after filling up means that the phenomenon visible on vessels damaged need more time to take place, for this reason it is important to fill up a new vessel not undergo to hydro test yet and follow the evolution of phenomenon filling it up and getting it empty once a week.

IDR-002

Rev. 01

Date: 18/12/2004

Written by: Antonio Amati

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GREAT MADE MAN RIVER INSPECTION REPORT IN IDRECO TAZERBO WELLFIELD

c
5.2 INSPECTION OF WELL 206, FILTER A On the bottom, the appearance of coating is quite good, without evidence of rust on the shell and strainers plate; only on the side toward north rust like spreads pitting, very close from each others was visible. Rust was also found on welds junction.(e,f) Thickness found was from 350 to 700 micron On the top side many rust like pitting on the most part of surface has been found in different concentrations on the shell. (g) Also on the surface of channel rust is visible like diffused pitting. (h) Corrosion on the welds of strainers plate reinforcement, and on all others welds, on edges and corners as well. (i) Very bad orange peel has been found.(j) Thickness checked by PIG (ASTM D4138 ) : 60 micron primer; 500 micro epoxy finish. IDR-002 Rev. 01 Date: 18/12/2004 Written by: Antonio Amati Page 7 of 13

GREAT MADE MAN RIVER INSPECTION REPORT IN IDRECO TAZERBO WELLFIELD

On strainers plate the surface of coating was clean and smooth on most parts, some area was affected by orange peel very thick; a few quantity of rusty pits have been found.

CANAL

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IDR-002 Rev. 01 Date: 18/12/2004

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GREAT MADE MAN RIVER INSPECTION REPORT IN IDRECO TAZERBO WELLFIELD 5.3 INSPECTION OF WELL 207, FILTER A

Top side, spread corrosion pits on almost the complete surface with different concentrations. Rust on weld, corners, cut edges, demonstrate that steel preparation and stripe coat have not been carried out. Bottom side and strainers plate, coated surface appear in good conditions except welds . 5.4 INSPECTION OF WELL 201, FILTER A Bottom side, 90% of coated surface appears free of rust; a small area in correspondence of the head toward north is completely rusty.(k) Corrosion is also visible on welds. (l) Strainers plate, most part of coated surface appears free of damages except welds. Some rust pits were found near the strainers, it was supposed a wrong engraving.(m) The top side of filter was already fill of sand, and it was almost completely empty, on the painted surface corrosion pits in different concentration were found. (n)

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IDR-002 Rev. 01 Date: 18/12/2004

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GREAT MADE MAN RIVER INSPECTION REPORT IN IDRECO TAZERBO WELLFIELD

5.5

INSPECTION OF WELL 201, BACKWASH

Corrosion pits in different concentrations are visible all over the painted surface (o,p) more visible on the roof (q) Rust on welds (r) and some mechanical damage, have been found in many places. Thickness checked by destructive method by PIG (ASTM D4138 ), with values of 550 micron, with 30 micron of primer. The vessel have been underwent to hydro test, by cyclic filling it up and empty , so that in this way, water have not been in contact with the painted surface in continuous and prolonged time, but in many different periods.

IDR-002

Rev. 01

Date: 18/12/2004

Written by: Antonio Amati

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GREAT MADE MAN RIVER INSPECTION REPORT IN IDRECO TAZERBO WELLFIELD 6.0 CONCLUSION Evaluating the conditions of painted surface the possibility that corrosion pits have been generate by thermal stress, have to be excluded: a) it is not possible to speak of cracking , because cracking and checking as well, are very different in comparison to the visual appearance that the damages occurred into filters have. Cracking, even thought is visible by magnifying, should appear like a irregular grid pattern (s). In this case there is just a irregular cross in correspondence of corrosion pits.(t) b) Supposed that is thermal stress, the conditions of painted surface should be different between sides exposed to north and sides exposed to south: the surface exposed to south should be more damaged than the surface exposed to north. There is not difference between these two sides, moreover the damage found on filter A of well 201 is very remarkable (see picture k) ; this surface is on the bottom part, near the ground, exposed to north (see picture u). This means that the sun reached the surface just for a few time in the early morning when the temperature is colder than the rest of the day and the sun is not so hot to stress something. On the surface of channel into filter A of well 206, corrosion pits have been found (see picture h). The channel is into the filter and the surface of it is not exposed to the sun, anyway, corrosion damages are similar to the damages founded on the coating exposed to the sun. This means that corrosion pits have not been caused by thermal stress. .

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GREAT MADE MAN RIVER INSPECTION REPORT IN IDRECO TAZERBO WELLFIELD 6.1 We have seen above that, if surfaces contaminated with sea salt are recoated and later immersed, humidity will penetrate the paint film to the contaminants. If the humidity has accumulated beneath a coating due to osmosis, the result will be a corrosion product; in correspondence of point where this phenomenon takes place, the volume of corrosion products increases a lot, so that the coating film is lifted and broken down. For this reason is possible to see as in picture (t) a irregular cross cracking, whit corrosion products included. Finally is possible to assume that the damages occurred on the coating film is not due to thermal stress, but its could be caused by salt contamination of the surface before coating application. This phenomenon could be increased due to the presence of voids in film, caused by solvent entrapment. Specimens have been taken and sent to laboratory to be analysed. Confirmation of the deduction above will be issued as soon as possible. 6.3 6.4 Other kind of damages like corrosion on edges, welds and corner, have been generate by bad steel preparation. Orange peel, sags and runs are defect due to inconvenient occurred during painting applications . 7.0 RACCOMANDATIONS 7.1 Coating applications Before to start reparation works, each kind of defect must be identified and marked. Two types of surface preparation shall be carried out depending from the type of defect: For localized damages, power and hand tool cleaning shall be performed, for others areas sweep blasting will be carried out. Before to start blasting operations the abrasive must be tested to asses quantity of chloride (salts) are presents. At the beginning of work the sweep-blasted surface shall be tested to determine the quantity of soluble salt on the surface after sandblasting (Bresle method ISO 8502-6), maximum conductivity of the water corresponding to20 mg/m NaCl. Stripe coat must be performed on welds, corners, edges, minor damaged areas, box channel. On extent areas application must be executed by airless machine following the indications on data sheets, about pot life, mixing and thinning. The DFT of coating applied shall be 250 microns and the paint should have a different colour to easily identify it from the old one. Complete procedure has been issued by IDRECO: DOCUMENT No. 15650-S-100-00PR-QA-0713-0A. and it has been approved by GRUPPO ISPAC. Modification to the procedure will be evaluated, if necessary, during start of work.

6.2

IDR-002

Rev. 01

Date: 18/12/2004

Written by: Antonio Amati

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GREAT MADE MAN RIVER INSPECTION REPORT IN IDRECO TAZERBO WELLFIELD

7.2 Warranty SOCOMENIN shall arrange with INTERNATIONAL PAINT to get a paint warranty for the full applied system. The document shall clearly indicate years of warranty, and shall declare that during this time any damage or coating failure like the one just occurred will appear again. If this kind of damage or other damages due to bad quality of applications, will comes out during the period of warranty SOCOMENIN and INTERNATIONA PAINT will be responsible about the total amount of cost ( removing sand from filters, paint supply, surface preparation, shut down of wells).

IDR-002

Rev. 01

Date: 18/12/2004

Written by: Antonio Amati

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