RAJASTHAN NORTHERN AREA DEVELOPMENT PROJECT

BHAGYAM FIELD DEVELOPMENT PROCEDURE FOR SURFACE PREPARATION AND PAINTING FOR STRUCTURAL STEEL AND PIPING BD1253AA-BHAG-Q-PRO-0005

ARTSON ENGINEERING

A1 Rev

26-03-11 Date

FOR CEIL REVIEW Purpose of Issue

SS Perumal Prepared By

Jayachandra Checked By

N. Makwana Approved By

TABLE OF CONTENTS
Proc. No.: BD1253AA-BHAG-Q-PRO-0005 Rev. A1 Page 1 of 23

PROCEDURE FOR SURFACE PREPARATION AND PAINTING FOR STRUCTURAL STEEL AND PIPING

DESCRIPTION
1. 2. 3. 4. 5. 6. 7. 8. 9.

PAGE NO 03 03 03 03 04 04 11 12 12 for construction 13 13

Purpose Scope Reference Documents Definitions Health and Safety Process Inspection Documentation Personnel

10. Equipments 11. List

of annexure

1. Purpose

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PROCEDURE FOR SURFACE PREPARATION AND PAINTING FOR STRUCTURAL STEEL AND PIPING The purpose of this method statement is to provide guide lines for surface preparation and painting of pipes and structural items and to ensure that proper quality control and documentation are maintained at site. 2. Scope This scope of method statement describes the method for abrasive blasting, paint Application, touch-up painting and inspection on exterior surface of structural Steel, above ground piping, & Equipments during construction in the Rajasthan Northern Area Development project of CAIRN India. 3. Reference Documents 3.1. 3.2. INSPECTION TEST PLAN ITP No. BD1253AA-BHAG-Q-ITP-0005 BCT1201-BHAG-L-SP-0002 "Specification for External Painting and Protective Coating 3.3. 3.4. 3.5. 3.6. 3.7. 3.8. BD1253AA-BHAG-Q-PLN-0001Project Quality Plan ISO 8501-1 'Preparation of steel substrates before application of paints SSPC VIS 1 "Visual Standard for Abrasive Blast Cleaned Steel SSPC PA 2 "Measurement of Dry Film Thickness with Magnetic Gauge ASTM D4417Standard test methods for measurement of surface profile Drawing references.

4. Definition MTC HSE WFT DFT MSDS JSA Material Test Certificate Health Safety and Environment Wet Film Thickness Dry Film Thickness Material Safety Data Sheet Job Safety Analysis

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PROCEDURE FOR SURFACE PREPARATION AND PAINTING FOR STRUCTURAL STEEL AND PIPING ASTM NACE SSPC ISO American Society testing of materials National Association of Corrosion Engineers Society of Protective Coating International Organization for Standards

5. Health and Safety As per HSE plan, the following systems shall be followed. All relevant elements of HSE Plan BD1253AA-BHAG-R-PLAN-0001 Emergency Response plan BD12533AA-BHAG-R-PLN-0003 shall be followed in

any case of emergency. Daily tool box talk shall be conducted prior to proceed for the work First Aid arrangements shall be followed as BD12533AA-BHAG-R-PLN-0001. HSE personnel shall be present at site during all activities. Qualified Scaffolders shall be used in scaffolding works. Fire Extinguishers shall be placed at work locations at all times. 6. Process 6.1. General 6.1.1. Material

Paint materials shall be purchased from the company approved manufacturers. All painting materials shall be stored indoor only. Materials shall be stored and used as per the manufacturer's recommendation. All necessary precautions shall be taken to prevent fire. Warning signboard shall be clearly displayed. Thinners shall be stored in separately and in sealed containers. 6.1.2. Extent of Painting

All above ground piping and structural steel shall be painted as per the Proc. No.: BD1253AA-BHAG-Q-PRO-0005 Rev. A1 Page 4 of 23

PROCEDURE FOR SURFACE PREPARATION AND PAINTING FOR STRUCTURAL STEEL AND PIPING painting system specified in BCT1201-BHAG-L-SP-0002 "Specification for External Painting and Protective Coating. Touch-up painting shall be done for the equipments, piping. All valves, fittings & flanges shall be painted. The following surfaces shall not be painted Welded joints of the pipe & ends of the pipe (During shop painting) Identification mark (During shop painting) Machined and threaded surface like flange faces, valve stem, sliding surfaces in equipments etc. Galvanized surfaces Name plates Weather condition

6.1.3.

Surface shall not be blasted & painted during rain, heavy wind, dusty wind, fog, moist. When the steel surface temperature is less than 3C of dew point, surface temperature is below 5C, whether relative humidity is greater than 85% or when the air temperature is below 10C, the surface shall not be painted. 6.2. Surface Preparation The type of surface preparation shall be in accordance with BCT1201BHAG-L-SP-0002 "Specification for External Painting and Protective Coating 6.2.1. Abrasive Blast Cleaning

Sand or other material producing silica shall not be used. Abrasive to be used for blast cleaning are listed below. Chilled Iron Grit or Shot

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PROCEDURE FOR SURFACE PREPARATION AND PAINTING FOR STRUCTURAL STEEL AND PIPING Non & Metallic Iron Grit or Shot Non Metallic Abrasive (Aluminium, Oxide, Copper Slag, Garnet) Grit Spec- Particles that are predominately angular have fractured faces and sharp edges and are less than half round in shape. The surfaces shall be blast at appropriate pressure, distance and right angles to the surface maintaining constant velocity and pressure.

Compressed air shall be free from moisture, oil and other contaminations. The compressed air temperature shall be less than 110C. Knock-out pots or vapour traps shall be installed to remove oil / moisture regularly. Prior to blast cleaning of pipes and pipe spools the identification of spool shall be covered by masking tape or Aluminium tag shall be tied to the spools/pipes. Machined surface such as flange faces and threaded surfaces shall be covered by masking tape so as not to damage the surface while blasting / painting. Surface profile of blast surface shall not be less than 25m nor be greater than 40m. Paint manufacturers data sheet shall be referred for the required surface profile. Grade surface finish shall be accordance with ISO 8501-1. Dead-mans handle shall be installed for safety purpose. Sa 1 -" Light Blast Cleaning" (SSPC SP 7) Sa 2 - " Through Blast Cleaning" (SSPC SP 6) Sa 21/2 - "Very Through Blast Cleaning" (SSPC SP 10) Sa 3 - " Blast Cleaning to Virtually Clean Steel" (SSPC SP 5)

On completion of blasting operation, the blasted surface shall be clean and free from mill scale, rust, oil, grit or other foreign material and first Proc. No.: BD1253AA-BHAG-Q-PRO-0005 Rev. A1 Page 6 of 23

PROCEDURE FOR SURFACE PREPARATION AND PAINTING FOR STRUCTURAL STEEL AND PIPING coat of paint shall be applied within 4 hrs of blasting. Presence of oil, grease shall be cleaned and removed with an approved solvent. Degree of surface cleanliness shall be checked with SSPC VIS 1 standard. Surface profile shall be checked recorded with Testex tape & Dial micrometer.

6.2.2.

Hand Tool Cleaning

Rust, mill scale spatters, old coating and other foreign and other foreign matter, shall be removed by scrapping tool, emery paper cleaning, brushing or combination of the above methods. On completion of cleaning, loose material shall be removed from the surface by clean rags and the surface shall be brushed, swept, and blown off with compressed air to remove all loose matter. Hand tool cleaning shall be done for touch up and repair works of painting. 6.2.3. Power Tool Cleaning

Power Rotary Wire Brushing, Rotary Power Discing, grinding machines shall be used for removal of rust mill scale, spatter, old coating and other foreign matters. On completion of cleaning, loose material shall be removed from the surface by clean rags and the surface shall be brushed, swept, and blown off with compressed air to remove all loose matter. Power tool cleaning shall be done at site for touch up painting. 6.3. Painting Painting system and colour coding system shall be in accordance with BCT1201-BHAG-L-SP-0002 "Specification for External Painting and

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PROCEDURE FOR SURFACE PREPARATION AND PAINTING FOR STRUCTURAL STEEL AND PIPING Protective Coating". Paint material shall be identified as per incoming Material receipt inspection procedure and also verification of material with respect to a) Specification b) Manufacturer c) Batch Test Certificates d) Pot life/Expiry date e) Storage area The paint manufacturer's recommendation shall be followed for mixing, thinning, storage, application of paint, drying time and weather condition. Paint application shall be carried out by air less spray. Brush and roller application shall be used for touch up and field painting of small areas and stripes coats. Surfaces that should not be painted shall be covered by masking tape. Zinc based paints shall be agitated continuously while painting. If there is rain just after application, before drying then protection will be done by covering tarpaulin. In case of air spray application, traps or separators shall be installed to remove oil and condensed water from the air. Blast cleaned surfaces shall be coated with one complete application of primer as soon as practicable before flash rusting occurs. Blast cleaned surface allowed to set over night shall be reblasted prior to priming. All paint containers shall be opened prior to utilisation and shall be carefully closed immediately after withdrawal of material. Material which become unserviceable during storage shall not be applied. All painting material shall be kept in weather proof barracks and shall be kept cool and dry.

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PROCEDURE FOR SURFACE PREPARATION AND PAINTING FOR STRUCTURAL STEEL AND PIPING Paint materials which exceed its pot life shall be removed and destroyed

immediately. Partial mixing of 2 pack system paints is not allowed. Mixing ratios, induction time & pot life period of paints shall be strictly observed as

recommended by the paint manufacturer. Each pass of the spray paint shall be overlapped by 50% and the spray shall be continuous until all paint material used up which has been taken out from the paint containers. Each coat shall be in proper state of dryness before the application of succeeding coat. The curing time shall be as per the manufacturer's recommendations. In case of two or more coats of painting, the successive coat shall be of contrast dark shade to the previous coat shade. Paint film thickness shall be maintained as indicated in painting system and the painted surface shall be free from defects. Proper application of paint shall be checked by measuring their WFT while painting. DFT will be measured with the help of coating thickness gauge after curing at every stage. All runs and sags shall be brushed out immediately or the paint shall be removed and surface re-painted. After painting, paint shall be visually checked with regards to unfinished surface, drips, wrinkles, peeling, crewing, decolourisation, strains, pinholes and dry spray. Where there are no marked defects in appearance the paint is accepted with respect to meeting the required DFT. When paint has been damaged, all damaged and loosely adhering paint shall be removed and surface cleaned mechanically to bare metal. Surface preparation of defective or damaged areas shall be extended over the

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PROCEDURE FOR SURFACE PREPARATION AND PAINTING FOR STRUCTURAL STEEL AND PIPING surrounding sound coating for a minimum of 25mm on all sides. Priming shall be done in the area with primer specified to the required DFT. Then 2nd & 3rd coat paint shall be applied as per specification. Shop coating of all members should be completed before erection. The left out unmixed paint will be preserved in a drum with tight cover. Scaffolding arrangement shall be done for painting of erected pipelines and structural works and equipments. Field painting of weld joints shall be done after the completion of applicable NDT and hydro test. 6.4. Color coding and Identification sign The strip color coding shall be in accordance with the Table M - Piping Painting color code of DECO-RX-L-SP-2003 "Project General Piping Design and materials" The Three strips 150mm width each shall be painted over the final coat. The three strips shall be placed each 9 meters length whenever necessary for identification (branches, valves, tanks, at curves, close to equipments, close to entrance and exit of equipments and before and after crossing of bulkhead). All strip colors shall be painted with polyurethane paint of specified colors. Flow direction shall be an arrow mark, colours of shall be black or white and in contrast to the colour on which they are superimposed. Line tags and arrows to indicate flow direction shall be painted with polyurethane paint. The text height shall be 20mm for DN 15 to DN 50 pipe sizes and 50mm for pipe sizes above DN 50. Insulated piping shall also be identified. 7. INSPECTION Proc. No.: BD1253AA-BHAG-Q-PRO-0005 Rev. A1 Page 10 of 23

PROCEDURE FOR SURFACE PREPARATION AND PAINTING FOR STRUCTURAL STEEL AND PIPING Inspection of surface preparation and painting shall be carried out as per the ITP No. BD1253AA-BHAG-Q-ITP-0005

7.1.

DEW POINT MEASUREMENT Dew point shall be measured 3 times a day as a minimum and records shall be maintained. Before any coating or painting activities commence, the substrate temperature shall not 3 C or less than the Dew point.

7.2.

SURFACE PREPARATION VISUAL INSPECTION Surface preparation shall be visually inspected in accordance with SSPC VIS 1 & 3. The measurement of surface profile shall be as per NACE RP 0287 or ASTM D 4417 and ISO 8502. Acceptance of the blast cleaned surface shall be made by visual comparison with 'Anchor Pattern Standards' or 'Surface Profile Comparator'. Surface profile shall be measured & recorded with Testex tape & Dial micrometer. 7.3. DRY FILM THICKNESS Painted area shall be devoid of bare metal and is free of holiday. The DFT requirements and color codes shall be achieved as per the requirements. The DFT shall be checked in the spots at random and documented, as per SSPC PA2

8. DOCUMENTATION Documentation shall be as follow

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PROCEDURE FOR SURFACE PREPARATION AND PAINTING FOR STRUCTURAL STEEL AND PIPING Refer Inspection and Test Plan for Surface preparation and Painting for structural steel and piping ITP No. BD1253AA-BHAG-Q-ITP-0005 Format for surface preparation and painting Report No. BD1253AA-BHAG-QRPT-0011 9. I. II. Color coding & Identification Mark report No. BD1253AA-BHAG-Q-RPT-0012

PERSONNEL

Peoples involved Construction Manager Project QC Manager QC Engineer Site Engineer HSE engineer QC Assistant Foreman Roles & Responsibilities - Refer Contract Quality Plan

10.EQUIPMENTS FOR CONSTRUCTION

a) Compressor along with hose and nozzles b) Hoppers c) Paint agitators d) Paint spraying equipment.

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PROCEDURE FOR SURFACE PREPARATION AND PAINTING FOR STRUCTURAL STEEL AND PIPING
e) Dry Film thickness gauge f) Surface profile comparators g) Cleaning tools like wire brush, scrappers, etc. h) Painting brush and rollers i) j)

Hygrometer Wet Film Thickness gauge

11.LIST OF ANNEXURE Appendix 1.0 - Color Code JSA for Surface Preparation and Painting Format for surface preparation and painting Report No.

Appendix 1.0 COLOR CODE ITEM 1 2 3 EQUIPMENT Tanks (except U/G), Vessels, Towers Storage Bullets Vendor Supplied Equipment COLOR Medium Gray White Medium Gray RAL COLOR (Note 1) 7004 9010 7004

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PROCEDURE FOR SURFACE PREPARATION AND PAINTING FOR STRUCTURAL STEEL AND PIPING 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Structural, Skids (except for handrails, safety cages and ladders) Handrails, Safety Cages and Ladders Process Gas Piping Instrument Gas Piping Fuel Gas Piping Process Hydro-Carbon Liquid Piping (Including inlet, Sales, Multi-Phase Oil Streams) Instrument Air Drain, Flare, Relief Piping Fire and Emergency Systems Water (Except Fire water) High Pressure Gas and Water (Over 10,204kpa or 1480 psi) Amine Streams (Or Other Gas Sweetening Agents) Glycol or Glycol/lf\later Streams Refrigerant Streams Flare and other Stacks Medium Gray Safety Yellow Medium Gray Medium Gray Safety Yellow Medium Gray Medium Gray Medium Gray Safety Red Medium Gray Medium Gray Medium Gray Medium Gray Medium Gray Black 7004 1024 7004 7004 1024 7004 7004 7004 3020 7004 7004 7004 7004 7004 9005

JSA for Surface preparation and Painting

Sl. No. 1

Activity Painting work for the MS Structural material

Hazard 1. Eye Injury 2. Toxic Inhalation

Control Measures

Action By

1. Permanent Fabrication installations, Shop Ininstruments, Charge. fragile items,

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PROCEDURE FOR SURFACE PREPARATION AND PAINTING FOR STRUCTURAL STEEL AND PIPING hazardous items to be removed or protected. 2. Material handling ergonomics posture shall be explained. 3. All work related to painting i.e., material handling, grit and spraying jobs shall be under supervision only 4. Painting material shall be stored in a well protected place. 5. Fire extinguishers and fire buckets shall be readily available nearby incase of emergency. 6. No hot work shall be carried out within the radius of 10 mts of area where spray painting is carried out. Proc. No.: BD1253AA-BHAG-Q-PRO-0005 Rev. A1 Page 15 of 23

3. Hearing Loss 4. Impact and Piercing Injury 5. Back and Limb Injury 6. Soil Contamination 7. Air and Nose Pollution.

PROCEDURE FOR SURFACE PREPARATION AND PAINTING FOR STRUCTURAL STEEL AND PIPING

7. Provide the necessary PPEs like dust musk, safety goggles ,etc to protect from paint spray

2.

Area 1. Insufficient Preparation accessibility and Barricading and material stacking. Unauthorized personnel movement ventilation

1. Painting Fabrication procedure Engineers shall be explained to all employees. 2. JSA to be made and its hazards, control measures to be communicated to all personnel. 3. Toolbox talk to be given to all persons

3.

Material Storage Paint Spillage and Soil contamination, and Grit Waste Disposal fumes and dust and fire hazard, chemical reaction hazards.

1. MSDS shall provide

be

Fabrication Engineers and HSE Team

2. Use secondary confinement and spillage tray

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PROCEDURE FOR SURFACE PREPARATION AND PAINTING FOR STRUCTURAL STEEL AND PIPING

3. Shed and confinement area shall be made of fire proof material. 4. Electrical connections shall be of standard at a continuous hazard zone 5. Worker shall be trained on fire fighting Approved Recycler.

4.

Material Handling and Arrangement (Manual)

1. Unauthoriz ed personnel shall not be at the job

HSE Team and Site Supervisor 1. Ensure sufficient accessibility, proper barricading shall be done in lifting operation area. 2. Ensure use of all proper PPEs while entering the site. 3. Ensure all personnel are following safe manual handling procedures

2. Manual shifting of material leads to back injury, limb injury and cut injury.

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PROCEDURE FOR SURFACE PREPARATION AND PAINTING FOR STRUCTURAL STEEL AND PIPING 4. Never overload. Fabrication Engineer 1. Ensure all personnel are following safe manual handling procedures. 2. Never overload crane the

5.

1. Material handling by equipments.

1. Unauthoriz ed operating of lifting equipments. 2. Fall materials dropping swinging loads. of and & of

3. Impact, crush injury and pinching injury.

3. Work shall be under supervision 4. Use safety boots, hand gloves and goggles. 5. Lifting equipments shall have inspection sticker

a Fabrication Engineer and HSE Team

6.

Air compressor 1. High Pressure air injury - Eyes & Skin due particular / splinters. 2. Exhaust and noise pollution. 3. Soil

1. Compresso r must be certified by Third Party and valid. 2. Ensure all hose connection Page 18 of 23

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PROCEDURE FOR SURFACE PREPARATION AND PAINTING FOR STRUCTURAL STEEL AND PIPING Pollution due to oil leakage properly fitted and whip check installed. 3. Ensure all other workers are using ear plugs while working or staying nearby. 4. Fire extinguisher to be readily available. 5. Use spill tray or plastic containment. 6. Use coverall and leather apron for blaster 7. Use of Electrical Hand tool like buffing wheel and grinder, etc 1. Electrocution 2. Electrical shock 3. Burn injury 4. Splinter / piercing injury form failed consumables. 1. Regular tool box talk and training on hazards involved to all the related workers. 2. Always maintain good housekeeping. 3. Use coverall and leather apron. 4. No parallel works to be permitted in front of the buffing and grinding work Rev. A1 Page 19 of 23 Fabrication Engineer and HSE Team

5. Noise pollution, repeated strain and injury to limb

Proc. No.: BD1253AA-BHAG-Q-PRO-0005

PROCEDURE FOR SURFACE PREPARATION AND PAINTING FOR STRUCTURAL STEEL AND PIPING area.

5. Ensure good earthing and insulation for the electrical cable. 6. No tampering with guards and other devices. 8. GRIT Blasting using copper slag using Air Compressor 1. Improper operation. 2. Unauthorized entry. 3. Compressor hose or clamp and Nozzle failure. 4. Dust and noise pollution. 5. Personnel injury like eyes, lungs, piercing and impact injury. 6. Fire/ Explosion 7. Tripping Hazards 8. Used grit waste 1. Only authorized workers to carry out blasting work. 2. Worker s shall be explained about the hazards involved in the blasting and painting work. 3. Whip check to be provided to Hose and Compressor out ports and joints. 4. Deadman switch has to be connected to the hose to be filled on blasting nozzle. Fabrication Engineer and HSE Team

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PROCEDURE FOR SURFACE PREPARATION AND PAINTING FOR STRUCTURAL STEEL AND PIPING 5. Workers shall be provided with Breathing HOOD and Ear Muffs. 6. Interim break/ stop; shall be provided to workmen to relax & rest and machine for checking critical parts. 7. Sparking nozzle shall be on hold or arrested when compressor ON avoid wipe moment. 8. Sign board of grit blasting shall be clearly displayed.

9.

Spray painting works

1. Inhalation of fumes at work area 2. Skin contact. 3. Eye contact 4. Fire hazards 5. Handling full paint cans 6. Damage to paint containers 7. Paint

Fabrication Engineer and HSE Team

1. All painting and blasting works shall be carried out in the booth to prevent spreading of grit particles and paint sprayed. 2. No drinking water container shall be used for storage of Page 21 of 23

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PROCEDURE FOR SURFACE PREPARATION AND PAINTING FOR STRUCTURAL STEEL AND PIPING spillage and wastages 8. Compresso r hazard 9. Tripping hazard paints/ thinners, etc 3. Use of half mask face piece with chemical cartridge by the painter and helper at work area. 4. Use secondary containments for transferring of paints. 5. Provide plastic sheet for preventing soil contamination. 6. Smoking/s ource of ignition not permitted in vicinity of spray area.

Format for Surface preparation and Painting Report

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ARTSON ENGINEERING LIMITED

SURFACE PREPARATION & PAINT INSPECTION REPORT CLIENT: CAIRN ENERGY INDIA LTD. PROJECT: RAJASTHAN NORTHERN AREA DEVELOPMENT PROJECT ITEM: PAINTING SYSTEM: IDENTIFICATION No: (Line No/Spool No. /Drawing No.) Total Surface Area : REPORT NO: DATE: LOCATION:

PROFILE REQUIRED

ACTUAL

SURFACE PREPARATION ACHIEVED

Sa 2

ABRASIVE TYPE: Stage of Painting Operation Blasting Primer Intermediate Coat

DDD Start Time

SIZE: Dry Bulb Temp. C C C

Wet bulb Temp. C C C

Surface Temp. C C C C C C C C

D %RH Maximum % % % %

BATCH No: Dry Film Thickness (DFT) (Total average readings) --m m m

C C Final Coat Paint Manufacturer: AKZO NOBLE/AMERON/CARBOLINE Painting Sequence Primer intermediate Final coat TOTAL Paint Details

Batch Number mmm DFT Required m m m

Remarks:

AEL
Name: Signature: Date: Name: Signature: Date:

CAIRN

BD1253AA-BHAG-Q-RPT-0011

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