ENGINEERING COMPANY STANDARD
This document is property of Eni S.p.A. Exploration & Production Division.
It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.
FUNCTIONAL SPECIFICATION
PROTECTIVE COATING, GALVANISING AND
METALLISING FOR INTERNAL AND EXTERNAL
SURFACES OF OFFSHORE AND ONSHORE
STRUCTURES AND RELATED COMPONENTS
20000.VAR.PAI.FUN
Rev. 3 March 2010
3 Complete Revision of the Specification RM/ST RP/MC TC March 2010
2 Complete Revision of the Specification RM MC DC September 1999
1 Included the specification relevant to “Characterisation of the painting products”
October 1997
0 Issue February 1995
FOREWORD
Rev. 0 General Part - N. 19 Sheets Appendix A - N. 7 Sheets Appendix B - N. 4 Sheets Appendix C - N. 11 Sheets Appendix D - N. 10 Sheets Appendix E - N. 4 Sheets February 1995
This specification was issued in agreement to CEE directives. It cancels and supersedes AGIP Specifications 0366.VAR.PAI.SPC Rev. 8, 02739.VAR.PAI.SPC Rev. 1 of February 1989, 07603.VAR.PAI.SPC Rev. 0 of January 1990.
Rev. 1 October 1997
Issued to include the specification “Characterisation of the Painting Products”. Revised sheet 3 “Summary” to included paragraph 1.2.5. Internal Standard .
Rev. 2 September 1999
Complete revision of specification to fulfil and/or include new standard and procedures as well as new paint systems.
Modified all pages included the index of Appendixes “A”, “B”, “C”, “D” and “E”.
The previous Appendix “B” has been integrated in Appendix “A” and previous Appendixes “C”, “D” and “E” have become respectively Appendixes “B”, “C” e “D”. New Appendix “E” cancels and replace the Company Specification “Characterization of coating materials” 20538.VAR.PAI.SDS.
Cancelled and included in this Specification all documents VAR.PAI.STD. (from No. 11619 to No. 11681).
It cancels and replaces previous Revision 0 and 1 of Functional Specification 20000.VAR.PAI.FUN.
General Part No. 30 Pages Appendix “A” No. 11 Pages Appendix “B” No. 13 Pages Appendix “C” No. 7 Pages Appendix “D” No. 14 Pages Appendix “E” No. 11 Pages
Enclosures: Paint Systems Sheets No. 30 Pages
Rev. 3 March 2010
Complete revision of specification to fulfil and/or include new standards and procedures as well as new appendixes and paint systems.
It cancels and replaces previous Revision 2 of Functional Specification 20000.VAR.PAI.FUN.
General Part No. 30 Pages Appendix “A” No. 10 Pages Appendix “B” No. 8 Pages Appendix “C” No. 8 Pages Appendix “D” No. 14 Pages Appendix “E” No. 13 Pages Appendix “F” No. 29 Pages
TABLE OF CONTENTS 1. GENERAL...5 1.1 INTRODUCTION...5 1.2 SCOPE...5 1.3 REFERENCE STANDARDS ...8 1.3.1 ISO Standards...8
1.3.2 Standards of other Organisations ...9
1.3.3 Laws and decrees ...9
1.4 DEFINITIONS ...10
1.5 ABBREVIATIONS ...10
2. FUNCTIONAL REQUIREMENTS...11
2.1 OPERATIVE ENVIRONMENTS ...11
2.2 SUPPORT AND SUBSTRATE DEFINITION ...11
2.3 CRITERIA FOR PAINT SYSTEM SELECTION ...12
2.4 PAINT SYSTEMS QUALIFICATION...12
2.4.1 Paint systems currently qualified ...12
2.4.2 Paint systems qualification...12
2.5 DESIGN AND STEEL IMPERFECTIONS ...13
2.6 GENERAL REQUIREMENTS ...14
2.7 PAINT AND COATING MATERIAL ...14
2.8 COATING MATERIAL STORAGE AND PRESERVATION...14
2.9 ENVIRONMENTAL CONDITION ...14
2.10 VENTILATION ...15
2.11 DEHUMIDIFICATION ...15
2.12 PROTECTION...15
2.13 SCAFFOLDING, STAGING AND ACCESSIBILITY ...15
3. SURFACE PREPARATION...15
3.1 GENERAL REQUIREMENTS ...15
3.2 EQUIPMENTS FOR ABRASIVE BLASTING...16
3.2.1 Abrasives ...16
3.3 SHOP-PRIMING ...17
3.4 SURFACE PREPARATION OF CARBON STEEL ...17
3.5 CLEANING AND PRECAUTIONS OF STAINLESS STEEL AND SPECIAL ALLOYS ...17
3.6 SURFACE PREPARATION OF HOT DIP GALVANISED STEEL ...17
3.7 SURFACE PREPARATION OF SHOP-PRIMED STEEL ...18
3.8 POWER TOOLING CLEANING ...18
4. HOT DIP GALVANISING...18
5. THERMAL SPRAY COATING (METALIZING) ...18
6. PAINT AND COATING MATERIALS APPLICATION ...18
6.1 GENERAL REQUIREMENTS ...18
6.2 SPRAY APPLICATION ...19
6.3 STRIPE COATING...19
6.4 BRUSH APPLICATION ...19
6.5 ROLLER APPLICATION ...19
6.6 WET FILM THICKNESS (WFT) AND DRY FILM THICKNESS (DFT) ...20
6.7 REPAIR OF DEFECTS...20
6.7.1 Inadequate coating thickness ...20
6.7.2 Contaminated Surfaces...20
6.7.3 Coating damages not exposing bare steel...20
7. PASSIVE FIRE PROTECTION...21
7.1 GENERAL...21
7.2 SCOPE...21
7.3 TYPES OF FIRE ...22
7.4 PFP MATERIALS AND APPLICATION...22
7.4.1 Materials...22
7.4.2 Approvals and certifications ...23
7.4.3 Surface preparation...23
7.4.4 PFP Application...24
7.4.5 PFP Repairs ...25
8. SAFETY AND ENVIRONMENTAL PROTECTION...25
8.1 GENERAL SAFETY REQUIREMENTS ...25
8.2 SPECIFIC SAFETY REQUIREMENTS ...25
9. REQUIREMENTS FOR QUALITY MANAGEMENT AND QUALITY ASSURANCE...25
9.1 GENERAL...25
9.2 PRE-JOB MEETING...26
9.3 RECEPTION OF PAINTS AND COATING MATERIALS ...26
9.4 INSPECTION AND QUALITY CONTROL...26
9.4.1 Contractor ...26
9.4.2 Paint manufacturer...26
9.4.3 “Third-Party” Inspection...26
9.4.4 Certification of personnel ...26
9.5 INSPECTION OF COATING PROCESS...26
9.5.1 Preliminary test ...27
9.5.2 Test during work execution ...27
9.5.3 Final Inspection ...28
10. DOCUMENTATION AND REPORTING...30
10.1 DOCUMENTS TO PRODUCE AT THE BEGINNING OF WORKS ...30
10.2 DOCUMENTS TO PRODUCE DURING WORK PROCESS ...30
10.3 DOCUMENTS TO PRODUCE AT COMPLETION OF WORKS ...30
11. APPENDIXES AND ENCLOSURES ...30
11.1 APPENDIXES ...30
1. GENERAL
1.1 INTRODUCTION
This Specification is formed by a general part in which the common requirements applicable to all Appendixes and Enclosures are described, by 6 (six) Appendixes identified with letter from “A” to “F“ and by the Enclosures containing the Paint Systems Sheets.
In the Appendixes are described the requirements for each specific type of structure, for storage tanks and risers, taking into consideration the different operating temperature, for particular application (Thermal Spray Coating) and for the qualification of the paint systems.
1.2 SCOPE
This Specification defines the minimum functional requirements related to surface preparation, application, supply, characterisation, inspection and testing of protective and thermal spray coatings intended to be applied to external and internal surfaces of Offshore and Onshore structures and related components, to storage and process tanks of new construction including surfaces under thermal insulation of carbon steel and non-ferrous metal
This Specification is not applicable to:
a) Painting maintenance works of any plant or structure.
b) External and Internal coatings for corrosion protection of immersed and buried pipes and related components, respectively subject of the Functional Specifications, 20550.PIP.COR.FUN. Rev.0 and 20551.PIP.COR.FUN. Rev. 0,
c) Conversion, transformations works and new construction of FPSO, FSO, In particular it describes the requirements for:
Characterisation and qualification of the paint systems, Paint systems selection,
Surface preparation, paint system application, equipments, qualification of personnel, etc. Methods and requirements for Hot Dip Galvanising,
Thermal Spray Coating, Inspection and quality control, Safety and environmental protection
This Functional Specification is intended to be general, not prepared for a specific project. Therefore according to the provisions of this Specification a “Project Technical Specification” shall be prepared taking into consideration and evaluating the specific project requirements with particular emphasis to:
Expected design life of the structure and its components
Operating environmental conditions of the structure and its components Operating temperature of the different substrates
Any other specific project requirement.
Based on requirements of the “Project Technical Specification” the Contractor shall prepare a “Working procedure” in which methods concerning each work and activity (e.g. abrasive blasting, coating application, cleaning, coating system selected, inspections, etc.) shall be described in detail.
Since the performance of the coating can be significantly affected by the quality of work execution (e.g. surface preparation, application of various coats, procedures and inspections) the requirements that shall be implemented during intermediate steps of coating works, are described as well.
Before coming into force, the “Working Procedure” shall be approved by the Company. As a general rule, recommendations and instruction listed in Product Data Sheets published by the Paint Manufacturers shall be followed. Possible conflicts and/or discrepancies between Products Data Sheets and this specification shall be submitted to the Company for approval.
In Figure 1 the general scheme for the development of the a coating project is reported for information only.
PROJECT Functional Specification 20000.VAR.PAI.FUN Operating Service Requirements evaluation Temperature Environment Paint system selection Project Technical Specification List of Company’s qualified systems Contractor Working Procedure Company Approval QCP EXECUTION Yes No
1.3 REFERENCE STANDARDS
This Specification refers to the most recent issue of the standards listed below, which become an integral part of the Specification and all related contractual documents.
It is Contractor’s duty to have copies of the standards applicable to each project and provide copies of them whenever work takes place. Contractor shall provide evidence of provision of standards to the Company before work begins and make standard available during each inspection step.
1.3.1 ISO Standards
ISO 834 – Part 3 Fire-resistance tests -- Elements of building construction -Commentary on test method and test data application
ISO 4628 Parts 1 – 6
Paints and varnishes – Evaluation of degradation of paint coatings – Designation of intensity, quantity and size of common types of defects.
ISO 8501 - Part 3: Preparation of steel substrates before application of paints and related products. - Visual assessment of surface cleanliness – Preparation grades of welds, cut edges and other areas with surface imperfections.
ISO 8502 Part 3 Preparation of steel substrates before application of paints and related products. - Test for the assessment of surface cleanliness. – Assessment of dust on steel surfaces prepared for painting (Pressure – sensitive tape method)
ISO 8502 Part 4 Preparation of steel substrates before application of paints and related products. - Test for the assessment of surface cleanliness. – Guidance on estimation of the probability of condensation prior to paint application
ISO 8502 Part 6 Preparation of steel substrates before application of paints and related products. - Test for the assessment of surface cleanliness. – Extraction of soluble contaminants for analysis – The Bresle method ISO 8502 Part 9 Preparation of steel substrates before application of paints and
related products. - Test for the assessment of surface cleanliness. – Field method for conductimetric determination of water-soluble salts. ISO 11124
Part 1 ÷ 4
Paints and varnishes – Preparation of steel substrates before application of paints and related products. Specifications for metallic blast-cleaning abrasives.
ISO 11125 Parts 1 ÷ 7
Paints and varnishes – Preparation of steel substrates before application of paints and related products. Test methods for metallic blast-cleaning abrasives.
ISO 11126 Parts 1 ÷ 8
Paints and varnishes – Preparation of steel substrates before application of paints and related products. Specifications for non-metallic blast-cleaning abrasives.
ISO 11127 Parts 1 ÷ 7
Paints and varnishes – Preparation of steel substrates before application of paints and related products. Test methods for non-metallic blast-cleaning abrasives.
ISO 12944 Part 2 Paint and varnishes - Corrosion protection of steel structures by protective paint systems. – Classification of environments
ISO 12944 Part 3 Paint and varnishes - Corrosion protection of steel structures by protective paint systems. – Design considerations
ISO 19840 Paint and varnishes - Corrosion protection of steel structures by protective paint systems – Measurement of, and acceptance criteria for, the thickness of dry films on rough surfaces
ISO 22899 Part 1 Determination of the resistance to jet fires of passive fire protection materials - General requirements
1.3.2 Standards of other Organisations
API RP 14G:2007 Recommended Practice for Fire Prevention and Control on Fixed Open-type Offshore Production Platforms. - 4th edition
ASTM A 123 Specification for zinc (hot-dip galvanized) coatings on iron and steel products.
ASTM A 153 Specification for zinc coating (hot-dip) on iron and steel hardware. ASTM A 392 Specification for zinc-coated steel chain-link fence fabric.
ASTM A 780 Specification for repair of damaged hot-dip galvanized coatings. ASTM D 2092 Practices for preparation of zinc-coated galvanized steel structures for
paint.
ASTM D 4285 Test method for indicating oil or water in compressor air.
ASTM D 4541 Test method for pull-off strength of coatings using portable adhesion testers.
ASTM D 4752 Standard test method for measuring MEK resistance of ethyl silicate (inorganic) Zinc-Rich Primer by solvent rub
NACE RP0287 Field measurement of surface profile of abrasive blast cleaned steel surfaces using replica tape.
NORSOK M-501 Rev 4 and Rev 5
Surface preparation and Protective Coating
OTI 95 634 Jet Fire Resistance Test of Passive Fire Protection Materials RAL 840 HR Deutschen Normen Auschuss
SSPC-SP 1 Solvent cleaning. SSPC-SP 3 Power Tool Cleaning SSPC-SP 5 White Metal Blast Cleaning SSPC-SP 7 Brush-off Blast Cleaning SSPC-SP 10 Near-White Blast Cleaning
SSPC-SP 11 Power Tool Cleaning to Bare Metal SSPC-TR 3 /NACE
6A192
Dehumidification and Temperature Control During Surface Preparation, Application, and Curing for Coatings/Linings of Steel Tanks, Vessels, and Other Enclosed Spaces
SSPC-VIS 1 Visual Standard for Abrasive Blast Cleaned Steel
SSPC-VIS 3 Visual Standard for Power- and Hand-Tool Cleaned Steel
1.3.3 Laws and decrees
The Offshore and Onshore structures, intended to be coated, could be built and/or located in various countries subjected to specific laws and rules; therefore, during the execution of the coating works, the rules, laws and decrees in force at the yard location or in the country where the coating works are performed shall be strictly observed.
1.4 DEFINITIONS
Contractor: Is the party accepted by the Company to perform the specified coating work.
Coating material: The liquid, liquefiable, mastic or any other composition and material that after application to a substrate, is converted into a solid protective adherent film.
Paint system : Is the total sum of the coats or similar products that are to be applied or which have been applied to a substrate to provide corrosion protection.
Paint Manufacturer: The manufacturer or supplier of the coating.
Dry-spray: Phenomenon that may occur during paint application by spray. Dry particles (dusting) of atomised paint fall over areas already coated or to be coated, but not yet dried, making surface rough and matt. If overcoated it can cause possible adhesion problem. Qualification: Evaluation process of a paint system allowing, through laboratory
tests, the selection of the suitable paint system intended for the different environments in which the structure will operate.
Material Safety Data Sheet:
Document published by the Paint Manufacturer describing all the aspects related to health and safety of a coating material or thinner.
Product Data Sheet: Document published by Paint Manufacturer describing product characteristics, use, application and storage instructions.
Specification: The terms “Specification” means this document namely the Functional Specification 20000.VAR.PAI.FUN. Rev. 3 including the Appendixes and Enclosures.
Stripe–coat: Additional coat of paint applied usually by brush on difficult-to-reach areas and on weld seams, edges, bolts, nuts, etc, to assure that the specified film thickness is achieved.
Substrate: Solid surface intended to be coated or lined with the specified coating system.
1.5 ABBREVIATIONS
ASTM American Society for Testing and Materials. VOC Volatile Organic Compounds
DFT Dry Film Thickness
(Dry thickness of a coating present on surface after the complete drying of the product).
ISO International Organization for Standardization. MSDS Material Safety Data Sheet
N.A. Not applicable. NACE NACE International.
NDFT Nominal Dry Film Thickness
Dry film thickness specified for each coat or for the paint system in order to achieve the expected durability
PFP Passive Fire Protection QCP Quality Control Plan
SSPC The Society for Protective Coatings.
RAL Colur definition system according to RAL standard of Deutches Institute für Gütesischerung und Kennzeichnung e. V.
TSC Thermal Spray Coating WFT Wet Film Thickness
Wet Thickness of the coating present on surface at the time of its application.
2. FUNCTIONAL REQUIREMENTS
Unless otherwise specified, the general requirements reported in this Section of the Specification are also fully applicable to the Appendixes and Enclosures.
2.1 OPERATIVE ENVIRONMENTS
The structures and related components coated according to the requirements of this Specification may be located in various geographical locations with different climatic conditions, but in general with similar environmental and service conditions.
According to the classification of environments defined in the standard ISO 12944-2, the atmospheric-corrosivity categories assumed by this Specification are as follows:
CATEGORY ENVIRONMENT DEFINITION
Exterior Industrial areas with high humidity and aggressive atmosphere.
C5-I
Interior Buildings or areas with almost permanent condensation and with high pollution.
Exterior Coastal and offshore areas with high salinity.
C5-M
Interior Buildings or areas with almost permanent condensation and with high pollution.
Im1 Fresh water – Structures permanently or intermittently immersed
installed in fluvial or lake areas
Im2 Sea water or brackish water – Structures permanently or intermittently
immersed installed in harbour, coastal and offshore areas.
Im3 Structures or components buried
In addition to the corrosivity categories listed in the previous Table in this Specification the storage tanks containing liquids and fluids of different type and nature than fresh, salt and brackish water are also considered as a specific operative environment, as better defined in Appendix “C”
2.2 SUPPORT AND SUBSTRATE DEFINITION
The different types of substrates considered in this Specification are as follows:
Any type of Carbon Steel of not less than 6 mm thickness
Shop-primed Carbon Steel
Hot Dip Galvanised Steel
Light and Special alloy
2.3 CRITERIA FOR PAINT SYSTEM SELECTION
The selection of paint systems suitable for the different facilities and plants shall be performed in accordance with the requirements reported in the relevant Appendix.
To select the most suitable paint systems for a specific project the following basic criteria shall be considered:
a) Project needs and requirements;
b) Operating environment (sea water, soil, other); c) Type of support or substrate to protect
d) Operating temperature.
The paint system shall be selected in accordance with the applicable paint system Tables reported in each Appendix and with the Paint System Sheets of the Enclosures.
2.4 PAINT SYSTEMS QUALIFICATION 2.4.1 Paint systems currently qualified
The paint systems qualified according to the procedure and requirements of the Functional Specification 20000.VAR.PAI.FUN. Rev. 2 are no longer valid; therefore they shall be submitted to a new qualification process as described and required by this Specification. Nevertheless the Company, in order to fill the gap following the issue of this Specification, should approve, during the first year after the issue, the application of paint systems currently qualified in accordance with the requirements of Functional Specification 20000.VAR.PAI.FUN Rev.2, provided that the selected Paint Manufacturer has demonstrated the begin of the qualification process of his paint systems according to the requirements of this Specification.
2.4.2 Paint systems qualification
Only the paints and paint systems qualified according to the requirements defined in the Appendix “D” shall be selected and applied.
The qualification process shaIl apply to all coating materials, paints and paint systems provided by this Specification, including the materials for repair. In the paint system sheet of the Enclosures the tests required for paint system qualification are listed.
As a general rule, two test levels are required:
a) Pre-qualification step, addressed to evaluate all the data relevant to the proposed paint system(s) in order to evaluate their consinstency with the general requirements of the Specification,
b) Qualification step, addressed to the execution of characterisation tests specified for each paint system with the scope to verify the suitability and performance for the intended environment and service.
All tests and analysis reported in the Appendix “D” shall be performed and certified by independent laboratories qualified and approved by the Company.
The tests and qualification analysis might be executed at Paint Manufacturer laboratories, subject to the audit and assessment of the Company of the real capability (including instruments, equipments and the general organisation) of the laboratory to perform the tests required by the Appendix “D”. The Paint Manufacturer shall prepare a detailed tests schedule in which the timing and location for sample’s preparation and test execution shall be reported; the schedule shall be sent in advance to the Company whom besides to have free access to
the Paint Manufacturer laboratory, reserve the right to attend during the execution of the test without notice.
The qualification of a coating material or coating system is not binding for the Company, which shall select, at its sole discretion, one of the paint system included in the list of qualified paint systems.
Company’s qualification is given for an open-ended term. However the Company reserve the right to require at any time the repetition of one or more of the qualification tests to verify the quality of the coating or as consequence of possible coating failure. If the result of one or more tests is negative, the qualification will be cancelled.
Any modification to the formulation or components of a coating material or system, even if considered minor, made by the producer after the qualification, shall be notified in writing to the Company. The Company reserves the right to require the performance of part or the complete the test procedure, or to accept or reject the modified paint, without further tests. The modified coating material or system - when qualified - may be used in place of the previous one or as an alternative.
The Contractor is obliged to select one or more paint system from the list of paint systems qualified by the Company.
Under no circumstance the Company approval of a coating system shall be considered a guarantee from the Company related to the coating materials and repair products and they performance, but just as an approval to use it.
2.5 DESIGN AND STEEL IMPERFECTIONS
During the design and the construction of metallic components, the basic criteria listed in standard ISO 12944-3 shall be taken in due consideration.
As far as possible, contact of different metals shall be avoided. In case, due to the unavoidable design requirements, the contact cannot be avoided, a suitable insulated material (Teflon or similar) shall be installed between the different metals. This includes pipes and related supports, bolts, clips, etc. installed in permanent or intermittent immersed areas and on external areas
The construction shall be designed in such a way that it will not interfere with the abrasive blasting or paint application according to this Specification. No openings, holes, etc. in structural members shall be less than 60 mm in diameter and the distances between structural members shall be≥50 mm.
Welding shots, drops and spatters, pores in the weld seams, lamination defects, edges, flame cuts, fragments and dents or any other foreign object not removed during construction shall be considered imperfections and therefore shall be removed before surface preparation. The steel imperfections detected before, during or after surface preparation shall be removed with suitable power tools according to the requirements of standard ISO 8501-3 as follows: Grade P3: for all surfaces intended to be permanently or intermittently immersed or
buried. Edges from flame or mechanical knife cutting shall be rounded to a radius of 2 mm.
Spot and discontinue welds shall be not permitted on these surfaces.
Grade P2: for all surfaces exposed to marine and industrial environment. Edges from flame or mechanical knife cutting shall be adequately rounded by tree passes grinding. Spot and discontinue welds shall be not permitted on these surfaces.
2.6 GENERAL REQUIREMENTS 2.7 PAINT AND COATING MATERIAL
All coating and finishing materials shall be high-grade commercial products of a quality satisfactory to the Company, in accordance with the Paint System Sheets enclosed and with Company’s colour standards.
Al coating forming a paint system shall be of the same Paint Manufacturer.
In case the paint system is applied on a shop-primer, this could be of different Paint Manufacturer. The Paint Manufacturer supplying the paint system shall confirm the complete compatibility of his paints applied on the shop-primer produced by different Paint Manufacturer
All coating materials shall be supplied to the work site in their original unopened and clearly identified containers, bearing readable labels of the Paint Manufacturer and clearly reporting the following information:
a) Commercial name of the coating material, b) Name of Paint Manufacturer,
c) Colour,
d) Batch number of each components (Part A – Part B), e) Date of manufacture.
2.8 COATING MATERIAL STORAGE AND PRESERVATION
All coating materials and thinners shall be properly stored in the Contractor’s facility. The following minimum requirements must be satisfied:
a) The store shall be appropriately ventilated and comply with provisions law in force concerning safety and fire prevention;
b) Coating materials (liquid, solid or packaged) shall be kept in their original sealed and labelled containers or package;
c) Coating materials shall be protected from direct sun, frost and rain, stored in a thermally controlled store with constant temperature in the range of +15 to +25°C;
d) The coating materials store shall be located at a proper distance from any significant heat source and from any area where free flames, welding works, and tools causing sparks are used;
e) Containers and packages shall not be placed nor stored on wet or damp surfaces, nor in areas where flood can occur;
f) All products that become altered for any reason or show the container and/or package partially or totally destroyed and/or damaged shall be removed from the store, not used for the coating work and properly disposed of;
g) Coating materials shall be stored and used in a manner that assures that products are used within their storage limits (shelf-life), and those stored first are the first used.
2.9 ENVIRONMENTAL CONDITION
Surface preparation shall not be carried out when the steel temperature is less than 3°C above dew point or when the relative humidity of the air is greater than 85%.
No coatings shall be applied when the steel temperature is less than 3°C above dew point, when the relative humidity of the air is greater than 85%, or when the air temperature is less than 10°C, excluding those products which are suitable for application at low temperature. Environmental conditions shall be measured according to standard ISO 8502-4.
In outdoor application, no coating materials shall be applied when there is a likelihood of a detrimental weather change within two hours after application.
2.10 VENTILATION
When the abrasive blast cleaning is carried out in confined spaces, the Contractor shall install a suitable and sufficient ventilation and extraction system to allow a good visibility of the operators. The ventilation system and trunking should be arranged to minimise or eliminate “dead spaces”.
Suitable and sufficient ventilation shall be maintained during the application of paint or other material and continues whilst solvent is released from the paint film during drying. The ventilation system shall assure the correct drying of the paint film and shall prevent the vapour concentration exceeding 10% of the Lower Explosive Limit (LEL).
2.11 DEHUMIDIFICATION
When coating works are performed in confined spaces (tanks, vessel, cofferdams, etc.) the Contractor shall install a dehumidification system suitable to keep the environmental condition in line with the requirements of the Specification and in any case at 40-60% of relative humidity independently from the variation of environmental condition on the exterior. As far as possible the recommendations reported in the standard SSPC-TR 3/NACE 6A192 shall be followed.
2.12 PROTECTION
The Contractor shall supply all necessary weather protection and any other equipment to ensure that the work is carried out in accordance with the Project Technical Specification and to the production schedule agreed with the Company.
The Contractor shall protect all equipments and structures and any other areas in order to avoid damages caused by surface preparation and coatings application.
2.13 SCAFFOLDING, STAGING AND ACCESSIBILITY
Whatever fixed or not, scaffolding or staging shall comply with the applicable safety rules. Fixed staging shall be such that easy and safe access will be provided for the correct coating application and inspection of all surfaces. All staging should be erected so that it will leave a clear area of at least 30 cm from all surfaces to be cleaned and coated and 2 m between each level.
Staging layout should be such that tubular scaffolding and/or wood planks should not mask surfaces to be coated and/or prevent the correct execution of the paintworks.
All open ends of tubular scaffolding erected should be plugged to prevent access of abrasive material, powder and dirt.
The staging shall not be removed before final inspection and required tests of the surfaces have been performed.
During destaging any damages to the coated surfaces shall be avoided. Any damage occurred shall be repaired according to the repair procedure provided by the Specification.
3. SURFACE PREPARATION
3.1 GENERAL REQUIREMENTS
Surface preparation method shall be selected in accordance with the requirements of Standards SSPC.
As general rule, all surfaces to be coated shall be cleaned to the specified preparation grade to obtain a surface that meets the requirements defined in the relevant Appendix and/or Paint System Sheets and in accordance with the specified SSPC standard.
Prior to any surface preparation (abrasive blasting, power tooling, etc.) it shall be removed with fresh water washing and/or proper detergent:
a) Any oil, grease, and other fatty materials in accordance with standard SSPC-SP1, b) Welding flux to obtain surfaces with a pH neutral (6,5 ÷ 7,5) ,
c) Penetrating and contrast fluids used for the non-destructive tests of the welding seams. Petroleum, kerosene, diesel oil or other fatty solvents shall not be used.
At completion of any surface preparation and in any case before application of each coat or other coating material, the maximum acceptable level of water-soluble salts shall be as follows:
3 µg/cm² (30 mg/m²) for stainless steel surfaces and for carbon steel surfaces
permanently or intermittently immersed
5 µg/cm² (50 mg/m²) for all surfaces exposed to the environment 10 µg/cm² for all other surfaces.
Extraction of contaminants from surface shall be done according to standard ISO 8502-6. The quantitative determination of water-soluble salts shall be performed according to standard ISO 8502-9.
The surface preparation shall not be performed on surfaces that are moist or may become moist before application of the scheduled coat.
No acid washes or other cleaning solutions or solvent shall be used on surfaces after they are abrasive blast cleaned. This includes inhibitive washes intended to prevent rusting.
3.2 EQUIPMENTS FOR ABRASIVE BLASTING
The compressed air supply used for abrasive blasting shall be free of water and oil. Adequate separators and traps shall be provided and these shall be kept emptied of water and oil and regularly purged. The control of the compressed air cleanness shall be done according to standard ASTM D4285.
In no circumstance, compressed air temperature shall be more than 100°C and pressure lower than 650 kPa measured at the nozzles.
3.2.1 Abrasives
All abrasive materials used for blast cleaning shall be dry, clean and free of water soluble salts. Conductivity measured according to standard ISO 11127-6, shall not exceed 300 µS/cm (microSiemens/cm) measured at 20°C and chloride content shall be less than 25 ppm. Non-metallic abrasives shall meet the requirements of standard ISO 11126 Parts 1÷8, applicable to the type of abrasive intended to be used. Tests and controls shall be done according to standard ISO 11127 Part 1÷7.
Metallic abrasives shall meet the requirements of standard ISO 11124 Parts 1÷4, applicable to the type of abrasive intended to be used. Tests and controls shall be done according to standard ISO 11125 Part 1÷7.
Abrasive type and size shall be selected in order to assure the specified profile of the substrate.
3.3 SHOP-PRIMING
The Contractor, in case of particular yard conditions, procedures and/or other project requirements, may use shop-primed steel plates and profiles for the construction of the various items. The shop-priming shall be performed in accordance with the following requirements:
a) The surfaces (steel plates, pipes, beams, profiles etc.) shall be cleaned by abrasive blast cleaning in accordance with standard SSPC-SP 5,
b) Application of one coat of Inorganic Zinc Ethyl-Silicate shop-primer (prefabrication primer) with DFT of 18 – 20 microns
The shop-primer and the relevant DFT shall comply with the standards, cutting and welding procedures and shall be approved by the competent authority.
The above procedure shall be performed only in shops with automatic equipments both for the steel grit blasting and for the shop-primer application.
Contractor shall perform all required checks two times per shift and any malfunction of the equipments and/or working defects shall be promptly corrected and repaired.
The metallic abrasive used shall comply with the requirements listed in item 3.2.1 of the Specification.
3.4 SURFACE PREPARATION OF CARBON STEEL
Surface preparation of carbon steel, shall be always carried out by abrasive blasting with the preparation grade provided for the paint system and in any case according to the specified SSPC standard.
Profile of the abrasive blasted surfaces shall comply with the requirements provided by paint system and measured in accordance with standard NACE RP0287.
3.5 CLEANING AND PRECAUTIONS OF STAINLESS STEEL AND SPECIAL ALLOYS
Stainless steel structures and components shall be carefully inspected before their installation and before any surface preparation.
Any damages noticed on the structures and components shall be immediately notified by the Contractor to the Company, which shall provide instructions for repairs or disposal of the damaged structures and components.
In particular, handling shall be carried out with particular care and precautions shall be implemented to avoid ferrous contamination of the stainless steel structures and components. Furthermore the handling shall be accomplished using suitable equipments to avoid damages and contaminations of the surfaces.
The surface preparation of stainless steel and special alloys shall be performed only when these surfaces have to be coated. In this case abrasive blasting will be executed with the only purpose to rough the metallic surface according to the requirements of the provided paint system. The surface profile shall be measured according to standard NACE RP0287.
In no case steel grit/shot material shall be used for abrasive blast cleaning of stainless steel and special alloys.
3.6 SURFACE PREPARATION OF HOT DIP GALVANISED STEEL
All steel surfaces hot dip galvanised, before being coated with the specified paint system, shall be cleaned as follows:
cleaning and degreasing according to standard SSPC-SP 1,
galvanising defects and anomalies shall be removed by power and/or hand tooling paying attention to not completely remove the zinc layer;
measurement of galvanising thickness according to standard ASTM A 123 or ASTM A 153. Any item falling below the required zinc thickness shall be repaired according to standard ASTM A 780;
galvanised surface shall be roughen by abrasive sweep or brush blasting according to ASTM D 2092 or, as alternative, with other method reported in the standard ASTM D 2092, approved by the Company.
3.7 SURFACE PREPARATION OF SHOP-PRIMED STEEL
All shop-primed surfaces shall be cleaned by high-pressure fresh water washing (approx 20 MPa) and simultaneously scrubbing with stiff brush, if necessary, to remove zinc salt, chalk marks and other contaminants.
All damaged areas, included but not limited to weld seams, cut and shop-primer decay shall be cleaned according to the grade reported in the relevant Paint System Sheets and repaired by application of an epoxy primer. If required by the relevant Paint System Sheets the shop-primer shall be blasted off and the surface cleaned according to the required preparation grade.
3.8 POWER TOOLING CLEANING
For limited surfaces and after Company approval, power tool cleaning (power discing, needle gun or “Scotch-Brite”™) can be performed according to standards SSPC-SP 3 or SSPC-SP 11 and in accordance with surface preparation grade required by the Paint System Sheets enclosed to the Specification.
4. HOT DIP GALVANISING
Hot dip galvanising shall be carried out according to standard ASTM A 123 and ASTM A 153. The amount of applied zinc shall be 700 g/m² and however no elements must have less than 600 g/m², unless otherwise specified.
All gratings, stair steps and handrails shall be hot dip galvanised only after all cutting, fabrication and welding operations have been completed.
Galvanised elements designed to be permanently welded to structures shall be assembled after the support components have been primed, but before application of subsequent coats. The surfaces affected by weld heat shall be abrasive blast cleaned according to standard SSPC-SP 10 and coated with one coat of inorganic zinc.
Metallic gratings, provided that use of fiberglass type is not required, shall be hot dip galvanised according to standard ASTM A 392.
All surfaces hot dip galvanised shall be coated as specified in the related Paint System Sheets and/or Appendixes enclosed.
5. THERMAL SPRAY COATING (METALIZING)
All surfaces and components for which the application of “Thermal Spray Coating” (Metalizing) is required, shall be prepared according to the provisions specified in Appendix “E”.
6. PAINT AND COATING MATERIALS APPLICATION
6.1 GENERAL REQUIREMENTS
Before the application of each coat, all surfaces shall be dry and free of rust, grease, oil, dust, water soluble salts and any other foreign material.
All residues and dust of the fabrication shall be carefully removed. Surface cleanliness shall be comply with grade 1 for dust size Class “3”. “4” o “5” of standard ISO 8502-3.
Paints and coating materials shall be applied to the abrasive blast cleaned surfaces before any oxidation appears. Surfaces that show visible oxidation or deterioration shall be re-blasted to the required grade.
Coating application shall be done according to recommendations reported in the PDS of each paint and according to the requirements of this Specification; special attention shall be paid to the following factors:
only the specified thinners and the related instruction for dilution shall be used,
all coating materials shall be thoroughly mixed and stirred with a power mixer for a time sufficient to thoroughly remix the pigments and vehicles and, for two components products, the base with curing agent,
for each coat, minimum and maximum overcoating time shall be fully applied,
during drying, as well as during application, the instruction regarding ventilation of closed spaces shall be strictly followed,
application equipments.
Finishing colours shall be in accordance with the Company’s requirements as reported in the relevant Appendix.
In order to make easy the paint application and further checks, the colours of intermediate coats forming a paint system shall be of contrasting colour.
Any conflicts between PDS and this Specification shall be submitted to the Company for approval.
6.2 SPRAY APPLICATION
Equipments and components recommended by Paint Manufacturer and reported in PDS shall be used.
6.3 STRIPE COATING
Before spraying each coat of a paint system, all areas as: corner, edges, welds, bolts, nuts, difficult-to-reach-areas, etc. shall be pre-coated by brush (stripe-coated) to ensure that they at least the minimum specified film thickness. The colours of each stripe-coat shall be different from the previous coat.
6.4 BRUSH APPLICATION
Brush application may be used only under the following circumstances: When the areas cannot be properly coated by spray,
For stripe-coat application,
In case where the spray application may affect equipment or persons of the working area,
For touch-up or small repairs to damaged areas.
6.5 ROLLER APPLICATION
Use of roller will not be allowed for application of any zinc rich primer and of first coat of the paint system. The roller should be used, subject to Company approval, only for top-coat application when thickness less than 40/50 µm is required.
6.6 WET FILM THICKNESS (WFT) AND DRY FILM THICKNESS (DFT)
In order to achieve the specified DFT, the CONTRACTOR shall perform frequent checks of the WFT.
The measurement of DFT, including calibration and acceptance criteria, shall be performed according to standard ISO 19840. For the measurement the “90/10” rule shall be implemented, namely 90% of all measurements shall be greater than or equal to the NDFT and none of the remaining 10% measurements shall be below the 90% of NDFT.
Over-thickness shall be avoided and in any case shall not be greater than 50% of the NDFT specified for each coat.
DFT thickness readings will be taken as much as deemed needed; no limitations are applicable..
DFT shall be checked for each coat of the paint system.
6.7 REPAIR OF DEFECTS
The Contractor shall repair all coating defects and damages that will occur during the construction or at its completion.
Products used for repair of defects and damages shall be supplied by the same Paint Manufacturer of the original paint system.
Any repair shall be performed according to the instructions listed in the PDS published by Paint Manufacturer. Failing or for better explain the instructions, the criteria reported in the following sections shall apply.
All damages occurred to previous coats shall be repaired before application of the next one and before the final acceptance of the Company.
Surfaces coated with inorganic zinc primer shall not be touched-up with the same product, but shall be repaired using another product suggested by the Paint Manufacturer and approved by the Company
6.7.1 Inadequate coating thickness
All areas with inadequate coating thickness shall be thoroughly cleaned, if necessary, abraded and additional compatible coats applied until they meet the specified thickness. These additional coats shall not be visible on the final coating and on adjoining areas.
6.7.2 Contaminated Surfaces
Surfaces to be over-coated, which have become contaminated by grease, oil, fatty materials and any other foreign material shall be cleaned and degreased according to the standard SSPC-SP 1.
6.7.3 Coating damages not exposing bare steel
The coating around the damaged area shall be feathered using sandpapering or rotary discing. The re-cleaning shall be extended, not less than 50 mm, to undamaged surrounding surfaces in order to assure film continuity. The complete specified paint system shall be applied on the cleaned area.
6.7.4 Coating damages exposing bare steel
Damaged areas shall be cleaned by abrasive blasting or power tooling as required by the original grade of cleaning.
6.7.4.1 Damages of small dimension
Any damaged areas less than 200 x 200 mm shall be cleaned by power tooling according to standard SSPC-SP 11 and coated with the original specified paint system.
Surface preparation shall be extended not less than 50 mm to the surrounding sound coating and the edges properly fathered.
6.7.4.2 Damages of medium dimension
Any damaged areas less than 1 m2 shall be cleaned by abrasive blasting according to standard SSPC-SP 10 and coated with the original specified paint system.
Surface preparation shall be extended not less than 50 mm to the surrounding sound coating and the edges properly fathered.
6.7.4.3 Extensive damages
The damaged areas shall be considered extensive in the following instances: When the surface affected by damages is greater than 1 m2,
When the extension of the damages of small and/or medium dimension, is greater than 5% scattered or greater than 10% localized of the coated area.
In this circumstances the complete areas shall be re-blasted and re-coated as originally provided by the Specification.
7. PASSIVE FIRE PROTECTION
7.1 GENERAL
This Section of the Specification defines the minimum requirements for the application of Passive Fire Protection (PFP) to be installed on areas, piping and elements detailed in the relevant Project Technical Specification.
The PFP material and the application method of the system shall be approved by competent authority. The Contractor shall submit in advance to the Company all necessary documentation attesting that all components, materials, procedures and tests for the manufacture and supply of the PFP materials meet the requirements and the rules issued by competent authorities.
In any case compliance with the safety and other requirements of competent authorities and bodies is mandatory.
The PFP system should be designed to be capable maintaining the fire performance over the design life of the structure specified within the Project Technical Specification with minimum maintenance of the structures and components. In this regard, test data, relevant certification and track record of use of the proposed systems in similar environmental conditions (both offshore and onshore) to support the proposed PFP system’s ability to satisfy the requirements of the project shall be submitted to the Company.
7.2 SCOPE
The PFP systems are generally installed on steel support and structural elements of process equipments, vessels and piping. Their scope is to limit, in case of fire, the steel temperature to the value of 538°C in order to ensure the integrity of the structure. The FPP system can be installed as well as to process vessel containing hazardous substances (e.g. GPL and equivalent substances) to reduce the correlated specific risks such as for example the BLEVE – FIRE BALL and resulting domino effects.
The factors that shall be considered for the selection of the proper PFP systems are as follows:
1) Load and risk of fire (quantity of hydrocarbon, temperature, volatility and leakage probability);
2) Equipments subject to high risk of fire (e.g. pumps, compressors, furnaces, etc.); 3) Containment and disposal of possible hydrocarbon leakages from the source; 4) Automated shutdown systems of the plant and/or unit;
5) Interception remote control systems and/or discharge and emergency ventilation of equipments;
6) Lay out of the units, equipments and structures;
7) Equipments’ accessibility (obstruction, irradiations, smokes);
8) Response time in emergency situations of the plant’s personnel and firefighting team; 9) Density of cooling water used in fixed and or portable extinguishing systems;
10) Reliability and redundancy of firefighting systems ; 11) Availability over the time of water supply;
12) Particular risks, e.g. radioactive sources, substances and materials reacting with water, water-soluble materials, etc.
7.3 TYPES OF FIRE
This specification refers to the following types of fire: “H” Class: Hydrocarbon Fire
“J” Class : Jet-Fire.
7.4 PFP MATERIALS AND APPLICATION 7.4.1 Materials
All PFP materials shall satisfy the requirements of this Specification.
As general rule the PFP material shall consist of an intumescent epoxy mastic reinforced with hybrid carbon and glass fibre.
The PFP system shall be tested at recognised independent laboratory with proven experience in standards and tests related to hydrocarbon fire.
Before any type of PFP system application the “Type Approval” certificate issued by competent authority, shall be submitted to the Company.
Furthermore, the materials shall be tested and pre-qualified by independent laboratories according to the following procedures and standards:
a) NORSOK M-501 Rev. 4 or 5 (System 5a), tested without topcoat. Where these systems are applied directly to the process equipments substrate, only primer systems pre-qualified under System 5a of standard NORSOK M-501 Rev. 4 or 5 will be accepted. b) Underwriter Laboratories (UL) Environmental Test Program and provide written
confirmation that products are subject to the “UL Follow Up programme.
c) Documented evidence that the intumescent materials, at saturation, shall not exceed 4% water absorption after 90 days of immersion.
The PFP system shall be compatible with the application of top coat as specified by the Company.
The PFP system is required to be suitable for application to exposed surfaces of structural elements, vessel, piping, valves, actuators, flange etc. and shall be appropriate for continuous service in the following conditions:
Humidity: up to 100% in highly saliferous conditions, average value 82%,
Fire deluge: deluge with seawater from the fire protection system with an application rate of up to 20.4 l/m²/min.
The PFP system shall be unaffected by exposure to water (water deluge and/or fire water hoses). It shall also be resistant to general chemical and hydrocarbon damage should the material accidentally come into contact with these substances.
7.4.2 Approvals and certifications
The PFP system shall be supplied with Third Party issued “Type and Fire” certificates only; reports, project specific testing may only be allowed with the Company’s approval provided in accordance with API RP 14G. Therefore Contractor shall provide the data required and obtain a certificate of conformity.
All certificates shall be appropriate for the specific application identified. In particular the certificates of “Type Approval” must be provided for the following:
“Type Approval” certificates appropriate to type of structure or item being protected. “Type Approval” certificates for the appropriate type of fire the PFP system is expected to
withstand (hydrocarbon pool fire, Jet Fire or combination of both) detailing additional thickness required to withstand the effects of jet fire.
In the case of Jet Fire Contractor shall produce approval to the standard ISO 22899-1. Furthermore Contractor shall demonstrate in writing the material erosion factor required to withstand heat flux of 250 Kw.
“Type Approval” certificates showing thickness of PFP system to be used, duration of fire protection and critical steel temperature limit in accordance with Project Technical Specification and Approved by the Company.
7.4.2.1 Tests for hydrocarbon pool fires
Hydrocarbon pool fires are defined as a turbulent diffusion fire burning on a pool of liquid involuntarily spilt on to an open surfaces and collected on flooring proof surfaces both on the ground and on upper level or into restricted surfaces of the same level. The PFP systems shall be tested and certified according to standard ISO 834-3.
7.4.2.2 Test for jet fires
The liquefied gasses under pressure do not normally form liquid pools as a result of accidental release but they disperse as a jet of liquid aerosol or vapour. This type of releases unlikely leads to liquid pools. Similarly the vapour releases disperse like jets. The trigger of a liquid aerosol or of vapour jet can lead to a jet fire with high radiation intensity. The flames length and width of the jet vary according to the upstream pressure of the release, the size and geometry of the hole as well as the wind speed if present.
Additionally, the velocity and turbulence of the jet may be highly erosive on certain PFP system. These effects may lead to rapid and intense localised damages and subsequent knock-on effects such as structural collapse, loss of containment and escalation.
Although all hydrocarbon fires produce a high heat flux, overall, the jet fire has potentially the greatest impact due to the combined heat fluxes and erosive effects. Therefore it represents the most severe fire scenario that a PFP system could be required to resist.
The PFP system shall be tested and approved in accordance with standard ISO 22899-1 and OTI 95 634.
7.4.3 Surface preparation
The surface preparation shall be in accordance with the requirements listed in Chapter 3 of this Specification and in particular:
• Degreasing: as per standard SSPC-SP 1
• Steel imperfection: Grade P2 of standard ISO 8501-3
• Water soluble salts: ≤5 µg/cm2 for C.S. and ≤3 µg/cm2 for S.S. and other metals and alloys
• Abrasive blasting of carbon steel: according to standard SSPC-SP 10 with surface profile of 50 – 75 µm.
• Abrasive blasting of aluminium, S.S. and HDG: according to standard SSPC-SP 7 in order to produce a surface profile as follows:
• Aluminium: 75 – 100 µm • Stainless steel: 35 – 50 µm • HDG: 50 – 75 µm
For aluminium and stainless steel substrate non-metallic abrasive shall be used according to the requirements listed in Chapter 3.2.1 of this Specification.
Power tool clearing may be used only to abrade plastic substrate only and to clean or abrade surfaces requiring repair work. In no circumstances power tool cleaning shall be used for the surface preparation of any metallic substrate.
7.4.4 PFP Application
The PFP system is listed in the paint system sheets Nos. 012 and 013 of the Enclosures of this Specification.
Type and DFT of the primer shall be approved by the PFP material manufacturer. The written approval shall be submitted to the Company before commencement of the primer’s application.
The adhesion of the primer shall be in any case not less than 10 MPa measured with hydraulic instrument (PAT) in accordance with standard ASTM 4541.
When the structure or components to be fireproofed have an operating temperature in the range of 80 e 150°C, a suitable epoxy based thermal insulation material shall be installed between the substrate and the PFP system.
In order to assure that the char formed during fire exposure remains in place to insulate the substrate, carbon and glass fibre mesh reinforcement shall be installed during PFP application. The mesh reinforcement shall be installed at mid-depth of total PFP system thickness and selected in accordance with the requirements of competent authority.
PFP thickness shall be fully in accordance with the certified design class of surface to protect as defined by the Project Technical Specification.
The tolerance of the average PFP system thickness shall be in the range of 0 and +2 mm. The PFP shall be applied in accordance with the recommendations and instruction reported in PDS published by the manufacturer and approved by Company including mixing equipments, application method, curing and inspection, method for measuring wet and dry thickness, repairs.
All working steps (substrate conditions, surface preparation, primers, application, topcoats, etc.) shall be inspected and accepted by the PFP manufacturer.
Contractor shall demonstrate that both the its company and the personnel who will be directly involved on the project as well as the specialised equipment intended to be used, are certified by the Manufacturer of the proposed PFP system.
A detailed QCP prepared by the Contractor shall be submitted to the Company for approval before commencement of the work. This shall include all the working steps, without exceptions, of the PFP application.
Once that the PFP is cured, and before the application of topcoat, the thickness shall be checked to verify the conformity with the specified requirements. For this purpose holes, which frequency and number shall be clearly specified in the QCP and approved by the Company, shall be drilled down to the substrate. The holes shall be marked and filled with fresh material immediately after the readings. Where feasible, ultrasonic techniques may be used as an alternative to verify the thickness of the coating.
On horizontal surfaces and cavities, adequate water drainage shall be ensured. Areas, which are difficult to access for spraying of PFP, shall be boxed, to the possible extent, before the application of the PFP.
7.4.5 PFP Repairs
The damaged area shall be removed and the edge around the area shall be cut back to solid materials. Adequate overlap with existing reinforcement shall be ensured. If the area is greater than 0,025 m2, the mesh shall be replaced and secured to the substrate. If the corrosion protection is damaged, the area shall be abrasive blast cleaned according to standard SSPC-SP 10 and coated as originally specified.
8. SAFETY AND ENVIRONMENTAL PROTECTION 8.1 GENERAL SAFETY REQUIREMENTS
The Company, in consideration of its policy for Safety and Environmental protection, forbids the use of any coating material containing tar and any abrasive material considered hazardous to health for the operators.
The Contractor shall observe the rules, laws and regulations on health, safety and environmental protection applicable to his premises, or in the country where the works are performed.
All coating materials, solvents, curing agents, etc. shall report on their containers, data required by local laws and rules, and shall be accompanied by the related Material Safety Data Sheets.
8.2 SPECIFIC SAFETY REQUIREMENTS
Safety requirements must be carefully observed during handling and application of each coating according to Material Safety Data Sheets and Product Data Sheets published by Coating Manufacturers.
Special attention is to be given to the following items:
Mixing and handling of coating material shall be performed in areas that are not judged to be dangerous and where air can circulate freely;
Blast cleaning abrasives shall not be harmful to operators' health;
Storage of coating material shall be done as reported in item 2.8 of this Specification; Disposal of residual materials (spent abrasives, coating materials, solvent, etc.) shall be
performed fully in accordance with rules, regulations and laws in force in the country where the coating work is performed.
9. REQUIREMENTS FOR QUALITY MANAGEMENT AND QUALITY ASSURANCE
9.1 GENERAL
Contractor shall comply with all requirements for Quality Management and Quality Assurance that are defined in the applicable “Quality and Execution Requirements Specification” attached to the invitation to bid.
9.2 PRE-JOB MEETING
Before the beginning of the works a pre-job meeting shall be held with attendance of the representatives of all involved parties (Company, Contractor, Coating Manufacturer, Subcontractors and Coating Third-Party Inspector). The purpose of the meeting is to clarify and agree the production procedures, qualification tests, checks and inspections program, report forms and any other necessary requirements to achieve the correct job execution.
9.3 RECEPTION OF PAINTS AND COATING MATERIALS
The Contractor shall ensure that coating materials purchased and supplied comply with the specified requirements reported in the paint system sheets and if applicable with the relevant Appendixes.
The Contractor shall keep for at least 3 years the technical and administrative documents related to the purchase, both those produced by himself and by the Paint Manufacturer. All coating materials shall be delivered to the job site in their original containers with intact labels and seals. The containers shall be provided with identifying documents clearly stating their content and shelf life.
9.4 INSPECTION AND QUALITY CONTROL 9.4.1 Contractor
The Contractor shall nominate in-house inspector responsible for performing quality control functions according to the Quality Control Plan (QCP). The inspector shall have adequate experience of the specific coating process to inspect and/or to test. A statement reporting the inspector’s name and the list of the coating work experiences shall be included to QCP when submitted to the Company approval.
The Contractor’s inspector shall perform all necessary QC checks and tests to ensure that work complies with the approved QCP and with the specific requirements defined by Company.
9.4.2 Paint manufacturer
The Paint Manufacturer shall provide technical support whenever work is performed.
The Paint Manufacturer representative shall verify that the paintworks are properly performed and he shall, through visits and inspections as necessary, assure the correct application of the paint according to the requirements.
9.4.3 “Third-Party” Inspection
In addition to the in-house inspector defined in item 9.4.1 above, the Company shall reserve the right to appoint an independent third-party inspector, who shall verify and confirm that the execution of every working step complies with the requirements of the Specification.
The independent third-party inspector shall verify the QC testing carried out by the Contractor, and prepare written reports that shall be submitted to both Contractor and Company, and to Paint Manufacturer when requested.
9.4.4 Certification of personnel
All personnel involved in the inspection process and defined in items 9.4.1, 9.4.2 and 9.4.3 shall be NACE Level 3 or FROSIO Certified, and shall have adequate experience in the Oil & Gas industry.
9.5 INSPECTION OF COATING PROCESS
Prepare a work procedure describing in detail the various activities to be performed, including the proper equipment to be used, an adequate work environment, compliance with reference standard and rules and with specific Company requirements;
Monitor and check the specific characteristics of any coating process.
9.5.1 Preliminary test
Before the start of the coating works the inspections and tests listed in Table 1 shall be performed and in particular:
Storage of paints and coating materials; Containers and packaging integrity;
Shelf life validity of paints and coating materials;
Compliance of all documents (shipping, packing list, marking, PDS, MSDS, etc.).
9.5.2 Test during work execution
The Contractor shall perform, during the works progress, all the inspections and tests required by this Specification and listed in Table 1. The inspections and tests shall be performed as well as for the repairs of the damages occurred during the coating process. Contractor shall prepared 1 set of 3 panels with the dimension of 300x500x5 mm, of the same material of the components intended to be coated, that shall be cleaned and painted together with any components, following the same surface preparation, application and paint system provided for the components or area, using “step method” as reported, for information only, in Figure 1.
All the panels shall be used to carry out the required destructive tests, as detailed in Table 1. The 3 panels, shall be univocally identified in the presence of the third-party inspector, with clear reference to the Project and to the specific item. The panels shall be kept at the Contractor Quality Control office for possible further controls and checks.
Figure 2
9.5.3 Final Inspection
Once coating works are finished, the Contractor shall perform all inspection and tests related to the paint or coating system as specified in Table 1.
TABLE 1 – Inspections and tests to be performed during coating works execution
Item Test Type Method Frequency Acceptance Criteria
1 Preliminary Tests
1.1 Storage of coating materials Visual All According to the Specification
requirements (Ref. Item 2.8)
1.2 Containers integrity Visual All According to the Specification
requirements (Rif. Item 2.8)
1.3 Shelf life Visual All According to Product Data Sheets
(Rif. Item 2.8)
2 Steel and welding imperfections ISO 8501-3 100%
According to requirements and conform to the grade specified (Rif. Item 2.5)
3 Surface Preparation
3.1 Environmental conditions ISO 8502-4 Before start of each
shift and twice a day
According to the Specification requirements (Rif. Item 2.9)
3.2 Welding flux removal Distilled water and
litmus paper 100% pH neutral (6.5 – 7.5)
3.3 Pre-cleaning of surfaces SSPC-SP 1 100% Free of oil, grease and other
contaminants.
3.4 Protection of fittings and accessories Visual 100% According to the Specification
requirements (Rif. Item 2.12)
3.5 Compressed air ASTM D4285 Every Shift Free of oil and moisture
3.6 Abrasive materials ISO 11127-6 Every Shift ≤300 µS/cm a 20°C
3.7 Abrasive blast cleaning SSPC-VIS 1 100% Conform to final grade specified inthe relevant paint system sheet
3.8 Power tool cleaning SSPC-VIS 3 100%
According to requirements and conform to the grade specified (Rif. Item 3.8)
3.9 Roughness NACE RP0287 Spot Checks(1) Conform to final grade specified in
the relevant paint system sheet
3.10 Dust test ISO 8502-3 Spot Checks(1) Conform to Grade 1 and dust
dimension Class “3”, “4” o “5”
3.11 Water soluble salts ISO 8502-6
ISO 8502-9 Spot Checks
(1) According to the required level (Rif.
Item 3.1) 4 Coating Application 4.1 WFT Metallic “Comb Gauge” Methodically during application
According to PDS for the specified DFT (Rif. Item 6.6)
4.2 Cleaning of each coat ISO 8502-3 Spot Checks(1) Conform to Grade 1 and dust
dimension Class “3”, “4” o “5”
4.3 DFT of each coat and of complete paint
system ISO 19840 100% of surfaces
According to the Specification requirements (Rif. Item 6.6)
4.4 Curing of the inorganic zinc silicate ASTM D 4752 Spot Checks(1) Conform to Level 5
4.4 Adhesion ASTM D 4541
TYPE III Spot Checks
(1) To be performed on test panels
Minimum value 5 MPa
4.5 Visual examination Visual and
ISO 4628 1 ÷ 6 100% of surfaces
No sagging, contaminations, orange peel, cracking, blistering rust damages and any other defects (1) Number and location shall be defined and agreed during pre-job meeting
10. DOCUMENTATION AND REPORTING
10.1 DOCUMENTS TO PRODUCE AT THE BEGINNING OF WORKS
Before to start the activity the Contractor shall submit to the Company the following documents:
Working procedures;
Plan and schedule of operation for surface preparation and application of each coat of the paint system;
Characteristics of storage area and location where the paint and coating material will be stored;
Plan of inspections (QCP) to be performed before, during and after coating operations;
10.2 DOCUMENTS TO PRODUCE DURING WORK PROCESS
During work progress, the Contractor must keep a working Data Log, which shall be available any time to the Company, as well as minutes, records and reports required by item 9.5. of this Specification.
Furthermore, PDS and MSDS of each product used shall be always available.
10.3 DOCUMENTS TO PRODUCE AT COMPLETION OF WORKS
When work is completed the Contractor shall prepare a final report including following data: Surface preparation characteristics;
Trade name and characteristics of each paint system applied; Sequence of the coats applied for each paint system;
Atmospheric and thermo-hygrometric conditions;
Inspections and tests performed and the relevant results, including final acceptance reports;
Repairs, if any, and corrective actions undertaken.
11. APPENDIXES AND ENCLOSURES 11.1 APPENDIXES
Appendix “A” Corrosion protection of Offshore structures and modules Appendix “B” Corrosion protection of Onshore facilities
Appendix “C” Lining and coating for storage and process tanks
Appendix “D” Pre-qualification and characterisation requirements for coating materials and paint systems
Appendix “E” Qualification and application of Thermal Spray Coatings (Metallising) for corrosion prevention of metallic structures - (Offshore – Onshore)
Appendix “F” Corrosion protection of external surfaces of risers - (Offshore)
11.2 ENCLOSURES
Paint system sheets
Technical Specification 27591.VAR.PAI. SPC – Table of approved Paint Systems – Attachment of Specification 20000.VAR.PAI.FUN