Ad CDZZZZ MT Spe 0022 000

TECHNICAL DOCUMENTATION FRONT SHEET
BP EXPLORATION
(SHAH DENIZ) LTD
AZERBAIJAN DEVELOPMENTS
Specification for Thermally Sprayed Aluminium (TSA) Coatings
D01
05/09/11
AFD
AB
IP
A1
08/12//10
IDC
PW
IP
Rev
Date
Prepared
Reviewed
Lead
Reason for
Issue
Notes:
NOTICE: These materials are the
Work Product of KBR, and no
reliance on this work product is
authorised by KBR, and KBR
accept no liability for any reliance
by any person on the work product
contained herein. BP has expressly
authorised KBR to issue this
disclaimer.
Originator
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AD
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Approved
Approved
Reviewed
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SPA
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N/A
KBR
Code
CDZZZZ
Document Type
SPE
System Number
00
UNCONTROLLED WHEN PRINTED
EAA
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This document shall not be

reproduced without permission of
BP Exploration (Shah Deniz) Ltd
CT
BP
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Specification
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AD
CDZZZZ
MT
SPE
0022
000
D01
Page 1 of 17
AD-CDZZZZ-MT-SPE-0022-000 D01
Specification for Thermally Sprayed
Aluminium (TSA) Coatings
Revision History and Hold Record

Revision History
Date
Rev.
No.
Detailed Description of Change
Ref.
Section
Hold Record
Hold Ref.
Description / Reason for Hold
Ref.
Section
Page 2 of 17
Table of Contents
1.0 INTRODUCTION............................................................................................................ 5
1.1 Scope......................................................................................................................... 5
1.2 References................................................................................................................. 5
1.3 Abbreviations and Definitions.....................................................................................6
2.0 GENERAL REQUIREMENTS.........................................................................................6
2.1
2.2
2.3
2.4
2.5
Health, Safety and Environment................................................................................6

CONTRACTORs Responsibilities..............................................................................7
Qualification of Blasters.............................................................................................7
Qualification of Coating Operators.............................................................................8
Qualification of QC Personnel....................................................................................8
3.0 MATERIALS................................................................................................................... 8
3.1
3.2
3.3
3.4
General....................................................................................................................... 8
Blast Cleaning Abrasives............................................................................................8
Aluminium Coating Material........................................................................................9
Sealer Coating............................................................................................................ 9
4.0 PRE-QUALIFICATION REQUIREMENTS......................................................................9

4.1 Materials..................................................................................................................... 9
4.2 Application Trial........................................................................................................10
5.0 SURFACE PREPARATION...........................................................................................10
5.1 Pre-blasting Preparations.........................................................................................10
5.2 Blast Cleaning..........................................................................................................11
5.3 Environmental Conditions........................................................................................12
6.0 COATING APPLICATION.............................................................................................12
7.0 REPAIRS...................................................................................................................... 13
8.0 MONITORING, INSPECTION AND TESTING..............................................................13
Page 3 of 17
TECHNICAL DOCUMENTATION FRONT SHEET

Total pages: 1
Advised Changes Listing
Changes to be Applied to
Document Title: Specification for Thermally Sprayed Aluminium (TSA) Coatings
Document Number: BR-CDZZZZ-MT-SPE-5063-D2
Bullet Point Listing of Changes

1. Scope clarified
2. Requirement for GFVE coating on TSA removed
Appendix A and references to the Appendix removed as it is no longer applicable. TSA will
not be used in these areas.
3. Changes to codes and standards

Added: ISO 14918 (operator qualification), ISO 8502-6 & ISO 8502-9 (measuring salt)
Deleted: BS 4800 (not referenced in spec).Updated as required.
4. Qualification of Personnel
Coating operators: Requirement added for approval testing of thermal sprayers to ISO
14918, Annex B.1 and B.9, witnessed and certified by an independent third party authority.
QC personnel: Replaced professional organisation specialising in thermally sprayed
metallic coatings with independent third party authority for certification.
5. ETP requirement for blast preparation
Surface preparation changed to ISO 8501-1 Sa 3 for TSA coatings per GIS 06-601.
6. Soluble salt measurement of blasted surfaces
Added inspection per ISO 8502-6 and ISO 8502-9 to a NaCl content of 20 mg/m 2 (5.1.5).
7. Updates to section Blast Cleaning - General
Numbering of paragraphs as 5.2.2.1 etc. Addition of paragraph for cleaning of surfaces
exposed to salts (5.2.2.10).
8. Deleted Failures to conform shall be treated as fraudulent.
This is not part of the technical specification (should be with contracts/legal).
9. Dust testing
Requirement added for one tape test for per item in addition to once per10m 2.
10. Adhesion testing

Adhesion testing to be done on test panels, not the production item, in the first instance.
Section 8 modified accordingly.
D01
A1
08/08/11
17/11/10
Rev
Date
For AFD issue

For Project Spec Update
Reason for Issue
AB
AB
IP
PW
AD
CT
EA
Prepared
Checked
Approved
Reviewed
Reviewed
Eng. Man
TA
EA
Disc. Eng.
Disc. Lead
KBR
(proposer)
BP
Page 4 of 17
Page 5 of 17
1.0 Introduction
1.1
Scope
This specification defines the minimum requirements for thermally sprayed aluminium (TSA)
coatings for the Azerbaijan Developments in the Caspian Sea area to provide protection
against corrosion, abrasion and impact.
This specification addresses the materials to be used, the minimum requirements for surface
preparation, qualification and application of coating materials, and inspection and testing of
both shop applied and site applied coatings.
1.2
BP Technical Practices
Related BP Technical Practices are as below (for internal use only).

Document Number
Document Title
GIS 06-601
Painting of Metal Surfaces - Group Instruction for Supply
1.3
References
Work shall be in accordance with the following codes and standards:

Document Number
Document Title
BS 3900
ASTM B117
BS EN 1301
ASTM D4285
Paints and varnishes. Determination of film thickness

Standard practice for operating salt spray (fog) apparatus
Aluminium and aluminium alloys. Drawn wire.
ASTM D7091
ISO 4624
ISO 8501-1
ISO 8502-3
ISO 8502-6
ISO 8502-9
ISO 8503
ISO 8504-2
ISO 14918
SSPC
SSPC PA 2
SSPC VIS-1-89
SSPC-SP 1
Standard test method for indicating oil or water in compressed air

Standard practice for non destructive measurement of dry film thickness of
nonmagnetic coatings applied to ferrous metals and nonmagnetic, nonconductive
coatings applied to non-ferrous metals
Paints and varnishes - Pull-off test for adhesion.
Preparation of steel substrates before application of paints and related products visual assessment of surface cleanliness
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
Preparation of steel substrates before application of paints and related products Test for the assessment of surface cleanliness - Sampling of soluble impurities on
surfaces to be painted - The Bresle method
Preparation of steel substrates before application of paints and related products.
Tests for the assessment of surface cleanliness. Part 9: Field method for the
conduct metric determination of water soluble salts
Preparation of steel substrates before application of paints and related products Surface roughness characteristics of blast cleaned substrates
Preparation of steel substrates before application of paints and related products Surface preparation methods - Abrasive blast-cleaning
Thermal spraying - Approval testing of thermal sprayers
Steel structures painting manual, volumes 1 & 2
Measurement of dry paint thickness with magnetic gauges
Visual standards for abrasive blast cleaned steel
Solvent cleaning
Page 6 of 17
1.4
Abbreviations and Definitions

1.4.1
Abbreviations
Abbreviation/
Acronym
ac
ASTM
BS
DFT
d.c
EN
ETP
HV
kV
ISO
MSDS
MPa
PQT
QA/QC
SSPC
TSA
VOC
Description
Alternating current
American Society of Testing Materials
British Standard
Dry film thickness
Direct current
Euro Norm
Engineering Technical Practice
Hardness Vickers
kilo Volt
International Organization for Standardization
Material Safety Data Sheet
Mega Pascal
Pre Qualification Test
Quality Assurance/Quality Control
Steel Structures Painting Council
Thermally Sprayed Aluminium
Volatile Organic Components
1.4.2
Definitions
The terms in this specification are defined as follows:

Term
Purchaser
Approved
Contractor
Meaning
As identified in the formal terms and conditions.

Document reviewed and approved by the Purchaser.
The Contractor responsible for carrying out the TSA coating.
2.0 General Requirements

2.1
Health, Safety and Environment
2.1.1
The Contractor shall be responsible for ensuring that the goods and services supplied
meet all applicable regulations on health, safety and environmental issues.
All
coating products shall be in accordance with relevant regulatory requirements of
Azerbaijan and accepted international practice regardless of where the coating
operation takes place.
2.1.2
The following documentation shall be provided to the Purchaser on a Material Safety

Data Sheet (MSDS) for each coating system prior to starting the work:
Chemical name of organic solvent and VOC content (Volatile Organic Components
g/l).
Percentage of low molecular weight epoxy (molecular weight < 700).
Content of hazardous substances. These shall be listed components stated in
terms of appropriate International standards.
Specification of hazardous thermal degradation components.
Combustibility.
Special handling precautions and personnel protection measures
Page 7 of 17
2.2
Contractors Responsibilities
2.2.1
The surface preparation and application of thermally sprayed coatings and sealers
shall be undertaken only by companies possessing the specialised facilities and
equipment, and employing the competent operatives necessary to execute this work
to the standards defined within this Specification. All aspects of the work shall be
subject to inspection by Contractors QC personnel qualified and experienced in the
application and inspection and testing of thermally sprayed coatings.
2.2.2
The Contractor shall submit to The Purchaser for approval fully detailed and
comprehensive procedures that will govern all aspects of the coating work. The
coating procedures shall as a minimum cover the following activities:
2.2.3
A full and comprehensive reporting / recording system shall be maintained by the

Contractor. Daily logs shall be kept covering the following data:
2.3
Method, equipment and materials for surface preparation

The degree of cleanliness, the surface profile and roughness desired for the
surface to be coated
Method, equipment and materials for coating application
Qualifications and resumes for key personnel, including the coating foreman and
all inspectors
Coating systems to be used as defined in this specification including coating
manufacturers product data sheets and colour shade for each layer of coating
Permissible ranges of substrate temperature, air temperature, relative humidity
and dew point during surface preparation, coating application and drying / curing
Minimum and maximum times between surface preparation and first coat and
subsequent coats
Number of coats and minimum individual and total dry film thicknesses
Repair of damaged coatings
Monitoring, inspection and testing procedures, and criteria for acceptance and
rejection
Frequency of monitoring, inspection, and testing
Surface preparation and coating record sheets
Safety and environmental control
Coating materials handling and storage
Air and work piece substrate temperatures;

Relative humidity;
Ambient conditions;
Type and grade / size of blast cleaning abrasives;
Coating materials;
Coating progress;
Coating film thicknesses measured;
Surface profiles, visual inspections;
Adhesion test results;
Coating / surface preparation material batch Ns; and
Any other information pertinent to the work.
Qualification of Blasters
All personnel employed in abrasive blast cleaning operations shall be suitably trained and
experienced and be capable of producing consistently the required surface profiles on
representative structural steel surfaces.
Page 8 of 17
2.4
Qualification of Coating Operators
2.4.1
Approval testing of thermal sprayers shall be in accordance with ISO 14918, Annex
B.1 and B.9, and witnessed and certified by an independent third party authority. The
certificate shall confirm the person has successfully completed and passed a
dedicated training course for the application and inspection of thermally sprayed
aluminium coatings.
2.4.2
Personnel shall have relevant knowledge of health and safety hazard, use of
protection equipment, thermally sprayed aluminium coating materials including
sealers, mixing and thinning of coatings, coating pot-life, surface preparation
requirements, etc.
2.4.3
Coating proficiency tests shall be carried out on a test panel (minimum 1 x 1 m)

containing at least 1 pipe-end, 2 pipes, 1 angle and 1 flat bar. Alternatively a location
providing similar geometrical complexity on the Project components to be coated may
be used.
2.4.4
The acceptance criteria shall be the ability to meet the full requirements of this
Specification. This shall include the testing and the visual and non-destructive
inspection of the coating system described in this specification. Operators failing to
meet these requirements shall not be permitted to carry out coating work on the
Project.
2.5
Qualification of QC Personnel
2.5.1
Personnel carrying out inspection or verification shall possess a certificate issued by

an independent third party authority. The certificate shall confirm the person has
successfully completed and passed a dedicated training course for the application and
inspection of thermally sprayed aluminium coatings.
2.5.2
Possession of a certificate confirming the successful completion of alternative coating

inspection training programmes which include thermally sprayed metallic coatings may
be an acceptable alternative qualification at the sole discretion of the Purchaser.
2.5.3
Coating application supervisors shall be qualified to the same standard as the

inspectors.
3.0 Materials
3.1
General
3.1.1
Materials to be used in the execution of the coating work shall be obtained from
reputable manufacturers well established in the field of heavy duty coating materials
for the oil, gas and petrochemical industries.
3.1.2
The Contractor shall submit to the Purchaser for approval full details of all surface
preparation and coating materials, including source of supply and manufacturers' data
sheets.
3.1.3
All coating materials shall be stored indoors in a dry environment at between 10C
and 35C until required for use, in the manufacturers' sealed containers.
3.2
3.2.1
Blast Cleaning Abrasives

All abrasives shall be clean, dry, sharp, and angular grit and possess a Vickers
hardness value exceeding 750 Hv10. Abrasive grit for carbon steel substrates shall
be chilled iron or steel grit, or aluminium oxide grit. Only aluminium oxide or stainless
Page 9 of 17
steel type grits shall be used for stainless steel and other noble metallic surfaces.
Abrasive grits containing soluble chlorides shall not be used.
3.3
Aluminium Coating Material
3.3.1
Aluminium shall be in wire form with a 99.5% minimum purity and conform to BS EN
1301.
3.3.2
Wire shall be smooth and free from kinks. It shall not contain visible oxide particles
or other substances which could adversely affect coating application, density or its
adhesion to the substrate.
3.4
Sealer Coating
3.4.1
All thermally sprayed aluminium (TSA) coatings shall be over-coated and sealed
within 24 hours after deposition of the aluminium on to the prepared steel substrate.
The sealers shall be of low viscosity suitable to penetrate into the TSA coating and to
seal its inherent surface porosity. Sufficient thickness of the sealer paint shall be
applied to fully wet out and subsequently seal the porosity of the TSA coating.
3.4.2
A low viscosity 2 pack epoxy coating shall be used to seal all TSA coatings applied to
substrates with maximum design temperatures up to 120C in atmospheric locations,
or up to 80C in seawater immersed and splash zone locations. For substrates in
atmospheric, immersed, or splash zone locations with design temperatures up to
120C a low viscosity high temperature vinyl ester primer equal to Leighs Paints
Duraglass P1 Primer may be acceptable subject to the Purchasers approval.
3.4.3
An aluminium silicone heat-resistant coating shall be used to seal all TSA coats
applied to sections of flare booms, flare towers and exhaust systems, and any other
items with maximum design temperatures above those defined in Section 3.4.2
above.
3.4.4
All sealers shall be suitably formulated to perform satisfactorily under the

environmental and operating conditions envisaged. Sealers used on seawater
immersed items subject to cathodic protection shall possess a high resistance to
cathodic disbondment.
3.4.5
All sealer coating materials proposed for Project use by Contractor shall be supplied
with certificates defining the infra-red fingerprint and ash content of all their
components as determined by testing in accordance with a recognised international
standards test procedure. The certification shall be issued by an internationally
recognised and independent testing laboratory and shall be submitted to the
Purchaser for approval. The Purchaser will require at least two random samples from
each coating product to be taken during the coating activities and tested at a
Purchaser approved independent testing laboratory to confirm that the supplied goods
match the products proposed by Contractor.
4.0 Pre-Qualification Requirements

4.1
4.1.1
Materials
All coating products proposed for the work shall be pre-qualified by a Purchaser
review of the coating material Manufacturers test data and product data sheets
submitted by Contractor.
Each coating Manufacturer proposed to be used by
Contractor shall provide documented service histories of satisfactory experience with
the full proposed system.
Page 10 of 17
4.1.2
The coating system proposals shall be corroborated by appropriate long term test
data or satisfactory in-service performance track record in equivalent design
conditions.
4.1.3
Alternative coating materials to those specified may be proposed, but will be

considered for approval by the Purchaser only if supported by comprehensive and
appropriate documented test data and / or service experience.
The coating
thicknesses stated are considered appropriate for the service but may be adjusted at
the sole discretion of the Purchaser to reflect the coating system in-service
performance history and test record.
4.2
4.2.1
Application Trial
Prior to commencing application of TSA coating systems, a coating trial to evaluate
the Contractors proposed production procedures and application of the chosen
product(s) under actual or simulated site conditions shall be performed. This trial
shall evaluate the competence of the Contractor to perform the work and the applied
coating system characteristics including:
Ease of application,
Sealer curing characteristics,
Robustness,
Health and safety
Ability to successfully pass the full range of tests required by this specification on
a repeatable basis.
4.2.2
The coating trial shall be performed at least 4 weeks prior to commencing production
coating on at least 5m2 of tubular surface, including both longitudinal and
circumferential weld areas. Records shall be maintained of equipment setting,
consumables and other relevant data during this trial.
4.2.3
A fully comprehensive coating trial report shall be compiled by Contractor and

submitted to the Purchaser for approval. The report shall detail all aspects of the
surface preparation and coating application work including all monitoring, inspection,
and testing results.
The test panels for these tests shall be preserved for the full duration of the contract /
purchase order together with the appropriate trial report.
4.2.4
5.0 Surface Preparation

5.1
Pre-blasting Preparations
5.1.1
Preparation methods and procedures for surfaces to be coated shall remove all
foreign matter, surface irregularities and contaminants to bring the surface to the
specified standard of cleanliness prior to the application of coatings. All metallic
surfaces shall be prepared prior to coating by dry abrasive blast cleaning.
5.1.2
Before any surface operations commence, all oil, grease or other contaminants on the
workpiece surface shall be removed by solvent cleaning in accordance with SSPCSP1, "Solvent Cleaning".
5.1.3
Sharp edges, fillets, corners and welds shall be rounded or smoothed by grinding (min
R = 2 mm).
Page 11 of 17
5.1.4
Hard surface layers, resulting from flame cutting, shall be removed by grinding prior to
blast cleaning, unless it can be demonstrated by appropriate trials that the required
surface profile can be achieved on a repeatable basis.
5.1.5
All steel shall be washed with clean potable water and checked for salt contamination
prior to commencement of coating operations. The frequency and nature of these
checks shall be sufficient to ensure complete removal of salt contamination.
Inspection of soluble salts on the blasted surface shall be in accordance with ISO
8502-6 and ISO 8502-9 at a frequency of every 10 m2 with an acceptance criteria
corresponding to a maximum NaCl content of 20 mg/m 2.
5.1.6
5.2
5.2.1
Any surface defects detrimental to the protective coating system such as surface
laminations, slivers, or scabs, shall be removed by suitable dressing. Where such
defects have been revealed during blast cleaning and dressing has been performed,
the dressed area shall be re-blasted to the specified standard. All welds shall be
inspected and if necessary repaired prior to final blast cleaning of the area.
Blast Cleaning
Equivalent Standards:
The following preparation grades of steel surfaces or quality designations are
considered to be equivalent for the purposes of this Specification. However, ISO
8501-1 should be used for practical assessment.
Commercial Definition
White Metal
Near White Metal
Solvent Cleaning
5.2.2
ISO 8501-1
SSPC
Sa 3
Sa 2
SSPC SP 5-63
SSPC SP 10-65
SSPC SP 1-63
General
5.2.2.1 Blasting abrasives shall be dry, clean and free from any contaminants that may be
detrimental to the performance of the applied coating system. Abrasives shall be
selected that are capable of producing the required degree of surface cleanliness and
surface profile, and that have a minimal health impact.
5.2.2.2 The minimum degree of surface cleanliness of the blast cleaned surfaces shall be Sa
3 to ISO 8501-1 unless otherwise specified in writing by the Purchaser
5.2.2.3 The peak-to-trough surface profile (anchor profile) of the blast cleaned surfaces shall
be in the range 75 to 115 microns. The type, size and particle distribution of abrasive
grits for blast cleaning shall be such as to achieve this requirement consistently.
5.2.2.4 Surface profiles shall be continuously checked using a surface profile comparator
Type G, complying with ISO 8503.
Alternatively, comparison may be made to
equivalent segments as defined on the Keane Tator Profile Comparator, subject to
Purchaser approval.
5.2.2.5 The Contractor shall submit details of all proposed abrasives to the Purchaser.
abrasives shall comply with Section 3.2 above.
All
5.2.2.6 The only abrasive types permitted to be re-cycled shall be chilled iron angular grit and
aluminium oxide angular grit. However, spent abrasives used on open sites or in
Page 12 of 17
facilities that are not specifically designed and constructed to preserve the cleanliness
of spent abrasive shall not be re-cycled. Spent abrasive shall be completely removed
from the prepared surface.
5.2.2.7 Blast cleaning shall not be performed in areas close to coating operations or wet /
uncured coated surfaces in order to prevent dust or grit contamination.
5.2.2.8 Welded areas and appurtenances shall be given special attention for removal of
welding flux in crevices. Welding slivers, laminations and underlying mill scale
exposed before and during grit blasting operations shall be removed by mechanical
means and the edges smoothed or rendered flush.
5.2.2.9 The dryness and cleanliness of the compressed air supply used for blast cleaning
shall be verified by testing the air on a white blotter as per ASTM D4285. The testing
shall be carried out at the start of each shift and every 4 hours thereafter and at the
restart of compressor operation when off for more than 15 minutes.
5.2.2.10 If the surface has been exposed to salt laden atmosphere, salts shall be removed by
high pressure washing with clean, fresh water prior to blasting or mechanical cleaning.
The Contractor shall be required to demonstrate by surface testing that the salt level
is not detrimental to the applied coating.
5.3
Environmental Conditions
5.3.1
Surface preparation shall not take place when the ambient air temperature is below
10C, when the relative humidity is greater than 80%, or when the work piece surface
temperature is less than 10C above the ambient dew point.
5.3.2
Prepared surfaces shall be kept free from any contamination and shall be completely
free from blast residues, dust or grit.
6.0 Coating Application

6.1
All coating application shall be in an environmentally controlled indoor location.

Application in outdoor locations shall not be permitted without the consent of the
Purchaser. Where the Purchasers consent is given the area to be coated shall be
fully protected against wind, rain, spray and other contamination until the application
is completed and inspected.
6.2
Coatings shall not be applied when the ambient air temperature is below 10C, when
the relative humidity is greater than 80%, or when the work piece surface temperature
is less than 10C above the ambient dew point.
6.3
Wire-fed electric arc or gas jet spraying equipment of proven satisfactory performance
shall be utilised unless otherwise approved by the Purchaser. The equipment shall be
operated and maintained in accordance with the equipment Manufacturer's written
instructions, which shall be displayed at the work site. Records shall be maintained
of all equipment settings at each stage of application.
6.4
The TSA coating shall be applied to a thickness in the range of 200 to 300 microns.
6.5
The TSA coating thickness shall be applied evenly in multiple passes of the spray
nozzle. In no case shall less than two passes be applied to any surface. Each pass
shall overlap the previous pass such that an even coating of uniform thickness results.
Page 13 of 17
The angle of the spray stream shall be as close to 90 to the surface being coated as
possible, and never less than 45.
6.6
Coating thickness measurement instruments shall be calibrated using film samples on

a steel plate grit blasted to provide a representative profile.
6.7
The final surface of the unsealed TSA shall be smooth and free from lumps, coarse
areas and loosely adherent particles.
6.8
Thickness checks shall be conducted within 1 hour of TSA application, before the
work piece is moved or further processed. Areas of thin coating shall be over coated
with additional TSA within 2 hours of the initial coating and whilst the surface is still
clean and dry.
6.9
After the TSA coating has been applied, inspected and approved, the sealer coat shall
be applied, without delay, to the clean, dry surface.
6.10
The sealer coat shall be mixed and applied in accordance with the coating
manufacturer's written instructions. Sufficient sealer shall be applied to fully wet out
and subsequently seal the porosity of the TSA coating surface. A suitable film
thickness testing method shall be established at pre-production trials by Contractor to
ensure that a uniform coating of the correct thickness is being applied.
6.11
Drying of the sealer coat shall be according to the coating Manufacturer's instructions.
Unless otherwise agreed by the Purchaser in writing all sealer coatings shall be dry
prior to handling. In general such exceptions shall apply only to large fabrications
where stoving of aluminium silicone may be required but is adjudged by the Purchaser
to be impractical.
7.0 Repairs
7.1
This section details requirements for surface preparation and coating application to
weld areas and to any areas of damage to the coating.
7.2
Following completion of welding operations on coated sub-fabrications, the weld

areas and areas of masked surface to each side of the weld shall be prepared for
coating by grinding of weld spatter, slag and sharp edges or protuberances. They
shall then be blast cleaned in accordance with Section 5.0 of this specification, taking
care not to damage adjacent coating except for a light feathering of the edges of the
coated area over a distance of 25 to 50mm. Grit used for external blasting operations
shall not be reused.
7.3
Application of coating shall be in accordance with requirements of Section 6.0 of this

specification. The coating shall overlap onto the existing feathered coating edges to
ensure that the specified thickness is maintained. The sealer coat shall be re-applied
over the whole area affected by blasting cleaning and coating application.
8.0 Monitoring, Inspection and Testing

8.1
Monitoring, inspection and testing during surface preparation, application of the TSA
coating, and application of the sealer coating, shall comprise the following as a
Page 14 of 17
minimum, and as further detailed below, with all results recorded in test reports in an
approved format:
Environmental conditions at all stages of surface preparation, coating

application, and cure.
Grading and cleanliness of abrasive
Surface profile after blasting cleaning
Visual cleanliness and residual dust test on blasted surfaces
TSA coating thickness and sealer coat thickness
Coating adhesion
Coating appearance and uniformity
8.2
All test methods and equipment shall be regularly and routinely re-calibrated. All
monitoring, inspection and test results shall be recorded and maintained by
Contractor.
8.3
Environmental temperature, relative humidity, dew point temperature, and work piece
surface temperature, shall be recorded at the start of each shift and at intervals of not
more than 2 hours throughout every shift.
8.4
All abrasive to be recycled shall be examined for grading and cleanliness at each
recovery operation. Correct size distribution shall be confirmed by a sieving analysis
with the results recorded. The grit to be re-cycled shall be free from oil and moisture
contamination and from rust, scale or other foreign matter.
8.5
The surface profile after blasting cleaning shall be subject to checking by 100% visual
examination against a surface profile comparator or prepared test panels,
supplemented by surface profile measurement using an approved method.
Frequency of supplemental profile measurement shall be such that at least one (1)
location per two (2) square metres, or one (1) per item coated if more frequent, are
tested.
8.6
All prepared surfaces shall be thoroughly visually inspected to ensure freedom from
surface contamination. Residual dust and grit shall be checked using 25mm wide
clear adhesive tape which shall be stuck onto, then peeled away from, the surface at
least once per item and once per 10m of prepared surface area. The tape shall then
be inspected over a white sheet for freedom from dust or grit. Particular care shall be
paid to checking of cleanliness in restricted areas and low points, as well as in acute
angles at welded joints.
8.7
The thickness of the applied aluminium coating shall be checked in accordance with
Section 6.6, and 6.8. Spot measurement values shall be taken at a minimum of three
points at any one location, with each location being not more than 1000mm apart in
accordance with the procedure of ASTM D7091.
8.8
The thickness of the sealer coat shall be checked in accordance with Section 6.10
using a suitable method developed by the Contractor. Wet film thickness gauges shall
be employed during the application. Where absorption into the TSA coating is too
rapid to allow meaningful wet film measurements to be made, a polished steel plate
may be coated in parallel with production coating. Wet and dry film thickness
measurements shall be correlated between this plate and the aluminium surface.
8.9
Adhesion tests between the applied TSA coatings and their substrates shall be
performed throughout the production coating work and shall meet 7.0MPa. The
Page 15 of 17
adhesion strength between the applied TSA coatings and their substrates shall be at
least:
5.0MPa on production coated items.
7.0MPa on pre-qualification and production test panels.Test panels for adhesion testing shall
be prepared alongside the production coating, where possible through attaching the
panels to the sub-assembly. The test panels shall be subjected to the same surface
preparation and coating application as the production coated components.
Coating adhesion tests shall be conducted on randomly selected areas to demonstrate
compliance with the minimum value stated herein. The adhesion tests shall be
performed throughout the production coating work using a calibrated tensile pull-off
instrument.
8.10
A minimum of three separate adhesion pull-off tests shall be conducted per For each
TSA coated work piece or one (1) per ten (10) square metres, whichever is the less
frequent, a test panel shall be prepared and shall be subject to a minimum of three
separate adhesion pull-off tests.
All three (3) results shall equal or exceed the
specified minimum adhesion strength values.
Failure to achieve the minimum specified adhesion strengths as a result of the
following failure modes shall be considered invalid tests and require the tests to be
repeated:
Cohesive failure in the adhesive

Adhesive failure between the test dolly and the glue / coating
8.11
Where any of the three (3) production tests fail to meet 7MPa the Purchaser shall be
notified and adhesion testing of the production coated component shall be done. Valid
adhesion results resulting in adhesion strengths below the specified minimum shall be
cause for rejection of the coating on the work piece or area represented by the test
results.Testing of the component shall meet 7MPa, if this is not met the coating shall
be rejected.
All such failed coatings shall be removed by Purchaser approved methods and the subject
work piece or area re-coated in accordance with the requirements of this specification.
All such re-coated areas shall be subject to additional adhesion tests.
8.12
The pull-off adhesion testing equipment and procedure shall be based on the
requirements of ISO 4624. The Contractors adhesion testing equipment and
adhesives shall be specifically designed for the intended purpose and shall be subject
to review and approval by Purchaser, including the review of results of the coating
trial.
8.13
All surfaces shall be visually assessed for uniformity and freedom from blemishes and
holidays. Any such defects shall be marked and repaired before sealer coat
application. Additional thickness and / or adhesion tests shall be performed at areas
of visual non-uniformity.
8.1.4
Following acceptance of the test results coated areas subject to adhesion testing shall
be repaired in accordance with Section 7.0 herein.All failed coatings shall be removed
by Purchaser approved methods and the subject work piece or area re-coated in
accordance with the requirements of this specification. All such re-coated areas shall
be subject to additional adhesion tests.
Components subject to adhesion testing that have passed the testing shall be
repaired in accordance with Section 7.0 herein.
Page 16 of 17
Page 17 of 17

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TECHNICAL DOCUMENTATION FRONT SHEET

Specification for Thermally Sprayed Aluminium (TSA) Coatings

UNCONTROLLED WHEN PRINTED

This document shall not be

Revision History and Hold Record

Detailed Description of Change

UNCONTROLLED WHEN PRINTED

Description / Reason for Hold

Health, Safety and Environment................................................................................6

4.0 PRE-QUALIFICATION REQUIREMENTS......................................................................9

UNCONTROLLED WHEN PRINTED

TECHNICAL DOCUMENTATION FRONT SHEET

Advised Changes Listing

Bullet Point Listing of Changes

3. Changes to codes and standards

10. Adhesion testing

For AFD issue

UNCONTROLLED WHEN PRINTED

UNCONTROLLED WHEN PRINTED

Related BP Technical Practices are as below (for internal use only).

Painting of Metal Surfaces - Group Instruction for Supply

Work shall be in accordance with the following codes and standards:

Paints and varnishes. Determination of film thickness

Standard test method for indicating oil or water in compressed air

UNCONTROLLED WHEN PRINTED

Abbreviations and Definitions

The terms in this specification are defined as follows:

As identified in the formal terms and conditions.

2.0 General Requirements

Health, Safety and Environment

The following documentation shall be provided to the Purchaser on a Material Safety

UNCONTROLLED WHEN PRINTED

A full and comprehensive reporting / recording system shall be maintained by the

Method, equipment and materials for surface preparation

Air and work piece substrate temperatures;

UNCONTROLLED WHEN PRINTED

Qualification of Coating Operators

Coating proficiency tests shall be carried out on a test panel (minimum 1 x 1 m)

Personnel carrying out inspection or verification shall possess a certificate issued by

Possession of a certificate confirming the successful completion of alternative coating

Coating application supervisors shall be qualified to the same standard as the

Blast Cleaning Abrasives

UNCONTROLLED WHEN PRINTED

Aluminium Coating Material

All sealers shall be suitably formulated to perform satisfactorily under the

4.0 Pre-Qualification Requirements

UNCONTROLLED WHEN PRINTED

Alternative coating materials to those specified may be proposed, but will be

A fully comprehensive coating trial report shall be compiled by Contractor and

5.0 Surface Preparation

UNCONTROLLED WHEN PRINTED

UNCONTROLLED WHEN PRINTED

6.0 Coating Application

All coating application shall be in an environmentally controlled indoor location.

UNCONTROLLED WHEN PRINTED

Coating thickness measurement instruments shall be calibrated using film samples on

Following completion of welding operations on coated sub-fabrications, the weld

Application of coating shall be in accordance with requirements of Section 6.0 of this

8.0 Monitoring, Inspection and Testing

UNCONTROLLED WHEN PRINTED

Environmental conditions at all stages of surface preparation, coating

UNCONTROLLED WHEN PRINTED

5.0MPa on production coated items.