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1.0 GENERAL
Painting is the most commonly used application for corrosion prevention both for external
corrosion as well as internal corrosion.
HPCL, Mumbai Refinery has a customized painting specification for all its equipment, piping and
structural. This painting specification is periodically reviewed by Inspection Division of the
Refinery to take care of the latest developments and requirements.
As part of the periodical review of the specification, a study was conducted during Jul-Aug,
2011 to review the existing practices vis--vis current industrial practices and to study the
available products with reputed painting manufacturers for more effectiveness and durability of
the painting systems used in the Refinery.
Based on the study findings, a detailed presentation was made in the Refinery weekly PRM
meeting dated 11/08/2011 prior to formal revision of the existing specification.
Basis the study results and the discussions during the presentation in PRM, the following
revised painting specification is being released for implementation at HPCL, Mumbai Refinery.
2.0 SCOPE
This specification is applicable only on metallic surfaces within HPCL, Mumbai Refinery.
Scope of work covered in this specification shall include, but not limited to the following:
1. Surface preparation
2. Selection and application of painting on:
A) Equipment
B) Piping
C) Steel structures
D) Storage Tanks
E) High temperature surfaces (Furnace Casings, Stacks, etc.)
The following surfaces and materials shall not be painted unless otherwise specified by
Inspection through specific recommendation:
4)
5)
6)
Page 3 of 17
7)
8)
2)
b.
c.
Blast cleaning
Mill scale, rust, rust scale and foreign matter shall be removed fully to ensure that a
clean and duty and dry surface is obtained. The minimum acceptable standard in case
of manual or hand tool cleaning shall be St.2 or equivalent, in case of mechanical or
power tool cleaning it shall be St.3 or equivalent, in case of blast cleaning it shall be
Sa2 or equivalent as per Swedish Standard SIS-055900-1967 / ISO-8501-1-1988.
Where highly corrosive conditions exist, and then blast cleaning shall be Sa3 as per
Swedish Standard.
Remove all other contaminants, oil, grease etc. by use of an aromatic solvent prior to
surface cleaning.
3)
Blast cleaning shall not be performed where dust can contaminate surfaces undergoing
such cleaning or during humid weather conditions having humidity exceeding 85%.
4)
Irrespective of the method of surface preparation, the first coat of primer must be
applied on dry surface. This should be done immediately and in any case within 4 hours
of cleaning of surface. However, at times of unfavorable weather conditions, the
Engineer-in-charge shall have the liberty to control the time period, at his sole discretion
Page 4 of 17
Mechanical or Power tool cleaning: Power tool cleaning shall be done by mechanical
striking tools, chipping hammers, grinding wheels or rotating steel wire-brushes.
Excessive burnish of surface shall be avoided as it can reduce paint adhesion. On
completion of cleaning, the detached rust mill scale etc. shall be removed by clean rags
and/or washed by water or steam and thoroughly dried with compressed air jet before
application of paint.
6)
Manual or Hand tool cleaning: Manual or hand tool cleaning is used only where safety
problems limit the application of other surface preparation procedure and hence does
not appear in the specifications of paint systems.
Hand tool cleaning normally consists of the following:
a. Hand descaling and/or hammering
b. Hand scraping
c. Hand wire brushing
6)
Water cleaning: Water blasting shouldbe used for surface preparation method where
water is available in sufficient quantity. The water used shall be inhibited with Sodium
chromate/phosphate.
7)
Water mopping: Fresh water mopping (maximum chloride content 50 ppm) shall be
carried out on Salt Water spray areas, before application of primer, to remove the salts
deposited on metal surface. Mopping can be repeated before application of other
coats to remove salts deposited on previous coats, if such deposits are suspected.
B. COATING APPLICATION
1)
Surface shall not be coated in rain, wind or in environment where injurious airborne
elements exists, when the Steel surface temperature is less than 5oF above dew point,
when the relative humidity is greater than 85% or when the temperature is below 40oF.
2)
Blast cleaned surface shall be coated with one complete application of primer as soon as
practicable but in no case later than 4 hourson the same day.
3)
4)
Each coat shall be in proper state of cure or dryness before the application of
succeeding coat. Material shall be considered dry for recoating when an additional coat
can be applied without the development of any detrimental film irregularities, such as
lifting or loss of adhesion of the under coat. Manufacturers instruction shall be followed
for inter-coat interval.
5)
When the successive coat of the same color have been specified, alternate coat shall be
tinted, when practical, sufficiently to produce enough contrast to indicate complete
coverage of the surface. The tinting material shall be compatible with the material and
not detrimental to its service life.
7)
Airless spray application shall be in accordance with the following procedure: As per
Steel structure Paint Manual Vol.1 & Vol.2 by SSPC, USA, Airless spray relies on hydraulic
pressure rather than air atomization to produce the desired spray. An Air Compressor
or Electric Motor is used to operate a Pump to produce pressure of 1,000 to 6,000 psi.
Paint is delivered to the Spray Gun at this pressure through a single hose within the Gun,
a single paint stream is divided into separate streams, which are forced through a small
orifice resulting in atomization of paint without the use of air. This results in more rapid
coverage with less overspray. Airless spray usually is faster, cleaner, more economical
and easier to use than conventional air spray.
8)
Guidelines for painting Color Bands: Color Bands shall be applied at following locations:
a. At battery limit points
b. Intersection points and change of direction points in piping ways
c. Other points such as midway of each piping way, near valves, junction points of
service appliances, walls, and on either side of Pipe Culverts
d. For long stretch/yard piping at 50 meters interval
e. At start and terminating points
f. Flow directions shall be indicated by an Arrow in the flow direction. Colors of Arrows
shall be Black or White and in contract to the color on which they are superimposed.
g. Size of Arrows or minimum width of Color band shall be as follows:
Nominal Pipe Size
3 NB and below
Above 3 NB up to 6 NB
Above 8 NB up to 12 OD
Width of Band
25 mm
50 mm
75 mm
Page 6 of 17
Above 12 OD
100 mm
Painting material shall be procured from HPCL approved Manufacturers as given below:
All paint materials shall be accompanied by Manufacturer Test Certificate. All Zinc based
paints shall have minimum 85% 5% of metallic Zinc by weight of total solids on dry
film. Glass flake Epoxies shall have minimum 20% ofGlass flake pigments in dry film by
weight of total pigments.
3)
4)
5)
All defects noticed during stages of inspection, shall be rectified free of cost by the
Contractor. All related records shall be kept by the Contractor.
6)
Wet film thickness shall be checked to ensure application of extra coat during wet stage.
7)
Dry film thickness shall be taken on each coat after drying and curing of the coat.
Page 7 of 17
8)
DFT Meter used shall be calibrated before each inspection and shall be witnessed by the
Inspector. It is the duty of the Inspector to satisfy himself with the performance of the
DFT Meter.
NO. OF COATS
APPLICATION
~DFT IN MICRONS
ONE
AIRLESS SPRAY
75
TWO
BRUSH/ROLLER
120 x 2 = 240
ONE
BRUSH/ROLLER
50
TOTAL
4 COATS
365
ALUMINIUM
TOTAL
NO. OF COATS
APPLICATION
~DFT IN MICRONS
ONE
AIRLESS SPRAY
75
THREE
AIR or AIRLESS
SPRAY
3 x 30 = 90
4 COATS
165
NO. OF COATS
APPLICATION
~DFT IN MICRONS
ONE
AIRLESS SPRAY
75
Page 8 of 17
THREE
TOTAL
BRUSH/ROLLER
4 COATS
40 x 3 = 120
195
SYSTEM 4: FOR CARBON STEEL MATERIAL FACING SALT WATER SPRAY (UP TO 100oC)
PAINT TYPE
NO. OF COATS
APPLICATION
~DFT IN MICRONS
ONE
AIRLESS SPRAY
60
TWO
AIRLESS SPRAY
200 x 2 =400
TWO
BRUSH/ROLLER
50 x 2 =100
TOTAL
5 COATS
560
Note: Salt water spray areas will requirefresh water blasting or fresh water mopping prior
to paint application or subsequent coat application to remove salts deposited on the
surface as per 5.A.7. This system shall be applied for surfaces up to 100oC. Beyond
this temperature, surface shall be insulated.
SYSTEM 5: FOR PAINTING OF STAINLESS STEEL SURFACES/BARE SS VESSEL/EQUIPMENT
SURFACE
TEMPERATURE
SURFACE
PREPARATION
PAINTING SYSTEM
~DFT IN MICRONS
0 TO 120oC
SSPC-SP-10 (15-25
3 COATS OF F-15
250
60
SURFACE PROFILE)
121 TO 500oC
SSPC-SP-10
(F-12 Heat resistant Si-Al paint & F-15 Phenolic Epoxy coating)
SYSTEM 6: FOR NEWLY FABRICATED HOT LINES/VESSEL & EQUIPMENT SURFACES WHICH
ARE TO BE INSULATED AND HAVING SURFACE TEMPERATURES UP TO 150oC
PAINT TYPE
HIGH-BUILD AMINE ADDUCT CURED PHENOLIC EPOXY
NO. OF COATS
TWO
APPLICATION
AIRLESS
DFT IN MICRONS
250
Page 9 of 17
SPRAY
2 COATS
250
APPLICATION
DFT IN MICRONS
ONE
Airless Spray
1 X 65 = 65
TWO
Airless Spray
2 X 100 = 200
ONE
Airless Spray
1 X 50 = 50
PAINT TYPE
4 COATS
315
SYSTEM 8: FOR PAINTING OF TANK INTERNAL,i.e.Shell, Roof underside, Roof Trusses& Supports,
Bottom, etc.) below 80oC
PAINT TYPE
ZINC RICH EPOXY (PRIMER)
HIGH-BUILD AMINE CURED EPOXY (FINSIH COAT)
TOTAL DFT
NO. OF COATS
ONE
APPLICATION
Airless Spray
~DFT IN MICRONS
1 x 50 = 50
THREE
Airless Spray
3 x 80 = 240
4 COATS
290
Number of
Application
Thickness
Coats
Method
(DFT in )
Surface preparation: Abrasive Blast (with Cu-Slag) cleaning, to SA 2 of Swedish Standard, with a minimum
Surface profile of 40
Primer Coat: Interzone 954
ONE
Airless or Air
Spray
1 x 400 = 400
Page 10 of 17
TOTAL
1 COAT
400
NO. OF COATS
APPLICATION
DFT IN MICRONS
TWO
BRUSH/ROLLER
50
ONE
BRUSH/ROLLER
100
COATS
APPLICATION
ONE
BRUSH/ROLLER
100
TWO
BRUSH/ROLLER
125 x 2 =250
ONE
BRUSH/ROLLER
50
TOTAL DFT
4 COATS
~DFT IN
MICRONS
400
COATS
APPLICATION
~DFT IN
MICRONS
ONE
BRUSH/ROLLER
08
ONE
BRUSH/ROLLER
50
TWO
BRUSH/ROLLER
50 x 2
Page 11 of 17
TOTAL
4 COATS
158
COATS
APPLICATION
ONE
BRUSH/ROLLER
100
TWO
BRUSH/ROLLER
120 x 2 =240
ONE
BRUSH/ROLLER
100
TOTAL DFT
4 COATS
~DFT IN
MICRONS
440
COATS
APPLICATION
ONE
Brush/Roller
ONE
Brush/Roller
20
TOTAL DFT
2 COATS
~DFT IN
MICRONS
28
SERVICE
1.
LPG; PROPANE
WHITE
2.
WHITE
3.
DARK GREY
4.
5.
SKY BLUE
Page 12 of 17
6.
FIRE WATER
PORED
7.
AIR
8.
OTHER HYDROCARBON
SMOKE GREY
9.
GOLDEN YELLOW
10.
CAUSTIC; CHEMICAL
GOLDEN YELLOW
11.
BLOWDOWN LINE
GOLDEN YELLOW
12.
NITROGEN
DARK GREY
13.
HYDROGEN
WHITE
14.
NMP
GOLDEN YELLOW
B. OTHER EQUIPMENT:
SL. No.
SERVICE
1.
SAFETY VALVE
YELLOW
2.
COMPRESSORS
3.
4.
5.
STRUCTURES (GENERAL)
SMOKE GREY
6.
7.
HAND RAILING/CAGE
ORANGE
8.
9.
PORED
10.
Page 13 of 17
Note: If any service or equipment class is not mentioned in the above list, then the color code
will be decided by the Inspector in consultation with Field Operations.
Mechanical damage
Welding damage
Scaffolding erection damage
Peel off
Blistering
Wrinkle marks
Adhesion failure
Discoloration
Edge separation
Edge fracture
Weathering
Any other damage considered serious for performance of the paint system by the
Inspector shall be considered.
Partial or complete removal and repair of damaged section shall be done in consultation
with the Manufacturer.
TYPE OF PAINT
InorganicZinc Silicate
HPCL SPECIFICATIONS
Self-priming Epoxy
Page 15 of 17
4.
Two-pack Epoxy(Highbuild)
5.
AliphaticAcrylic
modified (Isocynate)
curedTwo-pack
Polyurethane finish
6.
7.
Page 16 of 17
8.
9.
12
*****
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