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CONTRACT Nº UNIT Nº
AEGEAN REFINERY PROJECT (ARP) STAR-C-01 000
CONTRACTOR DOC No: SH/OF
2248-000-A-EE-0190469 2/14
PAINTING REPAIR PROCEDURE STAR DOCUMENT No.
FOR STEEL STRUCTURE 000-A-EE-0190469
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TABLE OF CONTENTS
1. PURPOSE 3
2. SCOPE 3
3. DEFINITIONS 3
4. REFERENCES 4
5. PAINTING REPAIR PROCEDURE FOR STEEL STRUCTURE 6
6. GENERAL APPLICATION CONDITIONS 14
7. ATTACHMENTS AND TEMPLATES 14
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1. PURPOSE
This procedure defines the type, materials and methods of application for the repair works which will be
carried out at Steel Structures at ARP Project.
2. SCOPE
This method statement covers the guidelines for surface preparation, paint materials, painting systems
and application of paints during the repair works for Steel Structures. The protective coating systems
specified include Surface preparation, paint material selection, paint application methods.
3. DEFINITIONS
CONTRACTOR: Joint Venture between Técnicas Reunidas (TR), Saipem (SP), GS E&C
and Itochu.
PROJECT: Means the Aegean Refinery (AR) Project, being executed by OWNER or its
affiliates.
SUBCONTRACTOR: Entity (and its legal successors in title) named as Subcontractor in the Contractor
purchase order and/or the contract awarded to the Subcontractor to perform
specific services and/or works
TANK “EC” The party which shall carry out all engineering, design and mechanical
CONTRACTOR : fabrication for the storage tanks (except sphere tanks) as per the work spit
between Tank EC contractor and Tank P contractor. In addition, it shall carry
out all the material procurements, surface preparation, installation, inspection
and testing of the lining systems.
TANK “P” The party which shall supply materials for tank fabrication in the site as per
CONTRACTOR : the work split between Tank EC contractor and Tank P contractor.
INSPECTOR: The individual responsible for implementing the inspection function specified
in the contract documents in order to minimize or eliminated defects or failures.
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4. REFERENCES
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PROJECT PROCEDURES
Abrasive Blast Cleaning: Also called abrasive-blasting, a surface preparation method that uses
an abrasive propelled by air pressure, centrifugal force, or water pressure to clean and usually to
add a profile (anchor pattern) to a surface.
Anchor Pattern (Profile): contour of a blast-cleaned surface, it is classified by peaks-to-valleys
depth (amplitude) and texture (dense, rounded or angular).
Dry-Film Thickness: Thickness of cured film, usually expressed in micrometres (or micron,
millionth of a meter).
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Holding Primer: A thin-film primer applied to prevent rust blooming prior to the application of the
subsequent build-up lining system.
Holiday: A discontinuity in a protective lining that exposes an unprotected surface to the
environment.
Holiday Detector, Low-Voltage Wet-Sponge Type: An instrument that uses 5 to 90V DC for
detecting holidays in a lining. It is typically used for linings less than 500 micron (dry film
thickness) thick.
Holiday Detector, High-Voltage Type: Also called spark-tester, it’s an instrument for detecting
holidays in a non-conductive coating applied over a conductive substrate. A spark-test instrument
applies a high-voltage (thousands of volt) to the surface with a probe that creates a spark
whenever a holiday, pinhole, or other film defect is found.
The spark triggers an alarm or light on the instrument.The voltage used depends on the lining
type and thickness. It is typically used for linings thicker than 500 micron (dry film thickness).
Manufacturer’s Technical Data Sheet: Sheet printed by the supplier of a product to provide
instructions and information on its use.
Operating Temperature: Means “Maximum operating temperature”
Pot-Life: the elapsed time within which a coating can be effectively applied after all components
of the coating have been thoroughly mixed.
Shelf-Life: the maximum length of time packaged materials (e.g. coating materials) can be
stored at specified conditions and remain in usable conditions.
Shop-Primer: synonymous of Prefabrication Primer (see above).
Primer and finish coats for a particular system shall be from the same manufacturer to assure
compatibility.
5.1.1 PAINT SYSTEM DESCRIPTIONS
PAINT SYSTEM 2.1 – (temp. up to 120 °C);
Primer: ZINC RICH EPOXY ……………………………….….75 mµ
Intermediate: POLYAMIDE EPOXY ………………………..125 mµ
Finish: ALIPHATIC ACRYLIC POLYURETHANE.……...…..50 mµ
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SPECIFIED TOUCH UP SYSTEM FOR SYS 2.1;
Primer: SURFACE TOLERANT EPOXY………….…..100~125 mµ
Intermediate: POLYAMIDE EPOXY ………………….……..125 mµ
Finish: ALIPHATIC ACRYLIC POLYURETHANE.……...…..50 mµ
A. SPECIFIED SYSTEM by JOTUN MANUFACTURER (SYS 2.1 temp. up to 120 °C);
BARRIER 80……………………………….………………........75 mµ
PENGUARD EXPRESS XT……...…………………………...125 mµ
HARDTOP XP……………………………………………….…...50 mµ
B. RECOMMENDED TOUCH UP REPAIR SYSTEM by JOTUN;
JOTAMASTIC 80…………………….……………...……100~125 mµ
PENGUARD EXPRESS XT…………………………….……..125 mµ
HARDTOP XP……………………………………………….……50 mµ
C. SPECIFIED SYSTEM by KANAT MANUFACTURER (SYS 2.1 temp. up to 120 °C);
KANEPOX ZINC RICH 80 (11420)………………………….....75 mµ
KANEPOX UNIFAST (12200)……………………………..…..125 mµ
KANPOLY ACR ENAMEL HS (37770)………………………...50 mµ
D. RECOMMENDED TOUCH UP REPAIR SYSTEM by KANAT;
KANEPOX MASTICOAT (15550)…………..…….……. 100~125 mµ
KANEPOX UNIFAST (12200)…………………………..……..125 mµ
KANPOLY ACR ENAMEL HS (37770)……………….…..……50 mµ
E. SPECIFIED SYSTEM by CIN MANUFACTURER (SYS 2.1 temp. up to 120 °C);
C-Pox Primer ZN800………………………………………….....75 mµ
C-Pox S100……………………………..……………………....125 mµ
C-Thane S258……………………………….…………………...50 mµ
F. RECOMMENDED TOUCH UP REPAIR SYSTEM by CIN;
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5.1.2. Completely Stripped Surfaces until the Steel for Cycle No 2.1;
Surface Preperation & Paint Applicaiton Method
For small defects;
Small defects defined as less than 50cm X 50cm dimensions can be power tool cleaned
to a minimum of ISO St 3 standard with a profile of no less than 25 microns.
For large defects;
The defects which are larger than 50cm X 50cm dimensions shall be spot blasted either
by vacuum blasting, or other suitable blasting equipment,
Blast cleaning shall be made in a covered area, provided by Contractor, to prevent dust spread
on the surrounding areas. For blast cleaning the approval of Owner is required.
After blasting all spent abrasive or grit must be removed
For areas Sa 2½ (ISO 8501-1) blasting is not possible due to site conditions after erection,
surface tolerant mastic epoxy which may be applied on top of mechanical surface preparation
as primer prefered instead of zinc rich epoxy for minor touch-up applications.
Completely stripped surfaces until the steel shall be cleaned mechanically by using power
tools (floppy, cup wire brush etc.) in St 3 level according to ISO 8501-1 standard.
Dusts occurred at the end of mechanical cleaning process shall be removed from surfaces by
using compressed air and scrubber. Also, other contaminations such as dirt, mud, oil etc.
remained on the surfaces shall be cleaned with suitable cleaning agent or solvent.
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Feathering the edges of existing undamaged coating (Sharp edges of intact coating should be
feathered), followed by application of repair paint system.
Mechanically cleaned surfaces shall be primed with Surface Tolerant Epoxy Primer defined in
touch-up paint system table in one coat with airless spray equipment or in 2 coats (50 microns
for each coat) by using roller & brush equipment in total 100 microns dry film thickness within
the shortest time (in 5 hours at the latest) after mechanical cleaning process was completed.
Care should be taken to prevent overlapping of surface tolerent mastic epoxy on intact with
Polyurethane film.
After 10 hours at the earliest and 30 days at the latest (at 20°C) when Surface Tolerant Epoxy
Primer application was completed, High Build Epoxy Midcoat shall be applied in one coat with
airless spray equipment or in 2 coats (65 microns for first coat+60 microns for second coat) by
using roller & brush equipment in total 125 microns dry film thickness.
After 4 hours at the earliest and 90 days at the latest (at 20°C) when High Build Epoxy Midcoat
application was completed, Aliphatic Acrylic Polyurethane Topcoat shall be applied in one coat
with airless spray or roller & brush equipment in 50 microns dry film thickness.
Ambient temperature, relative humidity and dew point should be checked out prior to each
surface preparation and each paint application. Ambient temperature should be at the values,
that the paint manufacturer recommended, and the relative humidity should be maximum 80%.
Temperature of the surface, to which paint application and surface preparation shall be done,
should be at least 5°C above the dew point.
5.1.3. Damaged Mid-coated Surfaces for Cycle No 2.1;
Damaged mid-coated surfaces shall be roughened by using sandpaper.
Dusts occurred at the end of sanding process shall be removed from surfaces by using
compressed air and scrubber. Also, other contaminations such as dirt, mud, oil etc. remained on
the surfaces shall be cleaned with suitable cleaning agent or solvent.
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Feathering the edges of existing undamaged coating (Sharp edges of intact coating should be
feathered), followed by application of repair paint system.
Roughened surfaces with sandpaper shall be painted with High Build Epoxy
Midcoat shall be applied in one coat with airless spray equipment or in 2 coats (65 microns for
first coat+60 microns for second coat) by using roller & brush equipment in total 125 microns dry
film thickness within the same day after roughening process with sandpaper was completed.
Care should be taken to prevent overlapping of surface tolerent mastic epoxy on intact with
Polyurethane film.
After 4 hours at the earliest and 90 days at the latest (at 20°C) when High Build Epoxy Midcoat
application was completed, Aliphatic Acrylic Polyurethane Topcoat shall be applied in one coat
with airless spray or roller & brush equipment in 50 microns dry film thickness.
Ambient temperature, relative humidity and dew point should be checked out prior to each
surface preparation and each paint application. Ambient temperature should be at the values,
that the paint manufacturer recommended, and the relative humidity should be maximum 80%.
Temperature of the surface, to which paint application and surface preparation shall be done,
should be at least 5°C above the dew point.
5.1.4 Damaged Top-coated Surfaces for Cycle No 2.1;
Damaged top-coated surfaces shall be roughened by using sandpaper.
Dusts occurred at the end of sanding process shall be removed from surfaces by using
compressed air and scrubber. Also, other contaminations such as dirt, mud, oil etc. remained on
the surfaces shall be cleaned with suitable cleaning agent or solvent.
Feathering the edges of existing undamaged coating (Sharp edges of intact coating should be
feathered), followed by application of repair paint system.
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Roughened surfaces with sandpaper shall be painted with Aliphatic Acrylic Polyurethane
Topcoat shall be applied in one coat with airless spray or roller & brush equipment in 50 microns
dry film thickness within the same day after roughening process with sandpaper was completed.
Care should be taken to prevent overlapping of surface tolerent mastic epoxy on intact with
Polyurethane film.
Ambient temperature, relative humidity and dew point should be checked out prior to each
surface preparation and each paint application. Ambient temperature should be at the values,
that the paint manufacturer recommended, and the relative humidity should be maximum 80%.
Temperature of the surface, to which paint application and surface preparation shall be done,
should be at least 5°C above the dew point.
5.2.1 PAINT SYSTEM DESCRIPTIONS
PAINT SYSTEM 2.5 – TEMP. up to 150 °C;
Primer: PHENOLIC EPOXY ……………………………….….200 mµ
SPECIFIED TOUCH UP SYSTEM FOR SYS 2.5;
Primer: PHENOLIC EPOXY ………….………………………200 mµ
OR
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B. RECOMMENDED TOUCH UP REPAIR SYSTEM by JOTUN;
EPOXY HR………………………………….……………….......200 mµ
C. SPECIFIED SYSTEM by KANAT MANUFACTURER (SYS 2.5 temp. up to 150 °C);
KANEPOX HYGIENIC (19570)…………………….……….....200 mµ
D. RECOMMENDED TOUCH UP REPAIR SYSTEM by KANAT;
KANEPOX MASTICOAT (15550)…………..…….………….. 100 mµ
KANEPOX HYGIENIC (19570)…………………….……….....100 mµ
E. SPECIFIED SYSTEM by CIN MANUFACTURER (SYS 2.5 temp. up to 150 °C);
C-POX TL 735 / C-POX TL740…………………….…...…….....200 mµ
F. RECOMMENDED TOUCH UP REPAIR SYSTEM by CIN;
C-POX TL740…………………….……………..…….……...….. 200 mµ
G. SPECIFIED SYSTEM by PPG / SIGMA MANUFACTURER (SYS 2.5 temp. up to 150 °C);
SIGMAGUARD 730 or SIGMATHERM 230…………...…….....200 mµ
H. RECOMMENDED TOUCH UP REPAIR SYSTEM by PPG / SIGMA (up to 40 °C);
SIGMAGUARD 350………………………….………..……...….. 100 mµ
SIGMAGUARD 730………………………….………..……...….. 100 mµ
I. RECOMMENDED TOUCH UP REPAIR SYSTEM by PPG / SIGMA (between 40~150 °C);
SIGMAGUARD 730………………………….………………...….. 50 mµ
SIGMAGUARD 730………………………….………..……...….. 150 mµ
5.2.2. Completely Stripped Surfaces until the Steel for Cycle No 2.5;
Surface Preperation & Paint Application Method
For small defects
Small defects defined as less than 50cm X 50cm dimensions can be power tool cleaned
to a minimum of ISO St 3 standard with a profile of no less than 25 microns.
For large defects;
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The defects which are larger than 50cm X 50cm dimensions shall be spot blasted either
by vacuum blasting, or other suitable blasting equipment,
Blast cleaning shall be made in a covered area, provided by Contractor, to prevent dust spread
on the surrounding areas. For blast cleaning the approval of Owner is required.
After blasting all spent abrasive or grit must be removed.
For areas Sa 2½ (ISO 8501-1) blasting is not possible due to site conditions after erection,
Completely stripped surfaces until the steel shall be cleaned mechanically by using power tools
(floppy, cup wire brush etc.) in St 3 level according to ISO 8501-1 standard.
Dusts occurred at the end of mechanical cleaning process shall be removed from surfaces by
using compressed air and scrubber. Also, other contaminations such as dirt, mud, oil etc.
remained on the surfaces shall be cleaned with suitable cleaning agent or solvent.
Feathering the edges of existing undamaged coating (Sharp edges of intact coating should be
feathered), followed by application of repair paint system.
Mechanically cleaned surfaces shall be primed with Surface Tolerant Epoxy Primer defined in
touch-up paint system table in one coat with airless spray equipment or in 2 coats (50 microns
for each coat) by using roller & brush equipment in total 100 microns dry film thickness within
the shortest time (in 5 hours at the latest) after mechanical cleaning process was completed.
Care should be taken to prevent overlapping of surface tolerent mastic epoxy on intact with
Polyurethane film.
After 10 hours at the earliest and 30 days at the latest (at 20°C) when Surface Tolerant Epoxy
Primer application was completed, Solvent-free Phenolic Epoxy shall be applied in one coat
with airless spray equipment or in 2 coats (50 microns for each coat) by using roller & brush
equipment in total 100 microns dry film thickness.
Ambient temperature, relative humidity and dew point should be checked out prior to each
surface preparation and each paint application. Ambient temperature should be at the values,
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that the paint manufacturer recommended, and the relative humidity should be maximum
80%. Temperature of the surface, to which paint application and surface preparation shall be
done, should be at least 5°C above the dew point.
1) Minimum and maximum time, required to be waited between each coat during application,
defined in product technical data sheets should be obeyed.
2) Paint application shouldn’t be applied under the conditions determined below:
i) If the surface is wet.
ii) If relative humidity is above the maximum value defined in product technical data sheets.
iii) If ambient or surface temperature is below/above the temperature defined in product
technical data sheets.
iv) If application environment is extremely dusty.
v) If the velocity of wind is more than 24 km/h.
3) Minor touch-up repair applications should be carried out using brushes. While using brushes more
coats will be required in order to achieve specified DFT.
4) Airless spraying during windy conditions may promote dry- spray formation and uneven thickness. If
a situation may arise it should be rectified prior to following coat application. Site HSE rules has to
be followed.
5) All coating works has to be carried out according to the project specifications and instructions stated
in technical data sheets and Application Guide of the products.
6) Applicators and all related parties are fully responsible to follow all information stated in TDS and
Application Guide documents of the products stated in the paint systems.
7) Depending on site conditions different situations which are not stated in this procedure may occur
during application operations, if such a situation may arise it will be evaluated additionally.
8) Weld fumes to be removed by Fresh water washing.
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PROJECT QC CODE
AEGEAN REFINERY PROJECT (ARP)
DOCUMENT TITLE N°
NFI No.:
PROJECT QC CODE
AEGEAN REFINERY PROJECT (ARP)
DOCUMENT TITLE N°
Paint Brand Name: _______________________ Colour: ____________ Batch No.: ______________ Manufacture Date: _______________
Thinner Brand Name: _________________________ Batch No.: _______________________ Manufacture Date: ____________________
PAINTING APPLICATION & AMBIENT CONDITION
Application by: Brush/ Roller Conventional (Air) Spray Airless Spray Nozzle Size: _________ Pressure: _________
Ambient Relative Dew Point Steel Surface
Working Shift Period Time Temperature (0C) Humidity (%Rh) Temperature (0C) Temperature (0C)
START
MID-POINT
END
SURFACE PREPARATION
Abrasive Brand: _____________________ Abrassive Type & Size:___________________ Abrassive Batch No.:__________________
Blasting Nozzle Pressure ____________ Blasting Nozzle Orifice Size _____________ Blasting Air Cleanliness Test_________________
Surface Cleanliness: Sa 2 ½ / SSPC SP 10 St 2 / SSPC SP 2 St 3 / SSPC SP 3 Sweep Blast / SSPC SP 7
Surface Condition: Visual Check_____________ Roughness____________(µm) Chloride Test Result ________________
PAINT THICKNESS CHECK (See Notes Below)
DFT
DFT Req. DFT Actual (µm) Result
Drawing/ ISO/ Area Item/ Spool Average
(µm)
1 2 3 4 5 (µm) Accept Reject