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CONTEC Comissão de Normalização Técnica SC - 14 Painting and Anticorrosive Coatings -PUBLIC- N-9 REV.

CONTEC

Comissão de Normalização Técnica

SC - 14

Painting and Anticorrosive Coatings

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Treatment of Steel Surfaces by Abrasive Blasting and Water Jetting

Procedure

This Standard replaces and cancels its previous revision.

The CONTEC - Authoring Subcommittee provides guidance on the interpretation of this Standard when questions arise regarding its contents. The Department of PETROBRAS that uses this Standard is responsible for adopting and applying the sections, subsections and enumerates thereof.

Technical Requirement: A provision established as the most adequate and which shall be used strictly in accordance with this Standard. If a decision is taken not to follow the requirement (“non-conformity” to this Standard) it shall be based on well-founded economic and management reasons, and be approved and registered by the Department of PETROBRAS that uses this Standard. It is characterized by imperative nature.

Recommended Practice: A provision that may be adopted under the conditions of this Standard, but which admits (and draws attention to) the possibility of there being a more adequate alternative (not written in this Standard) to the particular application. The alternative adopted shall be approved and registered by the Department of PETROBRAS that uses this Standard. It is characterized by verbs of a nonmandatory nature. It is indicated by the expression:

[Recommended Practice].

Copies of the registered “non-conformities” to this Standard that may contribute to the improvement thereof shall be submitted to the CONTEC - Authoring Subcommittee.

Proposed revisions to this Standard shall be submitted to the CONTEC - Authoring Subcommittee, indicating the alphanumeric identification and revision of the Standard, the section, subsection and enumerate to be revised, the proposed text, and technical/economic justification for revision. The proposals are evaluated during the work for alteration of this Standard.

“This Standard is exclusive property of Petróleo Brasileiro S. A. - PETROBRAS, internal application and PETROBRAS Subsidiaries and shall be used by its suppliers of goods and services under contracts or similar under the conditions established in Bidding, Contract, Agreement or similar. The use of this Standard by other companies / organizations / government agencies and individuals is the sole responsibility of the users ”

and individuals is the sole responsibility of the users ” Introduction PETROBRAS Technical Standards are prepared

Introduction

PETROBRAS Technical Standards are prepared by Working Groups - WG (consisting specialized of Technical Collaborators from Company and its Subsidiaries), are commented by Company Units and its Subsidiaries, are approved by the Authoring Subcommittees - SCs (consisting of technicians from the same specialty, representing the various Company Units and its Subsidiaries), and ratified by the Executive Nucleus (consisting of representatives of the Company Units and its Subsidiaries). A PETROBRAS Technical Standard is subject to revision at any time by its Authoring Subcommittee and shall be reviewed every 5 years to be revalidated, revised or cancelled. PETROBRAS Technical Standards are prepared in accordance with PETROBRAS Technical Standard N-1. For complete information about PETROBRAS Technical Standards see PETROBRAS Technical Standards Catalog.

-PUBLIC- N-9 REV. G ENGLISH 09 / 2013 Foreword This Standard is the English version

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Foreword

This Standard is the English version (issued in 05/2014) of PETROBRAS N-9 REV. G 09/2013. In case of doubt, the Portuguese version, which is the valid document for all intents and purposes, shall be used.

1 Scope

1.1 The objective of this Standard is to set out the procedure for preparation of steel surfaces for

application of paint systems or other anticorrosive coatings, by means of abrasive blasting or water jetting (with or without abrasives).

NOTE 1

NOTE 2 For the purposes of this Standard, the term water jetting refers to water jetting with or

Check the legal provisions described in 4.1.

without abrasives.

1.2 The provisions of this Standard apply to procedures started as of its date of issuance.

1.3 This Standard contains Technical Requirements and Recommended Practices.

2 Normative References

The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document applies.

Portaria do Ministério do Trabalho n o 99 de 19/10/2004 - Proíbe o processo de trabalho de jateamento que utilize areia seca ou úmida como abrasivo;

Norma Regulamentadora n o 15 (NR-15) - Atividades e Operações Insalubres;

ABNT NBR 15158 - Limpeza de Superfícies de Aço por Compostos Químicos;

ABNT NBR 15185 - Inspeção de Superfícies para Pintura Industrial;

ABNT NBR 15239 - Tratamento de Superfícies de Aço com Ferramentas Manuais e Mecânicas;

ABNT NBR 15488 - Pintura Industrial - Superfície Metálica para Aplicação de Tinta - Determinação do Perfil de Rugosidade;

ISO 8501-1 - Preparation of Steel Substrates before Application of Paints and Related Products - Visual Assessment of Surface Cleanliness - Part 1: Rust Grades and Preparation Grades of Uncoated Steel Substrates and of Steel Substrates after Overall Removal of Previous Coatings;

ISO 8501-3 - Preparation of Steel Substrates before Application of Paints and Related Products - Visual Assessment of Surface Cleanliness - Part 3: Preparation Grades of Welds, Edges and other Areas with Surface Imperfections;

ISO 8502-3 - Preparation of Steel Substrates before Application of Paints and Related Products - Tests for the Assessment of Surface Cleanliness - Part 3: Assessment of Dust on Steel Surfaces Prepared for Painting (pressure-Sensitive Tape Method);

ISO 8502-6 - Preparation of Steel Substrates before Application of Paints and Related Products - Tests for the Assessment of Surface Cleanliness - Part 6: Extraction of Soluble Contaminants for Analysis - The Bresle Method;

ISO 8502-9 - Preparation of Steel Substrates before Application of Paints and Related Products - Tests for the Assessment of Surface Cleanliness - Part 9: Field Method for the Conductometric Determination of Water-Soluble Salts;

-PUBLIC- N-9 REV. G ENGLISH 09 / 2013 ISO 8504-2 - Preparation of Steel Substrates

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ISO 8504-2 - Preparation of Steel Substrates before Application of Paints and Related Products - Surface Preparation Methods - Part 2: Abrasive Blast-Cleaning; ASTM D 610 - Standard Test Method for Evaluating Degree of Rusting on Painted Steel Surfaces;

ASTM D 4940 - Standard Test Method for Conductimetric Analysis of Water Soluble Ionic Contamination of Blasting Abrasives;

NACE WJ-1/SSPC-SP WJ 1 - Joint Surface Preparation Standard Waterjet Cleaning of Metals-Clean to Bare Substrate (WJ-1);

NACE WJ-2/SSPC-SP WJ 2 - Joint Surface Preparation Standard Waterjet Cleaning of Metals-Very Thorough Cleaning (WJ-2);

NACE WJ-3/SSPC-SP WJ 3 - Joint Surface Preparation Standard Waterjet Cleaning of Metals-Thorough Cleaning (WJ-3);

NACE WJ-4/SSPC-SP WJ 4 - Joint Surface Preparation Standard Waterjet Cleaning of Metals-Light Cleaning (WJ-4);

SSPC VIS 4/NACE VIS 7 - Guide and Reference Photographs for Steel Surfaces Prepared by Waterjetting;

SAE J-444 - Cast Shot and Grit Size Specifications for Peening and Cleaning.

NOTE For documents referred in this Standard and for which only the Portuguese version is available, the PETROBRAS department that uses this Standard should be consulted for any information required for the specific application.

3 Terms and Definitions

For the purposes of this document, the following terms and definitions are applicable.

3.1

abrasive blasting method for preparing steel surfaces for paint or other coating application by using steel grit, sintered

aluminum oxide or other abrasives impelled by means of compressed air or by centrifugal force

3.2

water jetting without abrasive method for preparing steel surfaces for painting by using water under high pressure [70 MPa to

210 MPa (10 000 psi to 30 000 psi)] or ultra-high pressure [above 210 MPa (30 000 psi)]

NOTE

This process does not create an anchor profile.

3.3

water jetting with abrasive method for preparing steel surfaces for painting by using water ultra-high pressure [above 210 MPa (30 000 psi)] and special abrasives, in order to create an anchor profile or remove adhering mill scale grade A and B

3.4

rust and preparation grades of steel surfaces the rust grade of a steel surface refers to the conditions of the surface before execution of the cleaning

process; the surface preparation grade, on the other hand, corresponds to the final cleaning standard of the surface before painting or other coating is applied.

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3.4.1

rust grades of unpainted steel surfaces according to ISO 8501-1

Grade A

- steel surface largely covered with intact and adhering mill scale with

Grade B

little or any rust; - steel surface on which atmospheric corrosion has begun and from

Grade C

which mill scale has begun to flake; - steel surface on which the mill scale has been removed by atmospheric

Grade D

corrosion or from which it can be scraped out, but with slight pitting visible; - steel surface on which the mill scale has been removed by atmospheric corrosion and on which general pitting is visible.

3.4.2

rust grades of painted surfaces according to standard ASTM D 610

Grade 8

- existing painting almost intact, with less than 0.1% of the surface with

Grade 6

corrosion; - calcined finish paint, which may present exposed primer; slight spotting

Grade 4

or blistering is permitted after the spots are treated. Less than 1 % of the area may be affected by corrosion, flaking or loose paint; - paint completely calcined, blistered or with rust spots, which may have

Grade 2

up to 10 % of its surface with corrosion, oxidation blisters, loose paint and slight pitting (punctiform corrosion); - paint completely calcined, blistered or with rust spots, which may have

Grade 0

up to 33 % of its surface with corrosion, oxidation blisters, loose paint and slight pitting (punctiform corrosion); - heavy presence of corrosion, loose paint and severe formation of pitting corrosion.

3.4.3

rust grades of steel surfaces by means of abrasive blasting according to ISO 8501-1 and ISO 8504-2

Grade Sa 1

- light blast cleaning: when seen with the naked eye, surface shall be

Grade Sa 2

free of loose mill scale, rust and non-adhesive foreign matter. The final appearance shall correspond to the photographs designated Sa 1. This cleaning process does not apply to surfaces presenting original Rust Grade A. For other ones, the cleaning standards are: BSa 1, CSa 1 and DSa 1; - commercial blast cleaning: when seen with the naked eye, surface shall

be free of almost all mill scale, rust and foreign matter. The surface shall be display a grayish color and correspond in appearance to the photographs designated Sa 2. This cleaning process does not apply to surfaces presenting original Rust Grade A. For other ones, the cleaning standards are: BSa 2, CSa 2 and DSa 2; Grade Sa 2 1/2 - near-white metal blast cleaning: when seen with the naked eye, surface shall be free of mill scale, rust and foreign matter, to the extent that the only traces remaining are in the form of slight stains or stretch marks. The surface shall be display an aspect corresponding to the photographs designated Sa 2 1/2. The cleaning standards are: ASa 2 1/2, BSa 2 1/2, CSa 2 1/2 and DSa 2 1/2;

Grade Sa 3

- blast cleaning to white metal: when seen with the naked eye, surface shall be completely free of loose mill scale, rust and non-adhesive foreign matter. The surface shall be display a uniform metal coloring, corresponding in appearance to the photographs designated Sa 3. The cleaning standards are: ASa 3, BSa 3, CSa 3 and DSa 3.

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NOTE

After treatment, the surface shall be immediately cleaned with a vacuum cleaner, clean and dry compressed air or a clean brush.

3.4.4

preparation grades of steel surfaces by water jetting according to NACE WJ-1/SSPC-SP WJ 1, NACE WJ-2/SSPC-SP WJ 2, NACE WJ-3/SSPC-SP WJ 3,

and NACE WJ-4/SSPC-SP WJ 4

WJ-1

- the surface shall be free of all previously existing visible rust, paint, mill

WJ-2

scale, and foreign matter, and present a uniform matte metal finish (see Notes 1 and 2); - the surface shall be cleaned to a matte finish, with at least 95 % of the

WJ-3

area free of all previously existing visible residues, and the remaining 5% containing only random stains of rust, paint and foreign matter (see Notes 1 and 2); - the surface shall be cleaned to a matte finish, with at least 2/3 of the

WJ-4

area free of all previously existing residues (except mill scale), and the remaining 1/3 containing only random stains of rust, paint or previously existing foreign matter (see Notes 1 and 2); - the surface shall be uniformly free of rust, paints and loose mill scale.

NOTE 1 High-pressure water jetting and ultra-high pressure water jetting do not present the same coloring as abrasive blasting. The matte metal coloring of the cleaned steel immediately after water jetting becomes yellowish. In old steel surfaces having areas with or without coatings, the color of the matte finish varies even if all visible surface material has been removed. NOTE 2 Ultra-high pressure water jetting is capable of removing oils and greases from the surface. However, this does not avoid the need for the previous degreasing stage.

3.4.4.1

no flash rust the steel surface, when seen with the naked eye, does not display visible surface oxidation

3.4.4.2

flash rust instantaneous surface oxidation that occurs after water jetting, which may be light (L), moderate (M) or

heavy (H), according to the photographic standards of SSPC VIS 4/NACE VIS 7

3.4.4.2.1

light flash rust (L) the steel surface, when seen with the naked eye, displays a very thin slightly orange rust layer, and is

easily observed on the steel substrate; oxidation may be evenly distributed or present in the form of localized spots, and is easily adhered and hard to be removed by cleaning using rags

3.4.4.2.2

moderate flash rust (M) the steel surface, when seen with the naked eye, displays a thin orange rust layer which hides the original surface of the steel; the oxidation layer may be evenly distributed or present in the form of localized spots, but it is reasonably well adhered, causing light marks on a rag when it is lightly rubbed over the surface

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3.4.4.2.3

heavy flash rust (H) the steel surface, when seen with the naked eye, displays a heavy orange/brown rust layer that completely hides the initial conditions of the surface; the rust layer may be evenly distributed or

present itself in the form of spots, but the rust is slightly adhered and easily removed, leaving significant marks on a rag when it is lightly rubbed over the surface

4 General Conditions

4.1 According to Ordinances No. 99 from the Brazilian Ministry of Labor and Employment and NR-15,

work processes that use dry or wet sand are forbidden in the whole Brazilian territory. In contracts for projects carried out outside Brazil, the legislation in force in the country in which the project is being undertaken shall be obeyed.

4.2 In the case of water jetting, the use of corrosion inhibitor shall be avoided.

4.3 Abrasive blasting and water jetting procedures shall contain at least the following information:

a) preparation grade of steel surface;

b) indication of chemicals and materials used in the cleaning process according to standard ABNT NBR 15158;

c) type of equipment to be used for surface preparation, indicating the separating filters and nozzles;

d) type and grain-size analysis of the abrasive material based on the roughness profiles to be obtained;

e) quality of water to be used (pH, salinity, contaminants, among others);

f) when corrosion inhibitors are used, it shall be informed the type and mechanism of anticorrosive protection, concentration, and methods to be used in its future removal;

g) methods to evaluate the salinity of abrasive according to ASTM D 4940;

h) acceptance criteria regarding the salinity levels of the abrasive, according to Table 1;

i) final cleaning procedures after surface preparation, before the paint systems are applied;

j) determination of salt content on the surface cleaned by blasting or water jetting before start painting, as established in ISO 8502-6 and ISO 8502-9;

NOTE

Other methods to determine the salt content may be used, as long as they are previously agreed by the parties.

k) description of the safety equipment to be used in the processes, as well as the personal protection equipment (PPE) used by blasting and water jetting operators, and collective protection equipment (CPE) for ultra-high pressure water jetting services.

4.4 The stages to be followed for surface preparation are described in items 4.4.1 to 4.4.5:

4.4.1 Remove oil or grease, complying with the methods established in ABNT NBR 15158.

4.4.2 Remove soil, cement spatters, salts, lime and any other contaminant (except grease and oil) by

means of fiber or wire brushes, by scraping, water jetting or by applying alkaline cleaning solutions with subsequent rinse with fresh water, or by the combination of those methods.

NOTE When there is found corrosion on plates, it is convenient to remove it by using manual or mechanical tools according to ABNT NBR 15239. The purpose of this previous removal is to facilitate the action of the solvent in contaminants such as salts, oils, and greases hidden by the plates. [Recommended Practice]

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4.4.3 In case of surface imperfections, the P3 finishing standards from ISO 8501-3 shall be adopted.

4.4.4 Removal of mill scale, rust, existing paint, and other contaminants, according to the preparation

grade specified in the paint system (see 3.4.3 and 3.4.4) by one of the following processes:

a) abrasive blasting with grit (angular or spherical particles) made of steel:

— steel grit shall display a proper grain size so as to provide the surface with the roughness profile specified in this Standard (see Annex A);

b) abrasive blasting with sintered aluminum oxide or other suitable abrasives for surface preparation, with a grain size providing the surface with the roughness profile specified in this Standard (see Annex A);

c) high or ultra-high pressure water jetting (only in case the surface has already been subjected to some type of abrasive blasting);

d) ultra-high pressure water jetting with abrasives:

abrasives shall display a proper grain size so as to provide the surface with the roughness profile specified.

4.4.4.1 After abrasive blasting, the surface shall be cleaned by means of a brush, and/or vacuum

cleaner, so as to remove grains of abrasives and dust.

4.4.4.2 In the case of water jetting, the surface shall be carefully cleaned with fresh water, so as to

remove, before painting starts, the abrasive, soluble salts, corrosion inhibitor (where applicable), and other materials existing on the surface.

4.4.4.3 In the case of water jetting, the paint to be applied directly on the surface shall be tolerant to

the substrate conditions after water jetting, besides being duly certified by the responsible PETROBRAS department. In these cases, the surface may be dry, with residual moisture or wet, and may present surface oxidation [light flash rust (L)] in all cases.

4.4.5 Before applying the first layer of paint, the surface to be painted shall be checked for the

presence of traces of oil, grease, dirt, and salts, which shall be removed according to the requirements of ABNT NBR 15158.

4.5 The compressed air used for application of the abrasive jet shall be free of water and oil. The

equipment shall be provided with suitable filters and separators, or air heating or cooling shall be

provided for the removal of water and oil.

4.6 Surface preparation services by means of abrasive blasting or water jetting shall be performed in

such a manner as to not cause damages to the work stages already completed. The restart of the services of surface preparation shall only be resumed when the paint applied to the adjacent areas is

at the minimum drying stage stickiness free.

4.7 Abrasive blasting services shall not be performed when there is forecasting of rain, fog or mist or

when the surfaces are not at least a temperature 3 °C above the dew point temperature, or when the

relative humidity is higher than 85 %. Except for paints tolerant to wet surfaces.

4.8 During abrasive blasting, primer shall be applied as quickly as possible and while the blasted

surface complies with the specified standard. As time goes by, the surface tends to oxidize and a new blasting operation may be necessary, depending on the specified standard, to the surface preparation.

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4.9 During water jetting operations, primer shall be applied considering the oxidation conditions of the surface before painting. The time interval between the process of washing the surface with fresh water and primer application shall be as short as possible, intending to reduce, particularly in aggressive environments (marine and industrial marine types), the concentration of chlorides and other undesirable substances on the surface as well as the intensity of flash rust. If light to moderate flash rust formation occurs, the paint manufacturer’s recommendations shall be followed. If heavy flash rust formation occurs, the surface shall be manually treated with a wire brush and washing with high pressure fresh water, at a minimum of 34 MPa (5 000 psi), before primer application.

NOTE

For conditions of internal painting of equipment, only light flash rust grade is acceptable.

5 Inspection and Acceptance Criteria

Inspections shall be performed according to Tables 1 and 2, following the established acceptance criteria.

Table 1 - Before Abrasive Blasting or Water Jetting

Inspection to be performed

Method

When

Acceptance criteria

 
 

ABNT

Before abrasive blasting or water jetting

Surface free of oil, grease, fat, paint, salts, or other contaminants in the entire area to be treated

Surface cleaning

NBR 15185

Rust grade of unpainted surface

ISO 8501-1

Before abrasive blasting or water jetting

According to ISO 8501-1

 

Rust grade of painted surface

ASTM D 610

Before abrasive blasting or water jetting

According to ASTM D 610

 
     

New grit

shall

meet

the

Grain-size analysis of abrasive

Before abrasive blasting or water jetting with abrasive

specification in Table A.1. In

Table A.1

case of reuse, it shall present

 

at least

80 %

(in

weight) of

 

retention on a number 40 sieve

Impurities in abrasive

-

Before abrasive blasting

Free of visible signs of impurities

 

Chloride content in abrasive

ASTM D 4940

Before abrasive blasting

Below 40 ppm

Oxidation in abrasive

-

Before abrasive blasting

Free

Water quality

-

Before water jetting

clean, fresh, free of contaminants, with pH ranging from 6.5 to 7.5, and maximum chlorine concentration below 40 ppm

Environmental conditions and determination of dew point

-

Before abrasive blasting

- Relative Air Humidity: Below 85 %; - Surface temperature: at least 3 °C above dew point temperature.

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Table 2 - After Abrasive Blasting or Water Jetting

Inspection to be performed

Method

When

Acceptance criteria

     

Surface

free

of

oil,

Surface cleaning

ABNT NBR 15185

After abrasive blasting or water jetting

grease, fat, paint, salts, or other contaminants in

the

entire

area

to be

 

treated

 

Evaluation of surface oxidation level

 

After water

Without flash rust, or light grade at most

SSPC VIS 4/NACE-VIS 7

jetting

 

ISO 8501-1 NACE WJ-1/SSPC-SP WJ 1 NACE WJ-2/SSPC-SP WJ 2 NACE WJ-3/SSPC-SP WJ 3 NACE WJ-4/SSPC-SP WJ 4 SSPC VIS 4/NACE VIS 7

After abrasive

According to standards established in items 3.4.3 and 3.4.4

Surface preparation grade

blasting and

water jetting

Roughness profile

ABNT NBR 15488 (see Note 1)

After abrasive blasting and water jetting with abrasive (see Note 2)

50 µm to 100 µm. (See Note 3)

 
   

After abrasive

Maximum of standard of Figure 2 of ISO 8502-3

Powder contamination

ISO 8502-3

blasting

 

ISO 8502-6

Right before

Maximum of 7 µg/cm 2 in atmospheric regions and maximum of 3 µg/cm 2 in immersed, buried or submerged areas

Chloride content on surface

ISO 8502-9

application of

primer

NOTE 1

The roughness profile shall be measured on the first m 2 of the blasted area or on the first linear

meter (m), in the case of piping; proceed with the measurements for every 30 m 2 or linear 30 m, respectively. NOTE 2 As an alternative to abrasive blasting, water jetting under ultra-high pressure with special

NOTE 3

abrasives may be used to create an anchor profile or remove adhering mill scale grade A and B. If the roughness profile is not specified in painting procedure standard of equipment or piping, use

the specification on this table.

 

6 Safety / Collection, Storage and Disposal of Wastes

The recommendations of local Health, Safety and Environment (HSE) departments shall be observed.

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Annex A - Table

Table A-1 - Profile Heights Obtained According to Abrasive

 

Type of abrasive

Maximum profile height µm

 

Copper slag:

 

Coarse #12/40

100

Medium #18/40

75

Fine #40

50

 

Angular steel grit:

 

G-14

150

G-25

100

G-40

75

G-50

50

 

Spherical steel grit:

 

S-390

110

S-330

85

S-280

75

S-230

65

 

Angular sintered aluminum oxide:

 

# 8/16

130

# 12/20

100

# 20/40

80

 

Spherical sintered aluminum oxide:

 

# 8/16

100

# 12/20

85

# 20/40

65

 

Abrasive with sponge:

 

With G-40 With aluminum oxide 16 With aluminum oxide 30

75

100

50

NOTE

According to SAE J-444.

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INDEX OF REVISIONS

REV. A, B, C and D

There is no index of revisions.

REV. E

Affected Parts

Description of Alteration

All

Revised

REV. F

Affected Parts

Description of Alteration

All

Revised

REV. G

 

Affected Parts

Description of Alteration

All

Revised