Академический Документы
Профессиональный Документы
Культура Документы
PTS 15.20.03
February 2016
Page 2 of 111
FOREWORD
PETRONAS Technical Standards (PTS) has been developed based on the accumulated knowledge,
experience and best practises of the PETRONAS group supplementing National and International
standards where appropriate. The key objective of PTS is to ensure standard technical practice across the
PETRONAS group.
Compliance to PTS is compulsory for PETRONAS-operated facilities and Joint Ventures (JVs) where
PETRONAS has more than fifty percent (50%) shareholding and/or operational control, and includes all
phases of work activities.
Contractors/ Manufacturers/ Suppliers who use PTS are solely responsible in ensuring the quality of work,
goods and services meet the required design and engineering standards. In the case where specific
requirements are not covered in the PTS, it is the responsibility of the Contractors/ Manufacturers/
Suppliers to propose other proven or internationally established standards or practices of the same level
of quality and integrity as reflected in the PTS.
In issuing and making the PTS available, PETRONAS is not making any warranty on the accuracy or
completeness of the information contained in PTS. The Contractors/ Manufacturers/ Suppliers shall
ensure accuracy and completeness of the PTS used for the intended design and engineering requirement
and shall inform the Owner for any conflicting requirement with other international codes and technical
standards before start of any work.
PETRONAS is the sole copyright holder of PTS. No part of this document may be reproduced, stored, in a
retrieval system or transmitted in any form or by any means (electronic, mechanical, recording or
otherwise) or be disclosed by users to any company or person whomsoever, without the prior written
consent of PETRONAS.
The PTS shall be used exclusively for the authorised purpose. The users shall arrange for PTS to be kept in
safe custody and shall ensure its secrecy is maintained and provide satisfactory information to PETRONAS
that this requirement is met.
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 3 of 111
ANNOUNCEMENT
Please be informed that the entire PTS inventory is currently undergoing transformation exercise from
2013 – 2015 which includes revision to numbering system, format and content. As part of this c hange, the
PTS numbering system has been revised to 6-digit numbers and drawings, forms and requisition to 7-digit
numbers. All newly revised PTS will adopt this new numbering system, and where required make
reference to other PTS in its revised numbering to ensure consistency. Users are requested to refer PTS
00.01.01 (Index to PTS) for mapping between old and revised PTS numbers for clarity. For further inquiries,
contact PTS administrator at ptshelpdesk@petronas.com.my
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 4 of 111
Table of Contents
1.0 INTRODUCTION .......................................................................................................... 7
SCOPE .................................................................................................................................. 7
GLOSSARY OF TERM ............................................................................................................ 7
Page 5 of 111
APPLICATION CONDITION.................................................................................................. 35
APPLICATION METHODS .................................................................................................... 36
REPAIRS AND TOUCH UP COATING ................................................................................... 38
Page 6 of 111
APPENDIX 13: TYPICAL COATING QUALITY INSPECTION AND TEST PLAN CHECKLIST ...... ....... 94
APPENDIX 14: COATING DAILY INSPECTION REPORT TEMPLATE ........................................... 96
APPENDIX 15: ITEMS TO BE EXCLUDED FROM PTS 15.20.03 .................................................. 97
APPENDIX 16: MAINTENANCE COATING .............................................................................. 99
APPENDIX 17: SURFACE PREPARATION BY BLAST CLEANING .............................................. 101
APPENDIX 18: RECOMMENDED ORGANISATION CHART FOR COATING WORK EXECUTION . 109
APPENDIX 19: REGULATIONS ON ABRASIVES, COATING PRODUCTS, WASTE PRODUCTION,
PRODUCT STORAGE AND LEACHING OF COATINGS ........... ........... ........... ..... 110
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 7 of 111
1.0 INTRODUCTION
This PTS provides the minimum technical requirement for surface preparations, application
procedures, selection of coating and coating systems, enhanced quality control measures,
personnel qualifications and updated colour schemes to be used on metallic substrates requiring
corrosion protection for new construction and maintenance.
SCOPE
1.1.1 The PTS covers both external and internal coating for onshore and offshore facilities on metallic
substrates for domestic and international projects. It shall also include initial and maintenance
coating.
1.1.3 Services which are not covered under this PTS and required to be coated shall be referred to the
Owner to advise the appropriate coating system.
1.1.4 Specialised equipment supplied by vendors such as valves, pumps, compressors, etc. shall be
coated in accordance to specific coating systems as dictated by the environment in Section 3.0 of
this PTS.
1.1.5 Other items excluded from this PTS as listed in Appendix 15.
GLOSSARY OF TERM
No Term Definition
Page 8 of 111
No Term Definition
Page 9 of 111
No Term Definition
Page 10 of 111
No Term Definition
No Abbreviation Description
Page 11 of 111
No Abbreviation Description
16 QA Quality Assurance
17 QC Quality Control
18 QP Quality Plan
Page 12 of 111
2.0 WARRANTY
GENERAL
2.1.1 Contractors, undertaking coating works in accordance with this PTS, shall guarantee the quality
of their coating work. Prior to start of coating works, warranty period shall be agreed with the
Owner.
2.1.2 A minimum warranty period of seven (7) years for all coatings and ten (10) years for TSA inclusive
of maintenance coatings. This requirement shall be incorporated in the coatings contract
document. For shorter design life the warranty period can be reduced to meet project
requirement based on owner’s agreement.
2.1.3 The severity of corrosion shall not exceed a Ri 3 scale based on ISO 4628-3 Assignment of Degree
of Rusting during the warranty period.
2.1.4 The warranty shall be based on the reference area within the structure or facility involved.
Reference area shall be selected at a location with typical corrosive stresses for the structure.
Surface preparation, coating application and the quality of work at the selected reference area
shall be agreed and witnessed by the Owner, the Contractor’s representative together with TPI.
Clear documentation and marking on the structure showing the reference area shall be made
available for the reference of the Owner, Contractor and TPI. Refer Table 3 for further details on
reference area.
Recommended
Recommended minimum total
Size of Coated Area,
minimum number area of reference
m2
of reference areas areas,
m2
Up to 2,000 2 10
2,001 to 5,000 4 24
5,001 to 25,000 6 60
25,001 to 50,000 8 80
Above 50,001 8 160
Table 3: Recommended reference area selection
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 13 of 111
2.1.5 Surfaces that have deteriorated beyond the acceptable level of breakdown within the warranty
period shall be repaired by the Contractor at Contractor’s cost. The Contractor shall also bear the
cost for materials, equipment, labour, transportation and storage necessary for the repair.
2.1.6 Initial acceptance of any new coating work by the Owner will not relieve the Contractor of his
obligations under this section until the final inspection has been carried out and acceptance of
the completed work has been agreed in writing.
2.1.7 A final inspection shall be carried by TPI to be agreed between the Contractor and the Owner
before expiry of the coating work warranty period.
2.1.8 In case of a dispute on the condition and quality of the coating work that has been applied, an
independent consultant shall be engaged to conduct a review inspection. Both the Owner and the
Contractor shall accept the inspection findings by this independent consultant.
2.1.9 Owner may engage a consultant as their representative in the event that requires detailed coating
failure investigation, services which shall include all the required laboratory and failure analysis.
2.1.10 In the event where dispute arises to assign responsibility of defect between the Contractor and
the coating manufacturer, an independent consultant shall be appointed by the coating
manufacturer and Contractor to arbitrate the issue. The Owner shall at no times be liable to this
process.
2.1.11 The
fromdegree of compensation
100% until coverage
the end of first shall
year, 90% tillbe
theonend
a diminishing value
of the second ofand
year 10%socoverage starting
on until the end
of the warranty period.
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 14 of 111
3.1.1 General
i. This section addresses the selection of coating system for external and internal
application. Selection of coating systems and products which are not listed shall
require approval from the Owner.
ii. Prior to execution of coating works, the items below shall be qualified to the
requirements of this PTS:
a) Coating Systems (Appendix 1)
b) Abrasive materials (Appendix 11)
iii. Recycled abrasive must comply with tests mentioned in Appendix 11
iv. Maintenance and touch-up coating systems shall be compatible with the New
Construction coating systems. Coating system compatibility shall be tested using
patch test methods described in ASTM D5064.
3.1.2 Primer
i. Sacrificial-type primer such as organic or inorganic Zinc-rich primer shall contain a
high percentage of zinc dust of greater than 80% by mass in the non-volatile portion
of the primer. The zinc dust shall comply with the requirements specified in ASTM
D520 (Type II or III) or ISO-3549. The zinc-rich primers shall be overcoated with
chemically resistant coatings to avoid direct exposure acid and strong alkalis such as
in marine environment. Cleaning using freshwater or power scrubbing shall be
required to remove contaminants prior to overcoating. Damaged inorganic zinc-rich
primers shall be repaired with an organic zinc-rich coating.
ii. Organic inhibitive primer contains inhibiting pigments that produce alkaline
conditions to protect the base metal against corrosion when exposed to moisture.
Overcoats are required to ensure the effectiveness of this inhibitive primer due to the
reactive pigments content.
Page 15 of 111
completely to Sa 2.5.
ii. The minimum volume solids for high solid epoxy shall be 75%. As an alternative,
surface tolerant high solid epoxy coating may be applied.
3.2.1 For new construction, single coating manufacturer responsibility shall be maintained by using
primers, intermediate coats and topcoats from the same Manufacturer.
3.2.2 For some systems, there are options available and the application of LCC shall be considered
during development of CDBM.
3.2.3 Unless otherwise stated by Manufacturer, the surface preparation for new construction shall be
blast cleaned to ISO 8501-1, Sa 2.5.
3.2.4 The list of approved coating products can be found under Appendix 3. This list will be updated
Page 16 of 111
Page 17 of 111
Page 18 of 111
N13
Stainless Steel 1 Epoxy(h) 150-200 200
Atmospheric zone N13-1 2 Polyurethane 50-75 75
Page 19 of 111
N19
Living Quarters, Pressurised
N19-1 1 Surface Tolerant Epoxy 150 150
Building, Interior Control Room
(Interior)
N21-1
Roof 1 Amine Adduct Epoxy 125 125
and 2 Amine Adduct Epoxy 125 125
Shell
Plate
N21 Total 250 250
Carbon Steel Storage Tank N21-2 1 Amine Adduct Epoxy 100 100
(Internal) Bottom 2 Amine Adduct Epoxy 100 100
Crude/Condensate (Sweet & Plate & 3 Amine Adduct Epoxy 100 100
Sour), Emulsion/Slop Vessels Total 300 300
N21-3 1 Amine Primer 50 50
Bottom 2 Amine Glass Flake 200 200
Plate 3 Amine Glass Flake 200 200
Alterna
tive Total 450 450
N22
Carbon Steel Storage Tank
1 Amine Adduct Epoxy 125 125
(Internal)
2 Amine Adduct Epoxy 125 125
Light/Heavy/Treated Naphtha, N22-1
Reformate, Jet A-1 Fuel, Fuel
Oil, Gasoline (leaded & un-
leaded) and Diesel Total 250 250
N23
Potable Water(i) Total 250 250
(Drinking/Aerated/Non-
Aerated), Seawater, 1 High Solids Epoxy 125-175 125
2 Stripe Coat
Produced/Brackish Water, N23-2 3 High Solids Epoxy 125-175 125
Demineralised Water and Brine Ballast
Water 4 Stripe Coat
Tank 5 High Solids Epoxy 125-175 125
Page 20 of 111
XX
Y Sytem number
System i.e. 2System
option i.e. nd 28in System 28
option
‡
Do not add to total DFT
Ɨ
End user specification
ᵠ Vendor specification
(a) Structural steel and piping can be coated in the shop with the first two coats. The third coat can be applied at
site after erection. A mist coat will be required following the application of primer as per M anufacturer’s
specifications
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 21 of 111
(b) Applicable for surface of cold insulated steel pipe operated down to -70°C under wet insulation
Coating may also be carried out in 2 coats (150 microns each)
(c) The average surface profile shall be 75 microns
(d) Allow thinned sealer to dry >30 minutes before application of next sealer coat.
(e) For service temperature >700C, polychloroprene rubber shall only use carbon black pigment, which gives better
thermal resistance.
(f) Ethylene Propylene Diene Elastomer
(g) High Temperature Silicone coating should not be applied more than 40 microns thick which could lead to
blistering. Alum colour can withstand temperature more than 200°C.
(h) Never use zinc based coating on stainless steel which can cause Liquid Metal Embrittlement during fire.
(i) Coating system applied for potable water system shall be accompanied with a health certificate.
(j) The temperature described in Table 3-1: New Construction Coating System shall be of design temperature.
(k) For Service N13, the stainless steel surface described is for Austenitic type stainless steel. 22%Cr and 25%Cr
stainless steels shall be painted in accordance to System N13 for operating temperatures ≥50°C and ≥80°C
respectively.
If the coating film, apart from local rust areas, is sound and adequate (Ri=3), the areas
that are corroded, approximately 100 cm 2 in size, shall be spot cleaned and touched
up using a single pack system to full film thickness with Owner approval.
All corrosion products shall be removed and the interface between the sound coat
and cleaned areas shall be properly prepared.
For renovation (Ri=4), spot repairs shall be carried out to the existing coating and a
full topcoat shall be applied. The existing coating system shall be sound and adequate
while the new topcoat shall enhance the corrosion protection.
Refurbishment requires total removal of the existing coating system (Ri≥5). Surface
preparation and application of a new coating system shall be carried out in
accordance with Section 3.0 of this PTS.
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 22 of 111
Page 23 of 111
M7
Carbon Steel M7-1 1 Underwater Curable Epoxy 375-750 500
Water condensing surface
M11
1 Epoxy(h) 150-200 200
Stainless Steel M11-1
2 Polyurethane 50-75 75
Atmospheric zone
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 24 of 111
120°CAtmospheric zone
to 150°C With/Without M12-1
Total 200-250 250
Insulation
1 Epoxy 150-200 200
M13
M13-1 2 Polyurethane 50-75 75
Stainless Steel
Atmospheric zone Total 200-275 275
150°C to 450°C With/Without
1 Thermal Spray Aluminium 50-100 75
Insulation M13-2
Total 400 400
1 Aluminium Wood Primer 50 50
M14 2 Alkyd Semi-gloss finish 50 50
M14-1 3 Alkyd Semi-gloss finish 50 50
Timber Decks
Total 150 150
ᵠ Vendor specification
(a) Applicable for surface of cold insulated steel pipe operated down to -70°C under wet insulation
Coating may also be carried out in 2 coats (150 microns each).
(b) Antiskid grits should be mixed with the liquid coating prior to application to obtain good wetting of
the grits. Fine grits should be used with the application of antiskid epoxy.
(c) DFT of the applied coating shall be calculated prior to the addition of antiskid grits.
(d) The average surface profile shall be 75 microns minimum.
(e) For service temperature >70 0C, polychloroprene rubber shall only use carbon black pigment, which gives
better thermal resistance.
(f) Ethylene Propylene Diene Elastomer.
(g) Average surface profile shall be 75 micron minimum.
(h) Temperatures described in Table 3-3: Maintenance Coating Systems are operating temperature whereby
evident operating experiences have been established and such that operating limits shall not exceed the range
described. In case of operating conditions shall be as per design limit, then Table 3-1: New Construction
Coating Systems shall be referred.
(i) For Service M11, the stainless steel surface described is for Austenitic type stainless steel. 22%Cr and 25%Cr
stainless steels shall be painted in accordance to System N13 for operating temperatures ≥50°C and ≥80°C
respectively.
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 25 of 111
3.4.1 New coating products, upgrading of existing product or formulation changes of approved coating
products shall be submitted for a full laboratory screening before the product can be considered
as an approved product.
3.4.3 For qualifications of coating system other than those already qualified and/or specified in
Appendix 3, Contractor shall engage with Owner on the test method and requirements.
3.5.1 Coating Manufacturers shall submit QA/QC reports on the coating products that passed the
laboratory screening tests. The QA/QC reports must have the following information:
i. Coating Product Name
ii. Manufacturer
iii. Batch number
iv. Manufacturing date
v. Testing date
vi. Drying time
vii. Hold up property
viii. Glossiness
ix. Specific gravity
x. Viscosity
xi. Coatings Fingerprint Certificate
3.5.2 Coating Manufacturers shall ensure that the properties of their coating systems selected for
actual coating work will be the same as the ones that passed the laboratory screening tests.
Owner may collect ad-hoc coating samples for verification an approved independent testing
agency to verify conformance to the QA/QC report stated herein.
3.5.3 Whenever deemed necessary, Owner may carry out a non-conformance audit on the coating
manufacturers.
3.6.1 Coating Manufacturers shall furnish their Coating Quality Control Batch certificates to ensure that
the properties of the products supplied are consistent with the laboratory tested products. The
Coatings Fingerprint Certificate shall be produced per batch per coating manufactured and data
stored in digital format. This data shall be submitted to the Owner’s MCI representative from the
project team during delivery of coating products.
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 26 of 111
3.6.2 Owner retains the right to conduct random coatings fingerprinting test at any given point during
the course of the project as it deems fit. This shall be referenced against fingerprinting results
i) Gloss
3.6.4 All QC test results shall be provided by coating manufacturer as and when requested by
the Owner.
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 27 of 111
GENERAL
4.1.1 The Contractor, in addition to his responsibilities under the general conditions of the contract
shall be responsible for the quality of the work which shall be performed in strict accordance with
this PTS and all other relevant documents, such as site regulations, safety rules and requirements,
product data sheets, referenced standards and codes.
4.1.2 The Contractor shall be fully responsible for all QA and QC activities. The Contractor shall submit
for any major coating work an appropriate work planning and a QP for implementing this PTS for
review and approval by the Owner. Copies of this PTS, work planning and the QP shall be made
available to the Contractor’s representative at site. The representative shall confirm his
understanding on the contents of the PTS, work planning and the QP.
4.1.3 The Contractor shall conduct a pre-job meeting to ensure that job and quality requirements are
fully understood. Attendees shall be a representative of the Owner, Contractor Coating Advisor,
the Coating Inspector and the Coating Manufacturer’s representative.
4.1.4 The Contractor shall conduct a site coating selection via panel test. This is to be executed before
any major projects or major maintenance work. The Contractor shall shortlist a minimum of 3
coating manufacturers for this exercise. The Contractor Coating Advisor shall witness and accept
the panel test results together with Owner.
4.1.5 The unmixed actual coating used for panel testing shall be marked, retained and properly sealed
in a minimum 2” diameter by 2” height stainless steel container for traceability and to avoid
product contamination. Owner may conduct fingerprinting test as deemed necessary.
4.1.6 The accepted test panels and retained unmixed coating samples shall be properly labeled and
stored. The coating samples, test panels and QA/QC documents shall be included as handover
items in the project handover checklist. MCI representative from Owner shall acknowledge
receipt of items in the handover documents.
4.1.7 Coating manufacturer shall be consulted if the Contractor is not familiar with the coating materials
to be applied.
4.1.8 The Contractor shall display his capability to Owner in achieving the requirements as specified in
the contract.
HSE
4.2.1 The Contractor shall be responsible for all aspects of HSE. Environmental regulations and rules
shall be met.
4.2.2 Safe working is of the greatest importance particularly during coating works in confined spaces
such as tanks and vessels. Site safety regulations shall be adhered to.
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 28 of 111
4.2.3 All personnel shall be provided with approved PPE suitable to the working environment as well as
weather e.g. protective clothing, safety glasses, safety shoes, hard hats, goggles, respirators,
earplugs, fresh-air-fed hood and any other necessary safety equipment.
PPE made of fabrics such as coveralls and gloves that do not provide chemical resistant protection
shall not be used to avoid dermal exposure to hazardous material during coating application. As
a minimum, leather gloves are required when handling abrasive blasting equipment and airless
spray gun. All safety equipment shall be maintained in good working condition adequate for all
work requirements.
4.2.4 Adequate warning signs shall be prominently displayed on each access way to all areas where
abrasive blasting and coating is in progress.
4.2.5 Handling and disposal of hazardous waste resulting from the Contractor's coating activities shall
be in accordance with regulations and specific contract requirements. However, the Owner’s
regulations on chemical management or banned materials shall be strictly adhered to.
4.3.1 The Contractor shall ensure that all layers of a coating system and blasting materials comply with
any local and/or regional standards or regulations on banned materials such as lead, chromate,
crystalline silica, and coal tar. The Owner’s regulations on chemical management or banned
materials shall be strictly followed. Any coating system shall fully comply with any local and/or
regional air quality or Volatile Organic Compounds (VOC) levels or emission standards or
regulations.
4.3.2 Reference to Occupational Safety and Health (Use and Standards of Exposure of Chemicals
Hazardous to Health) Regulations shall be made in the event of any hazardous components are
expected to be present for the identification of OEL/MEL. Coatings shall contain maximum 0.1%
Monomeric Isocyanate at the time of coating. If the CSDS/MSDS of the coating does not specify
the content of the isocyanate groups, Owner shall have the right to request for laboratory
assessment of the monomeric isocyanate content in the coating. Refer to ASTM D2572 or ISO
14896/3 for the testing procedures.
PERSONNEL
4.5.1 The Contractor shall protect all equipment, structures and any other areas from mechanical
damage, environmental damage, blockage or obstruction, damage caused by over blasting,
coating droppings and splashes or overspray.
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 29 of 111
4.6.1 The Contractor shall demonstrate that blasting and spraying equipment to be used are in good
condition and well maintained. Blasting and coating equipment shall fully comply with any local
and/or regional regulation. Wherever applicable, valid Certificate of Fitness for blasting and
spraying equipment from local authority shall be made available for reference by Owner.
4.6.2 The blasting and spraying equipment shall be capable of achieving the quantity and quality
requirements as prescribed in the contract.
4.6.3 Blasting equipment, its operators and the equipment being blasted shall be properly earthed to
prevent the occurrence of electrostatic discharges. Abrasive blast cleaning equipment shall be of
intrinsically safe construction and equipped with a remote shut-off valve triggered by the release
of a dead man's handle at the blasting nozzle.
4.6.4 Where air-operated equipment is used, the operator's hood or headgear shall be ventilated by
clean, cool air supplied through a filter, to prevent blast cleaning residues from being inhaled.
ACCESS
4.7.1 Access for coating work shall be constructed to provide safe and adequate access for surface
preparation, coating and inspection of all surfaces.
4.7.2 Scaffolding shall be constructed in accordance with local regulations and the requirements of the
Owner.
4.7.3 Where abseiling is required, the Contractor shall consult the Owner to conduct JHA prior to
execution and approval shall be at the discretion of the Owner.
4.8.1 To minimise the risk of damage, no lifting, transportation, erection or fabrication operations shall
be done before the coating has been fully dried and/or cured. Welding shall not be carried out on
the external surfaces of internally coated tanks or vessels.
4.8.2 Where transportation is required, canvas or nylon slings shall be used for lifting and wooden
blocks applied for securing the structure. If weather change is expected during transportation,
plastic wrapping may be applied based on the risk of coating deterioration of the structure.
4.8.3 Any damages to the coating from premature curing due to Contractor’s act of welding, erection,
fabrication or lifting activities shall be repaired by the Contractor as per srcinal specification.
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 30 of 111
STORAGE PROTECTION
4.9.1 The Contractor shall ensure the coating cans are stored in compliance to Manufacturer’s
recommendations, particularly in regards to storage temperature. As a general rule, all containers
containing coating materials shall be stored under cover giving protection from direct sunlight
and rain at a temperature below 35°C. The storage condition shall also allow for adequate
ventilation to minimize coating container deterioration from humidity. Materials shall be
systematically stored after delivery so that a First-In-First-Out (FIFO) withdrawal procedure can
be adopted.
4.9.2 The Contractor shall supply all the necessary protection when prefabricated coated steel or
coated steel for climate controlled areas has to be stored in the open air prior to erection, to avoid
premature failure of the applied coating layers.
4.9.3 Coating cans shall be stored away from any source of ignition.
4.9.4 The Owner has the right to audit and inspect the storage area while the materials are still kept or
stored.
4.9.5 Prior to removal of the material from storage area, a joint inspection by Owner and Contractor
shall be done to verify the condition of the material. Acceptance shall be as per agreed QA/QC
requirement.
SHELF-LIFE
4.10.1 The Contractor shall ensure that in the event that the quoted shelf-life period has been exceeded,
the usability of the product shall be confirmed by the Manufacturer and notified to the Owner.
The procedure described in ASTM D869 shall be used to evaluate the degree of settling of coating.
A coatings fingerprint is also required to be conducted to ensure product quality is in accordance
with Appendix 2. This needs to be accepted in conjunction with other tests.
4.10.2 Coating which has deteriorated during storage shall not be used and disposed of accordingly.
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 31 of 111
SURFACE PROFILE
5.1.1 Roughness or anchor pattern measurement shall be carried out by the Contractor using
instruments and procedures approved by the Owner. Where anchor patterns are not specified in
the coating manufacturer’s technical data sheet, Table 5 -1 below shall be used as a guide for
determining the anchor pattern.
Dry film thickness Anchor pattern
125-200 microns (5-8 mills) 25-50 microns (1 -2 mills)
200-500 microns (9-20 mills) 50-76 microns (2-3 mills)
> 500 microns (>20 mills) 75-125 microns (3-5 mills)
Table 5-1: Relationship between coating thickness and anchor pattern
5.1.2 Abrasives used in blast cleaning steels shall generally be in accordance with ISO 8504-2 and Table
5-2. In the event of other type of abrasive media not described in ISO 8504-2 and Table 5-2 is to
be used, prior written approval from Owner shall be obtained.
5.1.3 Aluminium oxide or other abrasives (free from any chloride or iron/steel contamination) shall be
used for blasting stainless steel.
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 32 of 111
5.3.1 The most technically effective surface preparation method is blast-cleaning. Manual preparation
shall only be used when blast-cleaning is either not feasible or not strictly required, e.g. for rust
scale Ri3.
5.3.2 Manual cleaning shall be performed using hand wire brushes or mechanically operated tools
(grinders, bristle blaster, chippers or wire brushes) in accordance with ISO 8504-3. The surface
shall be left roughly abraded and a burnished surface shall be avoided.
5.3.3 If the surface being prepared lies adjacent to a coated surface which is not to be refurbished, the
power tool cleaning shall overlap the coated surface by at least 50 mm.
5.3.4 The following two preparation grades (in accordance with ISO 8501-1) are recognised for hand or
power tool cleaning:
i. St 2 : Thorough hand and power tool cleaning
ii. St 3 : Very thorough hand and power tool cleaning
NOTE: Preparation grade St 1 is considered an unsuitable surface for coating.
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 33 of 111
SURFACE PREPARATION METHOD- STAINLESS STEEL, GALVANIZED STEEL, NICKEL ALLOY AND
NON-FERROUS ALLOY
Acceptable surface preparation methods can be varied for this specification dependent on the
size and the access to the item being coated.
Vessels, cabinets, large bore pipe and valves shall be “Brush –off blast cleaned” to standard NACE
No. 4/SSPC SP 7.
Small bore piping, valves and instruments may be prepared by hand tool cleaning by “sanding” to
achieve an abraded surface profile to enable adequate coating adhesion.
20ppm) atbefore
degreaser high pressure (e.g.
it dries on the200 psi) to remove the contaminated detergent or
surface.
iii. The surface shall then be “Brush –off blast cleaned” to standard NACE No. 4/SSPC SP
7 to give a dense surface profile of no more than 25 m. The purpose of the blast
cleaning in this instance is to give the primer a suitably “roughened “ surface to enable
good adhesion while also removing any minor corrosion products. Fine size abrasives
with low nozzle pressure (approx. 50-60 psi) shall be used for this blasting method.
iv. Significant areas of corrosion pitting or metal loss that are exposed during blasting
operations shall be referred to Owner for inspection prior to any further coating of
these areas.
Page 34 of 111
6.0 APPLICATION
PRE-APPLICATION PROCEDURES
Page 35 of 111
APPLICATION CONDITION
6.2.1 Coating shall be applied to dry, clean, prepared surface under conditions recommended in the
manufacturer’s product data sheet. The Contractor shall comply with the QP for work execution.
Where deviation may exist, it is the responsibility of the Contractor to highlight the deviations and
obtain the necessary approval from Owner Site Representative.
6.2.2 Coating shall not be applied when any of the following conditions exist:
i. The surface temperature is less than 3°C above dew point.
ii. The surface temperature is below 5°C as it could adversely affect the curing of
coatings. Refer to product data sheet for systems that can be applied at temperatures
below 5°C.
iii. The relative humidity (RH) is greater than 85%, except for moisture-cured urethane
coating systems which may be used at higher than 85% RH.
iv. The metal surface temperature is above 50°C or higher than that recommended by
the Manufacturer for application.
v. Surface preparation has not been completed or oil, grease and dust are present on
the substrate to be coated.
vi. Poor weather conditions example rain, heavy fog or blowing sand.
vii. When there is a deposition of moisture in the form of rain, condensation etc. on the
surface. Probability of condensation may be determined in accordance with
procedures described in ISO 8502-4.
viii. Where the available light is less than 500 lux.
ix. Coating may be suspended at the discretion of the Owner Site Representative due to
wind speed, wave height, or when adverse weather conditions are likely to develop
before coating could be carried out, or for other reasons deemed inappropriate to
proceed.
6.2.3 It is important to ensure residual salt contamination particularly from chloride ion is kept to as
minimal as possible. Contractor to agree with Owner on random residual salt test that shall be
conducted for these conditions:
i. Prior to primer application
ii. Subsequent coating layer application after a long interval e.g. after 1 day curing of
previous coating application.
6.2.4 The assessment of soluble chloride ion content shall be carried out in accordance with ISO 8502-
6 and 8502-9 or any approved commercial field test kit by the Owner. The soluble chloride ion
limit shall be 20mg/m2, except for maintenance coating works for other than stainless steels in
atmospheric zone where 50mg/m2 is acceptable. The test shall be carried out once per 200m2
area with a minimum of three times per shift.
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 36 of 111
6.2.5 If the soluble chloride ion content is high and obtaining a clean surface is too costly, the allowable
soluble chloride ion content shall be agreed by the Contractor and Owner.
recommended by psi)
pressure (e.g. 200 thefresh
Manufacturer whichever
water washing shall beisconducted
shorter. If prior
this istoexceeded, high
the application
of the subsequent coats and validated with soluble chloride ion test.
ii. Applied coatings for onshore away from marine environment shall not be left without
overcoating for a period of more than 14 days or the maximum over coating time
recommended by the Manufacturer whichever is shorter. If this is exceeded, high
pressure (e.g. 200 psi) fresh water washing shall be conducted prior to the application
of the subsequent coats and validated with soluble chloride ion test.
iii. Zinc or aluminium in the form of coating pigments or metal spray shall never be
allowed to come into contact with stainless steel, nickel-based alloys or copper-based
alloys.
iv. Any coatings or coatings used on stainless steel, nickel based alloys and copper based
alloys shall be chloride free and also free of low melting point metals such as zinc,
aluminum, tin and lead.
v. On structural steel areas subject to be assembled by high tension bolts, contact
surface shall be primed only with Inorganic Zinc Silicate. Intermediate and final coat
shall not be applied.
APPLICATION METHODS
Page 37 of 111
iii. Edges of existing coating shall be feathered towards the substrate prior to over-
coating to ensure good adhesion.
iv. Inaccessible surfaces after assembly, including the surface of lap joint flanges, nozzle
necks, lap joint stub ends, lap rings, bolt holds and some welded joints, shall receive
the complete coating system. Contact surface of bolted connections shall be primed.
v. Contrasting colour shall be used for each coat of coating so as to ensure different
coats are applied to meet the required dry film thickness.
vi. Zinc silicate primers shall be sealed with a tie coat as soon as practical after complete
curing has taken place to avoid salt or chemical contamination.
vii. A holding or temporary protective primer may be used to facilitate shop or site
handling procedures. Such primers shall in no way replace the function or part of the
film thickness of the priming coat srcinally quoted in the applicable coating
specification.
viii. Other considerations:
a) Coating of small bore pipework (3" NPS) and smaller shall be applied by brush
or pipe roller.
b) Externally marine exposed non-galvanised bolts and nuts which cannot be
over coated due to operational requirements shall be encased in a corrosion
resistant lubricant based on the approval of Owner.
c) Valve stems and threaded stems shall be applied with suitable corrosion
resistant lubricant, subject to approval of Owner.
ix. Type of application is as per Table 6-1 below.
Type of
Recommended Usage Description Notes
Application
Airless Spray For large areas Coatings are sprayed at Spray patterns have
application higher pressure without to be observed as
compressed
fast, providesair. Twice
higher as
film clogging
and may spray
different occur
build, higher transfer patterns may
efficiency and more require different
economical. nozzle.
Conventional Air Not Applicable Versatile use but often Not Applicable
Spray leads to overspray and
uneconomical costing.
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 38 of 111
Type of
Recommended Usage Description Notes
Application
Brush When spraying is not Good for complex shaped Correct application
Application possible substrate that cannot be and technique may
spray coated. avoid overcoating
i.e. too thick or thin
Roller When spraying is not Not Applicable Not Applicable
possible and primer
has been roller coated
as well
Table 6-1: Types of Application
Page 39 of 111
Page 40 of 111
GENERAL
7.1.1 Compliance to this PTS shall be controlled through inspection and testing during all phases of
surface preparation and coating application.
7.1.2 Owner shall have the right to inspect and assess the coating work at all stages of preparation and
application and to reject any or all tools, instrument, materials, equipment, personnel or work
which does not conform to this PTS.
7.1.3 All QC requirements and acceptance criteria shall be stated in Project Specification and
incorporating the requirement of this PTS, the Owner and coating manufacturer.
7.1.4 All and any coating activity greater than 2000 m 2 shall be supervised by a certified Owner
appointed Coating Inspector, and under no circumstances will the Contractor’s Coating Inspector
substitute this QA/QC role. All exceptions or deviations to this rule will be reviewed under an
approved MOC for approval by Owner.
QUALITY REQUIREMENTS
7.2.1 The Contractor shall be fully responsible for ensuring that all surface preparation, coating and
wrapping work meets the relevant Owner QC standards, in addition to being carried out in a
timely and professional manner.
7.2.2 The Contractor and his Sub-Contractors shall operate a Quality Management System meeting the
requirements of the relevant parts of ISO 9001.
7.2.3 Prior to placement of the contract, the Contractor and Sub-Contractors shall demonstrate the
compliance of their Quality Management System with Owner requirements by submitting their
QA Manual for review and approval. The QA Manual, as a minimum, shall contain:
i. The company profile and Quality Policy Statement.
ii. The management structure organogram and details of individual managerial
responsibilities.
iii. Detailed list of all the activities carried out by the company with their interactions,
preferably accompanied by a Flowchart.
iv. The QC Plans for each activity from material purchasing and handling through to final
inspection, testing and document control, including the treatment of non-
conformances and corrective actions.
v. Document Control System for the review and update of procedures and the retention
of quality control records related to each contract.
vi. Employee training and education system and records.
vii. Auditing methods procedures, including incident or accident investigation.
viii. Safety and environmental policy and assessment of each activity.
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 41 of 111
7.2.4 The Contractor and Sub-Contractors shall be subject to audit by Owner prior to placement of the
contract and during the execution of the contract, as deemed necessary.
7.2.5 All personnel involved in the preparation, coating work and any Sub-Contractor proposed for this
work shall be formally approved by the Owner, before the work begins.
7.2.6 Prior to commencement of the work, a formal minuted Pre-start Meeting shall be held between
the Owner, Contract Administrator, relevant Contractor management and supervisory staff and
Coating Inspectors. The full scope of the work required under the contract shall be discussed. All
issues relating to the clarity or consistency of the surface preparation and/or coating
requirements detailed within the tender documents and on relevant drawings shall be formally
raised and clarified at this meeting. This will enable the quality requirements for the work to be
mutually agreed.
7.3.1 Prior to commencement of the work, the Contractor shall submit his ITP (sample in Appendix 13)
to Owner for review and approval. This shall detail the individual preparation, coating activities
involved and the inspection and test methods that will be used to ensure that they are carried out
to an acceptable standard. The ITP will generally be in table form and will indicate the type and
level of inspection and testing that is required at each stage of the work. It shall also contain
references to verifying documents, acceptance criteria and personnel responsible for each
activity.
7.3.2 The Contractor shall maintain a comprehensive recording and reporting system on all aspects of
surface preparation, coating application and QC inspection and testing. This shall as a minimum
meet all the requirements of this PTS. A final report shall be submitted to Owner, summarizing all
the work performed and the inspection and test results for approval.
7.4.1 Prior to commencement of coating activities, Contractor shall submit surface preparation coating
application procedure which includes inspections and tests to be conducted for approval by
Owner.
7.4.2 All observations, data and test result of the surface preparation and coating application activities
shall be documented by Contractor in pre-approved format. These reports shall include:
i. Names of the Contractor and the responsible personnel including blaster, Painter, and
coating and lining applicator.
ii. Date, time and duration when coating activities were carried out, including surface
preparation, coating application, inspection and testing activities.
iii. Equipment, materials, abrasive media and techniques used for surface preparation
and coating application.
iv. Type and calibration validity of instruments and tools used.
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 42 of 111
Page 43 of 111
COATING CONTRACTOR
8.1.1 Coating contractors shall have the personnel, organisation, qualifications, procedures, knowledge
and capability to produce surface preparation and coating application of the required quality. The
procedure for evaluating qualifications of coating contractors is described in SSPC-QP1.
Coating To ensure the overall project Certified with either one of IMM Coatings
Advisor coating quality is in accordance below as a minimum. Fingerprint
with the specification. The role Institute of Materials Quality Controller
of the advisor is to oversee all of Malaysia (IMM) Level 1
the coating inspector’s activities. Coating Inspector Level certification is an
II advantage
This role is an ad-hoc position by NACE International
appointment given to a qualified Certified Coating
Owner. Note that this role does Inspector Level II
not absolve the Coating SSPC PCI Level II
Contractor of their overall FROSIO Level III
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 44 of 111
coating performance,
application and able to use
coating and coating
inspection tools.
Page 45 of 111
ii. Coating;
Equipment (Application Method, Air
Pressure, Tip Size)
Specialist Coatings and Linings
Applications (Product used, Generic
name, Mixing Ratio, Mixing Method,
Thinner, Percent thinning, Expected
Pot Life, Thickness required)
Blaster Shall be able to carry out Shall be certified with Abseiling certification may
and the company accepted either one of below as a be required
Painter surface preparation and minimum.
application of coatings Institute of Materials
safely and to the minimum Malaysia (IMM)
required quality of this PTS. Certified Blaster and
Shall be working under the Painter
supervision of a lead blaster Akademi Binaan
and Painter. Malaysia/CIDB
Shall be competent and Certified Blasters and
skilful with the following Painters
operations (as a minimum): SSPC Abarasive
i. Blasting; Blasting Program (C7)
Equipment Set Up (Type of and Spray Application
Nozzle, Compressor Pressure, Program (C12)
Type of Hose, After Cooler).
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 46 of 111
INSPECTION EQUIPMENT
8.2.1 The coating inspection equipment shall be provided by the Inspection Agency and the Contractor.
The appropriate instruments with valid calibration where applicable, to be used at various
inspection points, but not limited to the following:
Page 47 of 111
9.1.1 For international projects, all coating activities shall comply with the HSE requirements of the host
country.
9.1.2 Coating activities shall be in compliance to Factories and Machinery (Mineral Dust) Regulations,
1989 or equivalent, permissible exposure limit, exposure monitoring, methods of compliance,
personal protective equipment, housekeeping, medical examinations, changing rooms and
lockers, employee information and training, record keeping and warning signs.
9.1.3 If existing coating contains metallic lead, the removal of lead base coating shall comply with
Factories and Machinery (Lead) Regulations, 1984 or equivalent.
9.1.4 Coating products and abrasives shall be in compliance with Occupational Safety and Health
(classification, labelling and safety data sheet of hazardous chemicals) regulations 2013 on
packaging, labelling, safety data sheet, inventory of hazardous chemicals and confidential
business information.
Site blasting area shall have approval from the Local Authority of the host country (e.g. DOSH).
9.1.5 Owner shall have a stake in ensuring that Contractors employed have the capability to comply
with health and safety regulations, and that hazardous operations in the protective coatings
industry are recognized such as:
i. Materials
a) Fire Hazards and Explosions
b) Health Hazards
ii. Coating Application
iii. Surface Preparation
iv. Access and Ringing
a) Ladders
b) Fall Hazards
c) Confined Spaces
v. Equipment Grounding
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 48 of 111
9.1.6 Contractor shall submit and has full responsibility for maintaining a proper and sufficient safety
loss and prevention programme covering the work and covering the employees.
9.1.7 Contractor HSE Programme shall be designed to comply with PETRONAS Corporate Policy
Statement on Health, Safety and Environment (Appendix 10), the Malaysian National Council for
Occupational Safety and Health Act (OSHA), 1994 which states that it shall be the duty of every
employer and every self-employed person to ensure, as far as practicable, the safety, health and
welfare at work of all his employees.
9.1.8 The purpose of an OSHA Compliance Programme is to make further provisions for securing that
safety, health and welfare of persons at work, for protecting others against risks to safety or health
in connection with the activities of personnel at work.
ENVIRONMENTAL REGULATIONS
9.2.1 Under the Environmental Quality (Scheduled Wastes) Regulations 2005, every waste generator
shall ensure that the scheduled waste generated is properly treated, stored and disposed of.
9.2.2 Every waste generator shall ensure that the scheduled waste that is subjected to movement or
transfer be packaged, labelled and transported in accordance with the guidelines prescribed by
the director-general of the Department of Environment.
9.2.3 Scheduled waste shall be stored in containers which are compatible with the waste and durable
to prevent spillage or leakage.
9.2.4 All handling of waste materials including but not limited to spent abrasives, coatings, thinners,
solvents and cleaners shall be performed in safe and legal manner and shall comply with all
applicable regulations and laws.
9.2.5 For regulations on abrasives, coating products, waste production, product storage and leaching
of coatings, refer to Appendix 19.
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 49 of 111
10.2.1 The colour scheme for piping shall be as per Appendix 8. The piping identification system shall be
as per Appendix 7.
10.2.2 For insulated and non-insulated piping identification, the product contained shall be marked by a
legend specifying product name in full or abbreviated form. Arrows shall be used to indicate
direction of flow. In cases where the piping changes direction or where pipe passes through walls
or floors, arrows shall be placed in positions which are easily visible. As a minimum, arrows shall
be placed at each location where the direction of the flow changes or prior to penetration of wall
or floor.
10.2.3 Pipe marking may be done by either coating or using tape or markers. The application of tapes
for pipe identification shall be limited to 60°C for non-insulated pipe and no temperature limit for
insulated pipe. The detailed dimension, location and number of markings shall be based on
particular piping system as specified in Appendix 8.
10.2.4 For systems not described in Appendix 8, the facilities owner shall determine the marking as
appropriate based on ANSI A13.1- “Scheme for Identification of Piping System”.
10.2.5 Each line shall be labelled in English with its service and to/from designation (such as "Crude to
L.P Separator Train 1"). The labelling shall be as short as possible, but concise. The labelling shall
be applied only at the starting and termination of a line.
10.3.1 The colour scheme for equipment shall be as per Appendix 9. The storage tank identification
system which includes product content and the tank number shall be as described in Appendix 6.
10.4.1 Each pipeline/riser shall be marked in accordance with piping identification system as per
Appendix 7. The pipeline marking shall be easily visible.
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 50 of 111
10.4.2 The marking location shall be determined by the Owner. As a minimum, the marking should be at
beginning and end of pipeline.
For offshore pipeline, the marking can be made at the launcher to riser section and at the receiver
section.
For onshore above ground pipeline, the marking can be made at the pipeline section before and
after the pipeline is being buried.
10.5.1 The colour scheme and marking for escape route shall be as per Appendix 10.
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 51 of 111
11.0 BIBLIOGRAPHY
MALAYSIAN REGULATIONS
Page 52 of 111
INTERNATIONAL STANDARDS
Page 53 of 111
Standard Test Methods for Measuring Adhesion by Tape Test ASTM D3359
Standard Test Method for Resistance of Organic Coatings to the Effects ASTM D2794
of Rapid Deformation (Impact)
Standard Test Method for Abrasion Resistance of Organic Coatings by ASTM D4060
the Taber Abraser
Standard Test Methods for Cathodic Disbonding of Pipeline Coatings ASTM G8
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 54 of 111
Standard Practice for Operating Xenon Arc Light Apparatus for ASTM G155
Exposure of Non-Metallic Materials
Standard Test Methods for Evaluating Coatings for High Temperature ASTM D2485
Service
Standard Practice for Cyclic Salt Fog/UV Exposure of Coated ASTM D5894
Metal.(Alternating Exposures in a Fog/Dry Cabinet and a UV
Condensation Cabinet)
Standard Test Method for Specular Gloss ASTM D523
Standard Test Method for High-Shear Viscosity Using a Cone/Plate ASTM D4287
Viscometer
Standard Test Method for Viscosity of Coatings and Related Materials ASTM D5125
by ISO Flow Cups
Standard Test Method for Consistency of Coatings Measuring Krebs ASTM D562
Unit(KU) Viscosity Using a Stormer-Type Viscometer
Standard Guide for FT-IR Fingerprinting of a Non-Aqueous Liquid ASTM D7588
Standard Test Method for Indentation Hardness of Rigid Plastics by ASTM D2583
Means of a Barcol Impressor
Standard Practice for Testing Water Resistance of Coatings Using Water ASTM D870
Immersion
Standard Test Method for Tensile Properties of Organic Coatings ASTM D2370
Standard Test Method for Measuring Humidity with a Psychrometer ASTM E337
Page 55 of 111
Page 56 of 111
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 57 of 111
One (1) set of test panels shall be prepared for each generic coating system as per the various
ASTM test requirements listed in the table in section 6.5.2 below; depending on the types of tests
to be carried out.
The test panels shall be prepared in the field, for example in a coastal fabrication yard, to simulate
field application condition where adverse climatic conditions may prevail. Each test panel shall be
surface cleaned and coated to the requirement as prescribed in this specification.
All test panels should be kept indoors for a period of seven (7) days for curing before any testing.
The test panels shall be submitted to an approved third party testing agenc
y for laboratory testing.
Recommended laboratory test methods shall include, but not limited, to the following:
Salt Spray ASTM B117 To study the creep resistance Blast Cleaned Surface
(Scribed) ASTM D1654 of Flawed coatings under 3,000 hours, coating defects as per
(Proc. A) accelerated conditions of the ASTM D 1654 Proc. A, Rating 4-5 at
corrosive environment. scribe.
ASTMMethod
Test D3359,A To give a quantitative
indication on the adhesion For ASTM D3359
acceptance Method
criteria is 3A A, the
properties of the coating
systems with DFT < 200 m.
Impact ASTM D2794 To give a quantitative 18 J (Intrusion)
indication of the ability of
coatings to resist cracking due
Abrasion ASTM D4060 To assess quantitatively the 150 mg/ 1000 cycles/ 1kg load using
abrasion resistance of the wheel CS10
coatings.
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 58 of 111
Heat- ASTM D2485, To evaluate the heat-resistant Gradual increase in temperature to the
Resistance Test Method B properties of coatings requirement as per specific requirement
designed to protect steel of section 6.2. Cool down the panel to
surfaces exposed to elevated room temperature before salt spray for
temperatures during their 24hr. Result, without coating defect
service life. such as rust, blister & loss of adhesion
Cyclic Salt ASTM D5894 To observe the performance 4,200 hours, coating defects as per
Fog/UV of coatings subject to ASTM D1654 Proc. B, area failed Rating
Exposure accelerated conditions of the No. 9.
cyclic corrosion/UV exposure :
Salt Spray duration 72 hours
Drying in air duration 16
hours
UV-A 340 nm duration 80
Note :
Users may select ASTM D5894 test method to replace ASTM B117, ASTM D1654 and ASTM G 26.
Polyurethane topcoated coating systems for testing shall be measured for "glossiness" and colour
retention using Specular Excluded (SPEX) method at 60° angle (Specular Reflectance) depicted in
ASTM D523.
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 59 of 111
Shelf life
Section 2: Test Methods and Results
Section 2A: Physical analyses
Specification
Parameters Method (state method Result Specification Result
used)
Viscosity e.g. ASTM D4287
ASTM D5125
ASTM D562
ISO 2431
ISO 2884-1
Density e.g. ISO 2811-4
Colour code e.g. BS 4800
OSHA
Non-volatile
e.g. ISO 3251
matter (by mass)
Weight Solid:
Zn metal/Total Zn
Note: submit
certificate of %
purity by e.g. ISO14680-2
manufacturer
Note: applicable to
organic and
inorganic zinc only
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 60 of 111
material
Trade name and batch
number of reference
spectrum for curing agent
/ hardener
Notes:
1. Full range of FTIR spectra for both base and curing agent without automatic baseline correction and
in absorbance mode are to be attached with this report (raw data).
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 61 of 111
2. Compliance to matching criteria values do not exclude meeting the requirements of other QA/QC
checks e.g. drying time, gloss, hiding power etc.
3. Methods used shall reference latest published document.
Authorized QA/QC Executive:- Validated by:-
-
Signature: Signature:
Date: Date:
IMM membership member :
1 Notefiles)
(data : In addition, raw data of reference and sample FTIR spectra must be provided in two raw
Appendix Overlay reference and sample FTIR spectra for curing agent / hardener
2 (Note: In addition, raw data of reference and sample FTIR spectra must be provided in two raw
data files)
Appendix Relevant MSDS
3
Appendix Certificate of analyses which are relevant to the in-house standard testings
4
Appendix Certificate of % purity of zinc by metal manufacturer for organic zinc and inorganic zinc
5
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 62 of 111
Page 63 of 111
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 64 of 111
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 65 of 111
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 66 of 111
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 67 of 111
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 68 of 111
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 69 of 111
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 70 of 111
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 71 of 111
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 72 of 111
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 73 of 111
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 74 of 111
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 75 of 111
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 76 of 111
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 77 of 111
The maximum thickness of the glassflake shall be 5 ± 2 microns. The glassflake particles shall
be of 20 microns to 400 microns in any one direction of the planer surface. A maximum of
4% may be allowed outside the above range. Extenders such as silica flour, mica or talc shall
not be used.
The glassflake is an added product to give a low permeability. Therefore, the maximum
permeability should be 0.015 perm cm (0.0006 perm inches) measured in accordance with
ASTM D1653.
Page 78 of 111
D.9 Hardness
The Barcol hardness shall be within the range of 35 – 45 as measured in accordance with
ASTM D2583.
The coefficient of thermal expansion shall be in the same order as that of steel i.e. between
10-90 x 10 -6/° C.
D.13 Immersion
The coating shall be able to withstand immersion in sea water and distilled water according
to ASTM D870-92, test for 6,000 hours at ambient temperature without showing a coating
failure such as blistering, loss of adhesion, softening, or embrittlement.
D.15 Safety
The Manufacturer shall provide the Owner and the relevant applicator with a valid Materials
Safety Data Sheets (MSDS).
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 79 of 111
APPENDIX 5
However, the percentage of glass loading can be variable without a compromise on system
performance with respect to water resistance during immersion; and its acceptance shall be
based on the results of a successful qualification test.
The glassflake is an added product to give a low permeability. Therefore, the maximum
permeability should be 0.015 perm cm (0.0006 perm inches) measured in accordance with
ASTM D1653.
E.7 Hardness
The Barcol hardness shall be within the range of 40 – 50 as measured in accordance with
ASTM D2583. (Model GYZJ 935)
Page 80 of 111
The coefficient of thermal expansion shall be in the same order as that of steel i.e. between
10-90 x 10 -6/° C.
E.11 Immersion
The coating shall be able to withstand immersion in sea water and distilled water according
to ASTM D870-92 test for 6,000 hours at ambient temperature without showing a coating
failure such as blistering, loss of adhesion, softening, or embrittlement.
E.13 Safety
The Manufacturer shall provide the Owner and the relevant applicator with a valid MSDS.
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 81 of 111
2 1
= −
3 2
2
=
3
1
=
12
Lettering : Black
Location : Fixed at field
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 82 of 111
FLOW
IDENTIFICATION LEGEND DIRECTION
TYPE PIPE O.D.
ARROW
A B C D E
1 0.75 –
1.25 0.5 0.75 8.00 0.75 4.00
2 1.50 –
2.00 0.75 1.00 8.00 1.00 5.00
3 2.50 –
6.00 1.25 2.25 12.00 2.25 8.00
4 8.00 –
10.00 2.25 4.00 24.00 4.00 12.00
Page 83 of 111
COLOUR
IDENTIFICATION
SERVICE DIRECTION
LEGEND CODE BACKGROUND CODE
ARROW
PROCESS LINE
Gas Gas Black 00E53 OSHA Yellow RAL 1003
Liquid Liquid Black 00E53 OSHA Yellow RAL 1003
Process Process Black 00E53 OSHA Yellow RAL 1003
DRAIN & RELIEF
Drain, Hot Oil Hot oil drain Black 00E53 OSHA Yellow RAL 1003
Drain, Pressurised Pressure, drain Black 00E53 OSHA Yellow RAL 1003
Drain, Hazard Hazard, drain Black 00E53 OSHA Yellow RAL 1003
Drain, Condensate Cond. drain Black 00E53 OSHA Yellow RAL 1003
Flare, High Pressure H.P. Flare Black 00E53 OSHA Yellow RAL 1003
Flare, Low Pressure L.P. Flare Black 00E53 OSHA Yellow RAL 1003
Vent Vent line OSHA Blue RAL 5005 White 00E55
Vent, Atmospheric Atm. vent OSHA Blue RAL 5005 White 00E55
STEAM & CONDENSATE
Condensate Condensate Black 00E53 OSHA Yellow RAL 1003
Steam Steam Black 00E53 OSHA Yellow RAL 1003
Boiler Feed Water Boiler H2O Black 00E53 OSHA Yellow RAL 1003
UTILITY WATER
Cooling Water Cooling H2O OSHA Green RAL 6032 White 00E55
Firewater Fire H2O OSHA Red RAL 3001 White 00E55
Potable Water Potable H2O OSHA Green RAL 6032 White 00E55
Service Water Service H2O OSHA Green RAL 6032 White 00E55
Ballast Water Service H2O OSHA Green RAL 6032 White 00E55
Sea Water Washdown Service H2O OSHA Green RAL 6032 White 00E55
Chilled Water Chilled H2O OSHA Green RAL 6032 White 00E55
UTILITY AIR & GENERAL
Air, instrument inst. air OSHA Blue RAL 5005 White 00E55
Air, utility utility air OSHA Blue RAL 5005 White 00E55
UTILITY GAS & FUEL
Blanket gas blanket gas Black 00E53 OSHA Yellow RAL 1003
Diesel fuel diesel fuel Black 00E53 OSHA Yellow RAL 1003
Aviation fuel aviation fuel Black 00E53 OSHA Yellow RAL 1003
Fuel gas fuel gas Black 00E53 OSHA Yellow RAL 1003
Nitrogen nitrogen OSHA Blue RAL 5005 White 00E55
Gas, Instrument inst. gas Black 00E53 OSHA Yellow RAL 1003
Gas, Utility utility gas Black 00E53 OSHA Yellow RAL 1003
UTILITY OIL
Lube oil lube oil Black 00E53 OSHA Yellow RAL 1003
Seal oil seal oil Black 00E53 OSHA Yellow RAL 1003
Hot oil hot oil Black 00E53 OSHA Yellow RAL 1003
Hydraulic hydraulic Black 00E53 OSHA Yellow RAL 1003
CHEMICALS
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 84 of 111
COLOUR
IDENTIFICATION
SERVICE DIRECTION
LEGEND CODE BACKGROUND CODE
ARROW
Chemical chemical Black 00E53 OSHA Yellow RAL 1003
Glycol glycol Black 00E53 OSHA Yellow RAL 1003
Caustic caustic Black 00E53 OSHA Yellow RAL 1003
chlorine chlorine Black 00E53 OSHA Yellow RAL 1003
Chemical chemical Black 00E53 OSHA Yellow RAL 1003
GENERAL
Treated water treated H2O OSHA Green RAL 6032 White 00E55
Black water black H2O OSHA Green RAL 6032 White 00E55
Grey water grey H2O OSHA Green RAL 6032 White 00E55
Hot water hot H2O Black 00E53 OSHA Yellow 1003
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 85 of 111
CODE
NO COMPONENTS COLOUR
BS4800 RAL BS381C RGB
1.1 Splash Zone/Spider Deck
- Offshore structural members steel
below castellation point (shim
connection splash zone Yellow 10E53 - - 233;193;0
substructures), spider deck and boat
landing
1.2 Cellar Deck to Main Deck including
Bridge Structure
- Structural member, from cellar deck
up to the main deck, castellation Yellow 10E53 - - 233;193;0
point outwards, beam, girder, pipe
& cable support, conduits barrel
1.10 Helideck landing area (as per CAP437 Dark Green 14C39 - 267 66;94;79
and PTS 37.19.10.31) Red 04E53 - 537 160;68;59
White - 9010/ - 241;242;234
9003
1.11 Brucker Davit Structure for Lifeboat OSHA Yellow - 1003 - 249;168;38
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 86 of 111
- The colour may be selected from the OSHA Orange - 2009 - 222;83;7
options listed according to specific OSHA Red - 3001 - 155;36;35
operator practise. OSHA Green - 6032 - 35;127;82
OSHA Blue - 5005 - 0;83;135
1.12 Conductor pipe (splash zone and above)
Yellow 10E53 - - 233;193;0
2.2
Pipework for firewater service OSHA Red - 3001 155;36;35
Page 87 of 111
Note: This is applicable for all valves except valves White 00E55 - 241;242;234
for fire water system
Page 88 of 111
CODE
NO COMPONENTS COLOUR
BS4800 RAL RGB
4.1 Pressure vessels, columns, heat exchangers
White 00E55 - 241;242;234
4.5 Jib crane and gantry crane booms and monorail Alternate 00E53 - 47;47;48
track
Black & Yellow 10E53 - 233;193,0
Page 89 of 111
As per manufacturer
specification
4.14 Foam System
OSHA Yellow - 1003 249;168;38
5.2 Dangerous obstructions (inclusive piping & OSHA Yellow and - 1003 249;168;38
structure) Black 00E53 - 47;47;48
(in alternate bands)
I.6 MISCELLANEOUS
CODE
NO COMPONENTS COLOUR
BS4800 RAL RGB
6.1 Platform Nameplate
- Background Yellow 10E53 - 233;193,0
- Lettering Black 00E53 - 47;47;48
Page 90 of 111
Page 91 of 111
Environmental Ambient and steel Before start of each In accordance with specified No blasting or
Condition temperature work activity + Every 2 requirements and Coating coating
Relative humidity Hours during surface Manufacturer’s TDS application or
ASTM E 337 preparation and coating rejection of
Dew point
operations prepared or
Wind speed coated surface
Abrasive Materials Particle Size and SSPC AB 1 Every new batch and In accordance with specified No blasting
Sharpness check by SSPC AB 2 spot checks requirements, as per
visual at all work SSPC AB 3 Certificate checks relevant sections of ISO
sites ISO 11126 11126 and ISO 11127-6
Compressed Air Standard Test Method ASTM Before start of each No visible contamination Service,
Cleanliness for Indicating Oil or D4285 shift or change in air clean and
Water in Compressed system replace
Air
Visual Visual Inspection for N/A 100% of all surfaces No defects No blasting or
Examination of sharp edges, weld coating
Pre-Cleaned Metal splatter, Slivers, application until
lamination, structurally defect is
deleterious defects, rust repaired
grade etc.
Surface Visual Assessment of SSPC VIS 1 100% visual of all In accordance with specified Re-blasting
Cleanliness Surface Cleanliness or ISO 8501 surfaces requirements Re-cleaning
(visual) ISO 8502-3 Spot checks and
retesting
until
acceptable
Soluble Salts ISO 8502-6 Immersion Service: Average conductivity Steam or clean
(Not required if ISO 8502-6 (Bresle) ISO 8502-9 6 samples/2000 m2 corresponding to 20 mg/m2 water washing
(20,000 ft2) but not and maximum conductivity and retesting
Final surface
ISO 8502-9 less than 2 samples/ corresponding to 30 mg/m2 until entire 2000
preparation by
(Conductometric) pieces of equipment water soluble salt(s). m2 (20,00 ft2)
UHP Water test area is
or structure
Jetting) (or) acceptable
Page 92 of 111
Visual Visual to determine: N/A 100% of surface after None observed Repair of
Examination of Curing, contamination, each coat defects.
Coating solvent retention,
pinholes/popping,
sagging, surface
defects
Dry Film Thickness Measurement by Dry SSPC PA2 As per SSPC PA2 The average DFT of each Repair,
Film Thickness Gauge ISO 19840 requirements measurement point shall be additional
Calibration on smooth 100% specified DFT, coats, or
surface No single measurement shall recoating as
be less than 20% below the appropriate
specified DFT
Holiday Test NACE RP 0188 NACE As per system No holidays Repair and
(Supplementary Voltage, ref. TABLE 1 RP0188 specification / retesting
Test) ASTM 100% Surface of each
D5162 coat
Holiday Detection
only for Internal
Lining or
Immersion/Buried
Surfaces
Adhesion Standard Test Method ASTM Spot check – not to be For coating types other than Repair and
(Supplementary for Pull-Off Strength of D4541 used for coatings to be PFP minimum 5MPa (72PSI) retesting
Test) Coatings Using ISO 4624 placed in immersion
Portable Adhesion
Testers
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 93 of 111
Risk Evaluation
The overriding or ultimate consideration in evaluating risks associated with coatings is
whether the coating is maintaining structural integrity or if coating degradation is allowing
corrosion to proceed, leading to the possibility of structural failure. There is no standard
method to evaluate risks;
However, the most basic approach is to compare estimated partial or total metal work
replacement costs with the estimated costs of a maintenance coating program. Safety to the
public and workers may also be a major consideration, and these associated costs may be
difficult to assess. To provide a basis for risk evaluation, inspection of the coating and
substrate is recommended.
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 94 of 111
APPENDIX 13: TYPICAL COATING QUALITY INSPECTION AND TEST PLAN CHECKLIST
Page 95 of 111
Page 96 of 111
Ri 0 / 10 Ri 3 / 6 Ri 4 / 4 Ri 5 / 1
Heavy Light
……………………. Swabbed Sprayed Water Tested
Dry Blasting Sweep Blasting Wet Blasting Power Tool Hand Tool
Type………………. Brand………………. Batch No…………... Size Range………..
SSPC SP 5/*Sa 3 SSPC SP 10/*Sa 2.5 SSPC SP 7/*Sa 1 SSPC SP 3/*St 3 Other………….
35-50 50-75 75-100 Range………... Using………….
Salts…..…. Yes/No
Page 97 of 111
External
Ceramic New PTS Heater Tubes
External
Mitigation
High temperature
swing operations e.g.
Regeneration system
Subsea To refer to Norsork Standards or other Subsea equipment,
industry recognized standards structure, piping etc.
Page 98 of 111
Other Exceptions:
GRP Gratings
Equipment or Instrumentation designated to be hand or machine tool cleaned
All Electrical Wiring, Cables, and cable Trays
Safety Equipment, Sensors and Alarms
All piping/equipment operating above 55°C (NOTE: This refers to surface temp
during coating operations, not service temperatures)
Shock Cell Pads and Wear pads on boat landing
Fire Proofed Surfaces and Cryogenic Lines (external Surfaces)
Greased nipples and fittings and lubricated surfaces
Machined and close working tolerance surfaces
Gasket contact surfaces and exposed seals, bearings and Glands.
Threaded Connections shall not be coated unless otherwise specified.
Friction grip surfaces
Equipment identification plates and information / warning signs.
Valve stems, stem threads, movable linkages, pump shafts.
Glass components, Sensitive parts of Instrumentations and Gauges. (Instrument
tubing)
Area of component to be site welded or welds subsequently to be modified
especially during Shutdown.
Bolt and Nuts which are subjected to removal
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Page 99 of 111
ii. Repair work to rectify coating damage caused by corrosion, ageing facilties, fire
damage and mechanical damage.
Maintenance coating shall ensure coverage of field weld tie-in points which shall comply with
the relevant coating system.
Determine objectives
Design life of equipment or piping
Budget restraints
Maintenance philosophy
Special requirements
Determine approach
New application or maintenance
For maintenance repair - spot repair only, spot repair and full recoat or total system
replacement?
Prioritisation of repair area, projected maintenance life, cost of application,
expected performance etc.
Q.1 GENERAL
Q.1.1 For optimum coating performance surfaces to be coated or coated shall be completely dry
and free from burrs, weld spatter, flux, rust, loose scale, dirt, dust, grease, oil and other
foreign matter before any coating is applied. If dry blast-cleaning is not strictly necessary or
not feasible (e.g. due to limited access, risk of damage to equipment, light gauge steel, the
proximity of electrical components or instrumentation) then power tool cleaning shall be
applied.
Q.1.2 If the surface has been exposed to pollutants such as salt-lade from atmosphere, it shall be
washed down with clean fresh water prior to blasting or power tool cleaning.
Q.1.3 Prefabrication primers are allowed. However, after assembly, these primers shall be removed
by blasting and the surface shall be blasted to the initial specified surface cleanliness unless
otherwise agreed by the Owner.
Q.1.4 Alternative surface cleaning is only acceptable with written approval by the Owner.
Q.1.5 Alternative surface preparation such as power tool cleaning is not acceptable for areas
difficult to access such as areas exposed to water, steelwork to be insulated or to be buried
and the internal surfaces of equipment and tanks.
Q.1.6 Stainless steel surfaces shall not be treated with carbon steel cleaning tools.
Q.1.7 Any grit, dust or other contaminants shall be removed after substrate surface preparation.
Primer layer shall be applied within four (4) hours after blasting to avoid corrosion initiation
or recontamination occurs.
Q.1.10 Surface preparation performed outdoors should be completed during daylight hours, and
early enough to permit proper priming of the surface prior to the development of any
moisture or flash rusting of the prepared surface.
Q.1.11 At the time of surface preparation and priming, the surface temperatures shall be at least
3°C above the dew point.
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Q.2 PRE-CLEANING
Q.2.1 Prior to the blast cleaning and/or prior to any coating works, the surface shall be free of any
contamination and any excessive rust scale shall be removed by impact cleaning tools or high
pressure water jetting.
Q.2.2 Biodegradable detergent or freshwater solution treatment followed by copious rinsing with
clean, potable water shall be used to remove oil or grease contamination.
Q.2.3 All edges shall be ground to a minimum radius of 2 mm or otherwise agreed with the Owner.
Flame cut areas should be ground flushed. Weld spatter also shall be ground flushed. If this
is not the case, the Owner shall be informed, and corrective action shall be taken prior to the
application of the first layer of the coating system.
Q.2.4 All bolt holes shall be solvent cleaned prior to the commencement of blast cleaning. Solvent
cleaning shall be carried out in accordance with SSPC, SP1 “Solvent Cleaning”.
Q.2.5 Maintenance coating should always start with a high pressure steam or detergent cleaning
to remove dirt, grease and/or salt deposits. In addition, after a long interval prior to the
application of the subsequent layers of a coating system or exposure to a storm at offshore,
the surface shall be cleaned by using high-pressure water/steam or water wash before the
application of the next coating layer. In the specific case of uncoated stainless steel
components, water/ or steam cleaning shall not be allowed if the water temperature equal
to or above 50°C. The requirements regarding the soluble salts and other surface
Q.2.7 Before performing abrasive blast cleaning, all equipment which could be damaged by blast,
dust or particulate matter shall be suitably protected by masking, wrapping, taping or other
means to prevent damage. Where required, the degree of contamination shall be assessed
in accordance with procedures described in ISO 8502-3. The equipment shall include but not
necessarily limited to the following:
i. Bearings
ii. Control panels
iii. Control valves
iv. Conduit
v. Instrument dials
vi. Expansion joint bellows
vii. Machined surfaces
viii. Shafts
ix. Push buttons
x. Tags
xi. Screws
xii. Exposed moving parts
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Q.2.8 Adequate barricading of the work area by either canvas, tarpaulin or suitable material shall
be constructed and accepted by the Owner in order to avoid damage to other areas or
equipment. This enclosure shall be constructed such that to contain any waste produced
from the surface preparation activity. Any necessary equipment i.e. exhaust fan, air cooler,
lighting for night work and other related HSE requirement shall be installed within this
enclosure.
Q.2.9 Where rectification has been necessary on blast-cleaned surfaces, the dressed areas shall be
pre-cleaned as initially specified. All grating panels to be removed to expose supporting
structure.
Q.2.10 The level of free halides in cleaning materials to be used on stainless steel shall be confirmed
and reviewed by Owner. Particular care shall be given to areas which are not self-draining,
so that water collected is removed and not allowed to evaporate leaving salt deposits on the
surface. Flushing activity shall be less than 10 ppm while actual concentration shall be
maintained between 20 to 30 ppm.
Q.2.11 Detergents with a pH more than 9 shall not be used on aluminium substrates.
Q.3.1 General
Q.3.1.1 Blast cleaning shall be carried out through ISO 8504-2 to the required visual standard in
accordance with ISO 8501-1 or equivalent. The minimum requirement for successful surface
preparation shall be Sa2.5 at the time of coating, unless specified by coating manufacturer on
their surface tolerant coating systems.
Q.3.1.2 Blast clean shall not be done close to coating operations or wet coated surfaces to prevent
dust and abrasive contamination. Environmental restrictions shall be observed.
Q.3.1.4 If the surface being cleaned lies adjacent to a coated surface, which is not to be repaired, the
blast cleaning shall overlap the coated surface by at least 50 mm. The edges of the existing
coating system shall be feathered. The remainder of the existing coated surface shall be
properly protected with shields or screens to prevent any over blast damage. The following
four preparation grades (in accordance with ISO 8501-1) are recognized:
i. Sa 1 : Light blast-cleaning
ii. Sa 2 : Thorough blast-cleaning
iii. Sa 2½ : Very thorough blast-cleaning
iv. Sa 3 : Blast-cleaning to visually clean steel
Q.3.1.5 No acid wash, cleaning solvents or other chemical treatments shall be used on metal surfaces
after they have been (dry) blast cleaned. This restriction includes inhibitive washes intended
to prevent rusting.
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Q.3.1.6 The surface profile or anchor pattern for carbon steel and low alloy steels to be coated with
liquid organic coatings shall be in accordance with the written recommendation of the coating
manufacturer. When not specified by the coating manufacturer or when otherwise specified
in this document, the surface profile shall be between 40 m and 70 m.
Q.3.1.7 If stainless steel, galvanised or non-ferrous metal surfaces are to be coated with liquid
(organic) coating materials, blast cleaning of these surfaces shall be carried out by smooth
sweep blasting, using fine sized non-iron containing abrasive (e.g. aluminium oxide). On
galvanised surfaces, the zinc layer shall not be damaged, a smooth uniform surface roughness
shall be achieved, no defects such as break through or crisping of the zinc layer shall occur.
Surface roughness shall be in the range of 20 m to 30 m or shall be agreed with coating
manufacturer.
Q.3.1.8 After approval by the Owner, abrading with sandpaper or light grinding with a suitable
(flexible) disc maybe used for surface preparation if sweep blasting is impossible. In addition,
when aluminium or galvanised components have to be coated, white zinc or aluminium
corrosion products and/or rust present shall be removed.
Q.3.2.1 All masking to be removed and mechanical / hand tool cleaning / coating to be carried out on
“exceptions” as required.
Q.3.2.2 Scaffold contact points and surrounding GRP grating clamp screw points uncoated after
removal of scaffold to be coated to specification standard.
Q.3.2.3 Verify anchor profile in accordance with ASTM D4417 by using a spring-loaded micrometer
and/or either a coarse or extra coarse replica tape, as required by the anchor profile depth.
(Random-Spot check)
Q.3.3.2 Air cleanliness of air compressors shall be as described in Section 7.0 Quality Control. Air
compressors shall not be allowed to deliver air at a temperature above 110 °C.
Q.3.3.3 Where air-operated equipment is used, the operator's hood or head gear shall be ventilated
by clean, cool air served through a regulator filter, to prevent blast cleaning residues from
being inhaled.
Q.3.4 Blasting Abrasives
Q.3.4.1 Blasting abrasives for use in blast cleaning carbon steels and low alloy steels are specified in
ISO 8504-2. Recommended blasting abrasives are as follows but not limited to:
i. Chilled iron grit or shot
ii. Steel and malleable iron grit or shot
iii. Natural mineral abrasives
iv. Non-metallic abrasives
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Q.3.4.2 Where abrasives which are specified as a Scheduled Waste are used, the waste shall be
collected and disposed-off at prescribed premises as per the requirement of the
Environmental Quality Act (EQA) 1974.
Q.3.4.3 Sand or other materials producing silica dust shall notbe used.
Q.3.4.4 All metallic blast cleaning abrasives shall meet the requirements of ISO 11124 and shall be
tested in accordance with test methods specified in ISO 11125 Part 1-7.
Q.3.4.5 All non-metallic blast cleaning abrasives shall meet the requirements of ISO 11126 and shall
be tested in accordance with test methods specified in ISO 11127 Part 1-7.
Q.3.4.6 Product shall be sealed in hermetic packaging. Any product delivered in defective packaging
shall be rejected. Products must be stored sheltered from the elements.
Q.3.4.7 The blast profile and angular anchor pattern shall be of that recommended by the coating
manufacturer to suit the minimum requirement of their respective primers and the minimum
peak-to-valley height shall be 25 microns.
Q.3.5.2 Steel or iron grit iscommonly used as recyclable abrasives. In general, when steel shot is
used,
it shall be used together with steel grit and approved by the Owner.
Q.3.5.3 The abrasives shall befree from oil, grease, moisture, chloride contamination etc. Each batch
of abrasive should be tested to check the abrasive meets the requirements as specified in the
relevant ISO standard.
Q.3.5.4 The conductivity of abrasives to be used on carbon steels shall beless than 150 µS/cm.
be maintained at a maximum of 50% except for inorganic zinc silicate. NACE publication
6A
192 may be referred to determine the types of dehumidification equipment suitable for the
work.
Q.3.8.2 Abrasive blasting shall not be conducted in open areas close to coating operations or wet
coated surfaces to prevent dust and grit contamination. Normally, grit blasting shall be
permitted only during daylight hours. The illumination of the surface during final blasting shall
be at least 500 Lux and all environmental restrictions shall be observed.
Q.3.8.3 Work is recommended to be blocked out in 3 0cm square and each square blasted evenly until
complete. Blasting shall continue a minimum of 25 mm into any adjacent coated areas,
and the edges shall be feathered.
Q.3.8.4 Any blast cleaned steelworks onwhich rust develops shall bere-blasted prior to being coated.
Q.4.1 General
Q.4.1.1 Alternative surface cleaning is only acceptable after obtaining written approval from the
Owner. Alternative surface preparation such as power tool cleaning is not acceptable for areas
difficult to access such as under cellar and helidecks, areas exposed to water, steelwork to be
insulated, steelwork to be buried and internal surfaces of equipment and tanks.
Q.4.1.2 Alternative primers such as surface tolerant primers may eb required for alternative methods
of surface cleaning and be in accordance with coating manufacturer’s recommendations.
Alternative primers need the approval of the Owner.
Q.4.2.2 Corrosion inhibitors should not be used unless written approval from the Owner has been
obtained. Corrosion inhibitor such as 0.3% sodium nitrite and 1.2% ammonium phosphate
may be used. However, use of Chromate inhibitor is not permitted. Disposal of corrosion
inhibitor into the sea should not be allowed. The coating manufacturer shall approve the use
of an inhibitor or the removal of residues of the inhibitor before coating.
Q.4.2.3 The cleaned surface shall be dry at the time of coating. Particular care shall be given to dry
areas that are not self-draining to avoid water collection.
Q.4.3.2 Where black spots occur in pits orother surface defects, the surface shall be cleaned again at
higher pressure to remove the residual salts.
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Q.4.3.4 The cleaned surface shall be thoroughly dry at the time of coating. Particular care shall be
taken to dry areas, which are not self-draining, so that water collected is removed.
classification.
Q.4.4.2 It shall be conducted in accordance with the vendor/manufacturer recommendation which
includes proper site preparation, equipment set-up, choice of media and application.
Q.4.4.3 A range of surface profile 25, 50, 75 and 100 microns shall be achieved using the different
sponge jet media.
Q.4.4.4 A recycler shall be used to segregate light debris, dust and heavy collected waste from the
spent sponge jet media before being used again for blast cleaning.
Q.4.4.5 Personnel carrying out the blast cleaning shall be qualified and trained on the use of sponge
jet equipment and operation. A vendor technical representative shall be present at the work
site to assist during the execution of the blast cleaning activity.
Q.4.7.2 When power-tool cleaning to bare metal is not feasible, the surface cleanliness shall at
minimum meet the visual standard St 3 in accordance with ISO 8501-2 at the time of coating.
Care shall be taken to ensure that the steel surface does not become polished after power-
tool cleaning. Hand-tool cleaning is permitted prior to power-tool cleaning. If the surface being
prepared lies adjacent to a coated surface, the power-tool cleaning shall overlap the coated
surface by at least 50 mm and the coated surface shall be feathered.
Q.4.8.2 Sometimes it may be advantageous to use the wet abrasive or moisture injection blast
cleaning techniques, so as to avoid dust or in cases where fire and/or explosion risks are
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
present. Fresh water may be either mixed with the abrasive in the pressure tank or
introduced directly behind or ahead of the blast nozzle.
Q.4.8.3 To prevent rusting the cleaned surface should be washed off immediately after blast cleaning
using fresh water containing a suitable corrosion inhibitor such as 0.3wt% sodium nitrite with
1.2wt% ammonium phosphate. A suitable corrosion inhibitor in the water used for blast-
cleaning should also be considered.
Q.4.8.4 The cleaned surface shall be thoroughly dry before any coating is applied. In general it is not
necessary to remove residues of the inhibitor before coating. However, the coating
manufacturer should be consulted on the inhibitor/primer compatibility.
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
OWNER
Contractor
Blasting and
Manufacturer Painting
Supervisor
Blaster and
Painter
PTS 15.20.03
PROTECTIVE COATINGS AND LININGS February 2016
Quality (Clean
1989. The Air) Regulations
PEL averaged over an1989 andperiod
8-hour Factories and respirators
without Machinery (Mineral
shall be: Dust) Regulations
S.1.2 If respirators are used by employee and all control measures related to this hazard has been
employed, the exposure level shall be determined by the protection factor provided by the
respirator
S.3.2 The control of Scheduled Wastes shall be in compliance with the Environmental Quality Act
1974 (Act 127) Part IV A Section 34B. Scheduled wastes as identified in Environmental Quality
(Schedule Wastes) Regulation, 1989 First Schedule (Regulation 2) Part I “Schedule Wastes
from Non Specific Sources” and Part II “Schedule Wastes from Specific Sources” shall collected
and disposed of at Prescribed Premises.
S.3.3 These Prescribed Premises shall be in compliance with the Environmental Quality(Prescribed
Premises) (Schedule Wastes Treatment and Disposal Facilities) Order, 1989 and
Environmental Quality (Prescribed Premises) (Scheduled Wastes Treatment and Disposal
Facilities) Regulations, 1989.
S.4 PRODUCT STORAGE
S.4.1 The storage of certain products is regulated by EQA 1974 because of the potential ecological
damage that could result from a spill or leak from storage vessels.
S.5.2 The above activities collectively can affect almost all the major environmental receptors i.e.
air, soil, groundwater, surface water, potable water.
S.5.3 Contractor Environmental Programme shall comply with the Malaysian Environmental Quality
Act (EQA), 1974 relating to the prevention, abatement, and control of pollution and
enhancement of the environment.
S.5.4 Contractors hired to remove hazardous coating shall be qualified in accordance with the
procedures described in SSPC-QP 2(I). The qualification process shall evaluate four (4)
functions: