55
, NO. KOC-P-001 KUWAIT OIL COMPANY (K.S.C.) STANDARDS PUBLICATION KOC STANDARD FOR PAINTING AND COATING OF METAL SURFACES - NEW CONSTRUCTION DOC. NO. KOC-P-001 STANDARDS DlVlSlON

KOC Painting STD

Embed Size (px)

DESCRIPTION

KOC

Citation preview

Page 1: KOC Painting STD

, NO. KOC-P-001

KUWAIT OIL COMPANY (K.S.C.)

STANDARDS PUBLICATION

KOC STANDARD

FOR

PAINTING AND COATING OF

METAL SURFACES - NEW CONSTRUCTION

DOC. NO. KOC-P-001

STANDARDS DlVlSlON

Page 2: KOC Painting STD

KOC STANDARD

FOR

PAINTING AND COATING OF

METAL SURFACES - NEW CONSTRUCTION

DOC. NO. KOC-P-001

ISSUING AUTHORITY:

STANDARDS DIVISION

Page 3: KOC Painting STD

TABLE OF CONTENTS

FCrcWORD

SCOPE

APPLICATION

TERMINOLOGY

REFERENCE CODES AND STANDARDS

ENVIRONMENTAL CONDITION

HEALTH, SAFEN AND ENVIRONMENT

PAINTS I COATING MATERIALS

SURFACE PREPARATION

PAINTICOATING APPLICATION

INSPECTION AND TESTING

QUALITY ASSURANCE

DOCUMENTATION

PAINTINGICOATING SCHEDULES

COLOUR SCHEDULE

APPENDICES

APPENDIX 'I : Q A I ~ N G RECORDDATA SHEET.

APPENDIX 2A : COLOUR SCHEDULE (Table 1)

APPENDIX 28 : COLOUR JDENTlFlCAlION FOR HAZARDS AND FIREISAFETY (Table 2)

APPENDIX 2C : COLOUR IDENTlFlCAT ION OF GAS CYLINDERS f OR INDUSTRIAL GAS VIDE BS 349 (Table 3)

Page No.

5 -

6

6

6

8

10

11

13

16

22

27

30

30

31

32

33

35

36

37

Page 4: KOC Painting STD

DOC. NO. KOC-P-001 . Page 4 of 55 1 REV. 2

APPENDIX 2 D :

APPENDIX 3 A :

APPENDIX 30 :

APPENDIX 3C :

APPENDIX 3D :

APPENDIX 3E :

COLOUR IDENTIFICATION FOR MEDICAL GAS VIDE BS 131 9 (Table 4)

SCHEDULE A : EXTERNAL PAINTING1 COATING SYSTEMS FOR ONSHORE STORAGE AND PROCESSING EQUIPMENT

SCHEDULE B : PAINTING SYSTEMS FOR ONSHORE STRUCTURAL STEEL WORKS

SCHEDULE C : PAINTING SYSTEMS FOR MECHANICAL, ELECTRICAL AND INSTRUMENTATION EQUIPMENT

SCHEDULE D : PAINTING I COATING SYSTEMS FOR OFFSHORE STRUCTURE & EQUIPMENT (EXTERNAL SURFACES - ATMOSPHERIC ZONE, SPLASH ZONE & SUB

SCHEDULE E : INTERNAL PAINTING SYSTEMS FOR STORAGE AND PROCESSING EQUIPMENT

S E A )

Page 5: KOC Painting STD

FOREWORD

This document " KOC Standard for Painting and Coating of Metal Surfaces - New Construction " has been amended t o incorporate the several changes occurred since . its first publication (Rev.1) in 1995. Funher, it has been updated in line wrth " Preparation Procedure for Generating KOC Standards & Recommended Practices " (KOC-A-001). Thus the document (Rev.1) was superseded and withdrawn.

This revised Standard ( Rev.2 ) has been approved by the Standards Technical Comm~ttee ( STC ) and the Standards Division for publication which is ult~mately intended for use throughout the corporate engineering and operational funct~ons of Kuwait Oil Company.

This Standard sets out to achieve the following objectives:-

6) To esabltsh the basic technical requirements for surface preparation, paint~ng maierials, methods of application and inspection/testing of protective external & internal coatingtpainting of metal surfaces aboveground in oil, gas and sea water facilities and related utilities under both onshore & offshore conditions.

b) To provide the general technical guidance for developing project specifications in order t o achieve reliability, quality and safety in an economical manner.

C) To set our clear requirements t o monitor compliance in design, material seiect~on, applcation, inspection & testing with a contract.

d To maintain the KOC requirements of safety and environmental protection established by UOC regulations and procedures.

Feedback as well as any comments or suggestions derived from the application of this Standard at any stage of engineering, purchase or field application are invited and should be directed to:

Supdt. Standards Division (Chairman, Standards Technical Cornminee) Engineering Group, K.O.C. %

P.O. Box 9758, Ahmadi 61008 State of Kuwait.

The amendment of this Standard is acknowledged t o the Task force (TF-PC101 ) comprising of the following members:-

Mr. S. Kumar - Standards Division Dr. Muayyad Ajjawi - (Ex) Standards Division

- -

Page 6: KOC Painting STD

SCOPE

This Standard specifies the minimum basic requirements for surface preparation, coating materials, method of application and inspection/testing for - protective external and where applicable, internal paintinglcoating of metallrc surfaces above ground oil, gas and sea water facilrties and related utilities.

This Standard covers the paintinglcoating for both newly constructed onshore and offshore facilities. It also covers the repair of defects or damages t o the new painted items.

The internal linings (Gunite & Fibreglass) of tanks and vessels are covered in separate documents KOC-P-002, Pans 1 & 2 respectively.

This Standard is not applicable t o buried pipelines and subsea lines, decorative parnts for non-metal surfaces areas (concrete, masonry, wood, etc.), freld t r~a l of newly developed pa~ntrng/coating systems.

APPLICATION

The materials and equipment for surface preparation, paint and coating applcation and inspectionltesting, shall conform t o the requirements of this Standard and the referenced standardskodes mentioned herein.

Any exceptions or deviations from this Standard, along with their merits & justification, shall be brought t o the attention of KOC's Controlling Department for their review, consideration and amendment by Standards Division (if required).

Compliance with this Standard does not of itself confer immunity from legal or statutory obligations.

TERMINOLOGY

Definitions

For the purposes of this Standard, the following definitions apply:-

Abrasive

Natural or synthetic solid material used as a medium in abrasive blast-cleaning.

Grit

A term used to describe the angular or irregularly shaped particles of abrasives used.

<

Page 7: KOC Painting STD

Shot

A term used t o describe the spherically shaped panicles of abrasive used for blast cleaning.

Comparator

A specimen surface, or surfaces, of known average profile, representing a panicular abrasive blast-cleaning process.

Coat

A continuous layer of a coating material that results from a single application.

Cure

The chemical reaction resulting in the final polymerized product in the psin1 'coa;~ng system.

Discontinuity (Holiday

A void, crack, thin spot, foreign inclusion or contamination in the coating film that significantly lowers the dielectric strength of the coating.

Dry Film Thickness

The dry film thickness of paint is the thickness of paint without solvent and is measured by film thickness gauge & expressed in micron (1000 microns equivalent to 1 mm ).

Pot-life

The elapsed time within which a coating can be effectively applied after all components of coating system have been thoroughly mixed.

Rust grade (degree of rusting)

Classification describing the degree of rust formation on a steel surface prior t o cleaning.

Atmospheric Zone

The part of an offshore structure above the splash tone.

Splash Zone

The zone of the structure that is sfternately in and out of the water because of the influence of the astronomical tides, winds and sea waves.

Page 8: KOC Painting STD

DOC. NO. KOC-P-001 1 Page 8 of 55 REV. 2

Submerged zone

The zone that extends downward from the splash zone and include that structure below the mudline.

Surface Rofile

'he micro-roughness of a surface, generally expressed as the average height of ye major peaks relative to the major valleys.

Abbreviations

KOC Kuwait Oil Company (K.S.C.)

CS Carbon Steel

DFT Dry Film Thickness (of Paint)

WFT Wet Film Thickness (of Paint)

M I0 Micaceous Iron Oxide

RH Relative Humidity

LAT Lowest Astronomical Tide

REFERENCE CODES AND STANDARDS

Conflicts

In the event of conflict between this Standard and the standardskodes referenced herein, or other contractual or purchase requirements, the most stringent requirement shall apply, unless otherwise specified.

List of Standards, Codes and Specifications

The latest edition of the following standards, codes and specifications shall apply: t

National 1 International Standards

Paintin~Coating - General

BS 349 Identification of the Contents of Industrial Gas Containers.

BS 381C Specification for Colour for Identification, Coding and Special . .

Purposes.

Page 9: KOC Painting STD

D O C . N O . K O C - P - 0 0 1 R Page 9 of 55 REV. 2 I

Specification for Hot-dip Galvanized Coatings on lron and Steel Amcles.

Specifcation for Identification of P~pellnes and Services.

Specification for Bitumen-based Coatings for Cold Appl~catron, Suitable for Use in Contact with Potable Water.

Schedule of Paint Colours for Buildmg Purposes.

Code of Practice for Protective Coating on lron and Steel Structures agarnst Corrosion.

Metallic and Other Inorganic Coatings. Thermal Spraying, Zrnc, Alumrnum and their Alloys.

Surface Preparation --

ASTM D2092 Gu~de for Treatment of Zmc-Coated (Galvan~zedi Steel Surfaces for Painting.

ES 7079-A1 Specifcation for Rust Grades and Preparation Grades of ( I S 3 8521- 1) Uncoated Steel Substrate and of Steel Substrate After Overall

Removal of Previous Coatings - Visual Assessment of Surface Cleanllness.

ES 7079-D2 Preparation of Steel Substrate Before Application of Paints and (IS0 8504-2) Related Products. Abrasive Blast Cleaning.

SIS 05 59 00 Pictorial Surface Preparation Standards for Painting Steel Surfaces.

SSPC-SP Steel Structures Painting Council Surface Preparation Specifications.

Inspection nesting

ASTM Dl 186 Test Method for Nondestructive Measurement of Dry Film Thickness of Nonmagnetic Coatings Applied to a Ferrous Base.

ASTM Dl212 Test Methods for Measurement of Wet Film Thickness of Organic Coatings.

ASTM D2697 Test Method for Volume of Nonvolatile Matter in Clear or Pigmented Coatings.

ASTM D3276 Guide for Painting Inspectors (Metal Substrates).

Page 10: KOC Painting STD

ASTM D3359 Test Methods for Measuring Adhesion by Tape Test.

ASTM D U l 7 Test Methods for Field Measurements of Surface Prof~le of Blast Cleaned Steel.

ASTM D4541 Test Method for Pull-Off Strength of Coatings Using Portable Adhesion-Testers.

BS 3900 - H3 Designation of Degree of Rusting.

IS0 9000 Model of Quality Assurance in Design, Development, Production, Installation and Servicing.

NACE RP0188 Discontinuity (Holiday) Testing of Protective Coatings.

& A C E R23287 Surface Profile Measurements of Abrasive Blast Cleaned Steel Surface Using a Replica Tape.

SSPC - PA2 Measurement of Dry Paint Thickness with Magnetic Gauges.

Health and Safety

API 2217 Guidelines for Confined Space Work in the Petroleum Industry.

BS 1319 Specification for Medical Gas Cylinders, Valves and Yoke Connections.

BS 5378 Safety Signs and Colours.

NFPA 231 Standard for General Storage

OSHA 29 CFR 1910 Regulation, Penaining Work in Confined Areas.

KOC Standards

KOC Fire and Safety Regulations.

KOC-GO02 KOC Standard for Hazardous Area Classification.

KOC-G-007 KOC Standard for Basic Design Data.

ENVIRONMENTAL CONDITION

The env i ronme~t of Kuwait, is severe on all plant and equipment and must be considered carefully before selection/approval o f paints and coating materials.

$

Page 11: KOC Painting STD

The ambient temperature range is - 3°C to + 55°C. The exposed black body metal temperature due to solar radiation is 8 5 T .

Humidity can pose a serious problem with long periods of relative h u m ~ d ~ t y (RH) level of 100% being pan of normal weather pattern.

9 other environmental conditions in Kuwait, refer t o KOC Standard for Basic 3esiyn Data, KOC-G-007, which provides the detailed design informat~on ,.?garding the environmental, site and utility supply conditions prevailing i rough out the KOC facilities.

HEALTH, SAFETY AND ENVIRONMENT

General

The contractor shall employ all necessary health and safety procedgres to pro;ect persome! and surrounding environment during on-site f~eld works.

Ali r~ ievant s ~ f e t y requirements of the KOC Fire and Safety Regulations shall be conformed, in particular the requirements for blasting and power tool cleaning, for scaffolding and access platforms, for compressors and compressed air equipment for ventilation and ventilation equipment in confined. areas and for personnel protection, protective equipment and clothing.

The contractor shall comply with the KOC Fire & Safety Regulations and the Health & Hygiene Procedures while performing the works within KOC areas.

Where there 1s a risk of flammable atmosphere being present in a particular vbiork area, KOC may, with relevant safety authority, impose restr~ctions on methods of surface preparation. Flame heating equipment shall not be used in hazardous areas. KOC-G-002 describes area classif~cation for facil~ttes and eqil~pment.

For internal paintingkoating of drinking water facilities (tanks, vessels, etc.), the contractor shall submit evidence ( Kuwait heath authority approval) that the paint system will not in any way contaminate the water.

Storage, Handling and Mixing Safety Precautions

Safe Storage

a) All paints, coatings and thinners shall be stored in enclosed storage ereas or structures that are well-ventilated and protected from temperatures exceeding manufacturer's recommendations, open flames, electrical discharge and direct sunlight. Air conditioned storage areas shalt be considered where excessive ambient temperatures are expected.

Page 12: KOC Painting STD

b) The storage area shall be secluded and no other materials shall be stored in the enclosed place. The enclosure shall be demarcated as " NO SMOKING " area strictly.

C) All paints, coatings, solvents, oil and equipment cleaners shall be s;ored in closed labelled original containers.

d) Portable fire extinguishers of suitable quality and appropriate.quantlty shall be provided at the storage areas and such extinguishers shall be inspected and approved by Fire & Safety Depanment.

Manufacturer's HealthISafety Precautions

Manufacturer's healthhafety precautions and procedures for mixing, handlrng, storage and application of paints and coating materials shall be strictly adhered. Safety precautions shall be clearly described on the technical data sheet of pamt and coatrng materials supplied as well as on the containers.

Safety Precautions for Blasting!Painting Equipment

Blast cleaning and spray painting guns shall be earthed (spark proofmg) to prevent building up of an electrostatic charge, especially when the application is in confined work places.

All blasting equipment shall be inspected and certified by an authorised competent third party. Pressurised hoses shall be tested and certified for maxlmum safe working pressure. Hoses and other pressure items shall be checked period~cally t o make sure that any damage or loss of electrical conductivity will not lead to a safety hazard.

Pressurised hose and blasting gun shall compulsorily be equipped w ~ t h 'Deadman Switch'.

Suitable fire extinguishers shall be provided near the air compressor.

Enclosures shall be provided all around the area, where shot / grit blasting will be carried out.

4

Clean sir-mask PPE shall be worn by the technicians while blasting or spray painting.

Safety Precautions in Fbmmable Atmos@wres - KOC will advise on the area classification for both plant design and construction / maintenance projects. Cenain paint compositions shall not be used in some plant design area classification (e.g. zone I ) , 8s it can ignite with explosive force at certain conditions.(see clause 7.1 5 of this Standard).

Page 13: KOC Painting STD

The contractor shall provide KOC with all necessary material safety data sheet for the proposed paint systems, solvents and painting procedure In order to determine area classifcation for the duration of painting work.

Safety Precautions in Confined Space

All tank / vessel interiors shall be gas-free. Approval under entry permit procedure is required before the tanklvessel can be entered.

A!I elecrrical equipment used including lighting equipment, ventilat~on equipment, high voltage holiday testing equipment, etc., shall be grounded and suitable for the hazardous area classifcation of the working areas as advised by KOC. All other equipment including ladders, tools, etc., shall be spark- proof.

The procedures for performing safe work in confined spaces shall be in 2,-cordance ~ w t h OSHA 29 CFR 191 0 or API 221 7.

Site Clearance & Environmental Protection

On completion of painting works, facilities shall be arranged by contractor for effective and safe removal of spillage collection and disposal of paintskoating materials, brushes, scaffolding, waste, equipment, etc. All necessary precai l t~ow shall be taken to safeguard the surrounding environment.

PAINTS I COATING MATERIALS

General

All palnts ! coating materials shall be chemically pure, and free from foreign contaminants. The age of coating material components shall not exceed the recommended pot-life as limited by the manufacturers.

All paints 1 coating materials shall be delivered t o the site in original sealed manufacturer's containers with batchkode numbers and date of manufacture clearly marked thereon.

Approvals

All paints and coating materials, including thinners and equipment cleaners, in any one system shall originate from one manufacturer.

The KOC approved schemes are only those used in the paintinglcoating schedules A-E (Appendix 3) end as defined in c lauses 7.3-7.14 of this Standard. The use of alternative schemes shall be approved in writing by KOC.

Page 14: KOC Painting STD

The contractor's submittal for paintingkoating materials shall include details of generalized composition, service temperature and technical specificat~ons of the products to be used for KOC review and approval.

The selected composition of painting / coating materials shall comply with the relevant clauses penaining to the materials given below.

' 'inc-Rich Epoxy Rimer

- his primer based on polyamide cured 2 pack epoxy. Minimum volume of

solids shall be 63% as per ASTM D2697.

Inorganic Zinc Silicate Primer

Sased on ethyl silicate media. Minimum volume of solids shall be at least 5890 as per ASTM D2697. Capable of withstanding continuous high temperature ( u p t o 403'C) and have excellent abrasion and chemical resistance.

Zinc Phosphate Primer

Based on long oil alkyd and urethane alkyd media. Minimum volume of solrds shall be 48% as per ASTM D2697.

Mordent Solution (1-wash) Pre-treatment Primer

Used for preparation of galvanized surfaces. It is a two components etch primer, based on phosphoric acid solution incorporating copper salts and corrosion inh~bitive pigments in a solventlwater solution.

High Build Epoxy Intermediate

Based on polyamide cured two pack high build epoxy binder. Pigmented with M~caceous Iron Oxide (MIO). Minimum volume solids shall be 55% per ASTM D2697.

Coal Tar Epoxy Rimer/lntermediate/Finish

The formulation of the two pack incorporate:

Pack 1. Epoxy resin and suitable pigments.

Pack 2. Polyamide or amine curing agent and coal tar.

The Epoxy tesin shall comprise at (east 35% by weight in the resin/coal tar blend as per ASTM 02697.

For contrasting of intermediate coats, aluminium or red oxide may be used.

Page 15: KOC Painting STD

Two - Pack Polyurethane Finish

B2sed on acrylic modified t w o pack aliphatic polyurethane with titaqium dioxide or M I 0 pigment.

Minimum volume of solids shall be 45% per ASTM D2697.

\ sevi-gloss and colour retention finish is required.

;mine Adduct Epoxy Paint

4 t w o pack epoxy amine adduct cured paint which cures to a coating with excellent resistance to chemicals.

Mmimum volume of solids shall be 48% as per ASTM D2697.

IT shail be approved by the NIYC (National Water Council) and Kuivait heal:? a~thor i ty .

"Solvent Free" High Build Epoxy Paint

f32sed on polyamide cured t w o pack epoxy with a coating with good resistance to fresh water and to abrasion.

Minimum volume of solids shall be 100% per ASTM D2697 (solvent free).

It shall be approved by the NWC (National Water Council) and health authority.

"Zinc Free" Inorganic Silicate Finish

Air curing zinc free inorganic sil~cate based on ethyl silicate media; capable of wrthstandmg continuous high temperature (up t o 400'C) and have excellent abrasion and chemical resistance.

High Temperature Aluminum Silicone Finish

Based on silicone alkyd or modified silicone alkyd media (e.g. ecrylic silicone). M~n imum volume of sohds shall be 49% as per ASTM 02697.

Ptgmtrnted with leafing aluminium pigment.

Heat resistant, capable t o withstand continuous high temperature up t o 400°C. Must be capable of "curing" t o handle at ambient temperature.

Page 16: KOC Painting STD

Metal Spray Coatings

a) Based on molten Aluminium metal sprayed on surfaces prepared in accordance with BS EN 22063.

b) Aluminium metal spray coating is suitable for high temperature (up to 550°C) surfaces with restriction (see clause 7.1 5). The sprayed aluminium may be silicon sealed and for temperatures up to 250'C silrcon - sealed sprayed aluminium can provide more protection and longer I~fe.

Restriction on Using Aluminium Pigments and Metal Spray

Due to the susceptibility of metallic aluminium to ignite with explosive force, Aluminium metallic pigments and Aluminium metal spray shall not be used on any surface operating above 1 2 0 T in area tolie 1 as specified in KOC Standard for "Hazardous Area Classification" (KOC-G-002) or KOC Hazardous Area drawings.

SURFACE PREPARATION

General

All fabrication works including cutting and drilling of holes shall be completed prior to surface preparation. In special areas, however, preparation and priming of structured steel members and piping may be approved by KOC prior to final assembly.

Surface preparation shall preferably, for optimum coating performance, be '

carried ou! by dry abrasive blast cleaning. Alternative techniques shall only be applied in some circumstances as described in clause 8.7.

The surface preparation requirements for painting systems are indicated in the painting schedules A-E (Appendix 3) and detailed in the clauses as follows:

Working Restrictions

Weather Conditions

All surface preparation shall not be conducted in the following conditions:

a) When the steel surface temperature is less than 3% above dew point.

0) When the air temperature is below 5°C. -

C) When the relative humidity (RH) is 85% or higher.

d) Under adverse weather conditions, e.g. rain, fog, sandstorm, high wind velocity (56 Kmhr. or higher), high wave tide or when such conditions are likely prior to completion of the work ( i.e abrasive blast cleaning 1.

Page 17: KOC Painting STD

8.2.2 Work Cond~tions

F~eld surface preparation shall not be conducted in the following cond~t~ons:

Outside daylight hours on exterior locations, unless permitted by KOC. - Approved special lighting shall be arranged for night blast cleaning.

When the initial primer coe? cannot be completed within 4 hours of prepara:ion. Surfaces which remain uncoated for longer than this period shall be reblasted prior to priming.

When adjacent areas or equipment are insufficiently protected from damage or contamination by abrasive dust or debris.

In areas close to painting operations, t o prevent damage or contamination of wet palnt films by abrasive material.

8.3 Surface Imperfections Removal

Surface imperfections or irregularities shall be removed completely (made flush or smooth) prior t o blast cleaning. Imperfections shall be considered as follows:

LVel3 spatter and slivers shall be removed. Sharp or rough welds shall be rounded and contoured. Any other observed defects in welds and material should be referred to KOC for disposit~on.

Poros~ty (weld voids) shall be cleaned and filled with acceptable filler mz?erial or closed over by a suitable mechanical method approved by KOC.

Sharp or rough edges shall be rounded, chamfered or broken.

Such imperfections that appear after blast cleaning or acid pickling shall be similarly removed. If grinding is needed, checking of the remaining wall thickness and KOC's approval are required.

8.4 Surface Contaminants Removal

8.4.1 The metal surface shall be cleaned t o remove any oil, grease, din, etc. using solvent andlor suitable emulsifying alkaline cleaners followed by washing with clean water or wet steam rinsing. SSPC-SP7 outlines these methods.

8.4.2 Degreasing b y wiping the surface with solvent only is not recommended in heavily oillgrease surface contamination, because this invariably leads t o the

Page 18: KOC Painting STD

DOC. NO. KOC-P-001 1 Page 18 of 55 I REV. 2

spreading of a thin film of oil over wide area. The solvent/emulsifying agent cleaned surface shall be allowed to dry before proceedmg with further preparation or painting.

Soluble salts on steel surface exposed to a salt laden atmosphere shall be removed by washing or by any other suitable technique. See clause 10.5.3 for iron salts contaminant free testing.

Dry Abrasive Blast Cleaning Practice

Dry abrasive blast cleaning shall be used to remove all rust and mill scale and to achieve the required visual standard and surface profile defined in the approved painting'coating schedules (Appendix 3).

Ab:ssive material shali satisfy the following requirements:-

Abrasive material for mild / carbon steel preparation shall be industr~al grade metal angular grit or shot (generally iron or steel). Contaminated or re-cycled grit or shot shall not be used. Abrasives for stainless steel substrate shall be non-metallic materials. New less-dust generating abrasive media such as "Garnet" plastic granulates and alike, capable of producing the required surface profile, may be used for blast cleaning.

Sand may be used as abrasive material for field blast cleaning, subjected t o KOC's approval. Sand material shall be graded (30 - 60 mesh), hard, version, silca or olivine sand with less than a 10 percent breakdown. No sand shall be used more than once.

The selected abrasive material shall be in accordance with SSPC-SP-COM or BS 7079 R. D2 (IS0 8504-2).

Abrasive material shall be dry and free from oil, grease, dust, salts and any other impurities or contaminants.

Abrasive materials shall be capable of achieving the required surface profile without contamination of the substrate. To produce the required surface profile, abrasive particle size shall follow the surface preparation commentary of SSPC manual as necessary t o comply with visual blast cleaning standards mentioned in clause 8.6 of this Standard.

All abrasive materials shall be kept dry, and covered when not used.

Abrasive material sample shall be provided by the contractor, for KOC's testing and approval before work commencement.

The blasting equipment and technique shall comply with the following requirements:

Page 19: KOC Painting STD

The contractor's abrasive blast cleaning equipment shall satisfy KOC's safety requirements (See clause 6.3).

For field and shop blast cleaning, abrasive shall be carried by a jet of compressed air through a hand-held nozzle. The compressed air s u ~ p l y and volume shall meet work requirement and shall be substantially free from oil and wa:er contamination. Traps and filters shall be cleaned regularly.

For blast cleaning of large horizontal surface areas, like tank roofs ,:'

bottoms etc., a self contained vacuum blast unit can be used. Sirch machines are usually operated by remote compressed air or hydraulica!ly actuated for traction.

'Deadman handles' shall be fixed to the blast line as close as practicable to t h ~ blast nszzle and shall be held by the blast operator alone.

Nrjzzles used shall have a maximum oriflce size of 9 mm and shall be of venturl des~gn.

Openings in vessels, piping, access fittings, nozzles, etc. shall be properly protected against entry of abrasive material. All previously painted or ga!~,anised surfaces shall be adequately protected prior t o commencine any blasting operation.

Giast cleaned rusty surface (due t o rain or condensation) and surfaces with temporary holding primer, shall be re-blasted t o the specified surface profile.

Surface blast cleaning t o the specified surface profile shall extend a minimum of 150 mm beyond the area to be coated during the same day.

Surface blasting t o the specifled surface profile shall continue a minimum of 25 m m into adjoining previously coated surface. The edges of the previous coating shall be feathered.

All prepared surfaces shall be cleaned from any dust / abrasive material preferably by dry brushing andlor vacuuming with industrial vacuum cleaner. Pressure air blowing is not permitted. Any surface showing signs of contamination, after blast cleaning, shall be solvent cleaned and re-blasted.

Blast Cleaning Standard

The surface profile height shall be in accordance with the requirement of painting system. The measurement techniques of surface profile testing are specified in ASTM D4417.

Page 20: KOC Painting STD

DOC.NO.KOC-P-001 Y P a ~ e 20 of 55 REV. 2

Blast cleaqing shall be carried out t o a visual standard in accordance w t h S!S 05 59 00, e~ther a s Sa 2, Sa 2'/1 or Sa 3. (identical to BS 7079 Part A1 or IS0 8501-1) subjected t o the requirements of paint manufacturer's data sheet. Reference shall be made t o these standards for photographs of equivalents to the mentioned qualities.

Gestrictions on Atterna tive Techniques to Blast Cleaning

- some circumstances, blast cleaning shall not be done and alternative surface .reparation techniques ( like manual 1 power tool cleaning 1 shall be applied.

These alternative techniques are subjected to KOC's approval and restricted as iollows:

a) When dry abrasive blast cleaning is unsafe or any of KOC's safety precautions / requirements cannot be met.

b) When there is a risk of damage to instrumentation, equipment (e .g . , electrical, rotating, etc.) within the proximity of blasting operations.

c ) Where there is a flammable atmosphere or similar condition present, restrictions may be applred by KOC.

d ) Where blast cleaning is not practical, e .g . for welds, edges, bolts, nuts, corners, crevices etc. and for paint defectstdamages repair.

Power Tool Cleaning

Power tool cleaning shall be t o a visual standard in accordance with SIS 05 59 00 St3 or BS 7079 Part A1 St3 (equivalent t o U.S. Standard SSPC-Sp3).

Where power tool cieaning is carried out, 100% of the surface shall be covered using abrasive or wire type power discs. In some locations which can not accommodate a power disk, e.g. welds, power impact tools shall be applied (vibratory and rotary, needle guns, scrapers) followed up by wire brush cleaning.

Power tool cleaning shall extend a minimum of 25 mm distance into adjoining coated surfaces.

*

Hand Tool Cleaning

Hand tool cleaning may be used for cleaning rusted surfaces in some circumstances as specified in clause 8.7 and for paint defectsJdamages repair.

Hand tool cleaning shall be to visual standard in accordance with SIS 05 59 00 S t2 (BS 7079 St2) which is equivalent to SSPC-SPZ..

Page 21: KOC Painting STD

Acid Pickling (Etching) Preparation

This method may be used by contractors, in some circumstances and locattons a s an alternative t o blasting provided that it is compatible with palnt system and approved by KOC.

When using this method, the surface shall be etched t o a degree suitable for the specified coating system. Details on this method are specified in SSPC- SPB.

KOC Flre and Safety Regulations shall be adhered t o when using this method

Preparation of Stainless Steels

Sramless steels shall not be painted unless specifled by the relevant equipment d 6 : ~ ~ ' 7 e e t . The surfsce specifled t o be painted shall be:

th0:oughly degreased using solvent cleaning or suitable emulsify~ng aaent and washed with fresh water t o remove any contamination.

blast cleaned t o a surface profile of 25-50 micron using chlorlde free abrasive such a s alumina. Copper slag abrasives shall not be used. Hand or power tools using P60 grade paper may be used for surface preparmon, when grit blast cleaning is impractical. ( see clause 8.7).

protected from any funher contamination by debris produced during grit blas?ing of adjacent carbon steel because embedded panicles could promote corrosion. Any observed contamination should be referred to KOC for disposition.

Blast / Power tool cleaning equipment used for carbon steel shall not be subsequently used on stainless steel.

Preparation of Galvanized Surfaces

Painting of n e w galvanized surfaces shall be only for top coating purpose in conformity with sys tems B1, Dl -1 0, Dl -1 1 of Appendix 3 of this Standard. The surface preparation method shall be carried out as follows:

a) The greasy film on the n e w galvanized steel surface and any other oil or grease contamination shall be removed using emulsifying agent:

b) The surface shall be chemically e tched (primed) b y using proprietary T- wash solution. (see clause 7.6 )

C) Weathered surfaces shall be cleaned using wire brushing or s w e e p blasted to remove all corrosion products or deposi ts and degreased wrth emulsifying agent .

Page 22: KOC Painting STD

8.12.2 Other surface preparation methods may be used in accordance with ASTM D 2092 for painting new galvanized surfaces subject t o KOC's approval.

PAINT/COATING APPLICATION

General Requirements

Paintingkoating works shall be in accordance with the requirements

established by this Standard and t h e recommendations of the paintlcoatlng manufacturer. Any area not specifically covered, shall be in accordance wrth the principles and guidelines set fonh in the SSPC Manual.

The contractor shall provide all materials, tools, equipment and manpower required for carrying out the works.

Surfaces, t o be painted /coated, shall be inspected and approved by KOC before any pa~ntlng coatmg is applred. Thrs shall be after surface preparation

and between each subsequent coating. No primer or paint shall be applled v,~~thout KOC's approval.

All surfaces, t o be painted 1 coated, shall be dry and dust / contaminants free before applcatlon of the first coat.

Precautions shall be taken t o prevent painting from being appl~ed to name plates, coupl~ngs, shafts, valve stems, vent openings, gauge glasses, pressure gadges, etc. Masking tape, plastic film or any other suitable material shall be used, and all shall be removed after completion and acceptance of the palntlng apphcatron.

All areas prepared for field welds shall be kept free from paint over a drstance of at least 100 mm from the weld centre, except welding I shop primer of 25 mrcrons.

A minimum of 1 00 mm around edges of abrasive blasting shall be left unless adjoining a recently prepared and coated other surface.

Crevices created by t w o surfaces in close contact which cannot be protected by painting should be mastic sealed on both sides.

Selection of paint in^ 1 Coating System

The selection of painting / coating system for particular applications and required surface preparation Shall be as given in t h e approved painting Schedules A, B, C, D, and E (Appendix 3) of this Standard.

Page 23: KOC Painting STD

DOC. NO. KOCP-001 I REV. 2

Paint Mixing and Thinning

Mlxing of paint t o an even consistency, manufacturer's mixing instruct~ons, environmental conditions and maximum pot life shall be strictly adhered, specially for T w o - pack paints.

Mixing, by h g h speed mechanical agitators or rotary mixers, with flat blade ?nd speed control, shall be used for containers larger than 5 I~tres. Hand 71xrng is permrned only for containers up t o 5 litres.

tor painting systems where pigment separation readily occur e.g. zinc silicate ~r imers , continuous mixing shall be carried out during application.

After thorough mixing, the correct viscosity of the paint shall be proved by measuring with an approved f low cup.

Thinners shall not be added to paint without KOC's approval, only the thlnners recommended by the palnt manufacturer may be used, even for cleanrng.

When thinning is permitted by KOC, paint manufacturer's instructions shall be strictly adhered and the accepted procedures mentioned in clause 7.3 of ASTM D3276 shall be followed.

Restrictions on Painting

Weather Conditions

Palnting shall not be conducted in the similar weather conditions of abrasive blast cleaning as specified in clause 8.2.1 of this Standard and also under the following condit~ons:

a) When the metal surface temperature above 50°C.

b) Under adverse weather conditions, e.g. rain, fog, sandstorm, high wind velocity (56 Kmlhr. or higher), high wave tide or when such condit~ons are likely before the paintkoating has become dry.

Work Conditions

Painting 1 Coating shall not be conducted in the following work conditions:

a) Where the specified surface finish is not existed at the time of applying the first coat.

b) When adjacent areas or equipment are not sufficiently protected from paint application.

Page 24: KOC Painting STD

DOC. NO. KOC-P-001 1 Page 24 of 55 REV. 2

C) Outside daylight hours on exterior locations, unless permitted by KOC Approved special lighting shall be arranged for night painting.

9.5 Paint Application Practice

9.5.1 General

The specified surface fmisfi, of all areas t o be painted, shall be prepared before applying the first c o a t ff required, surfaces shall be re-prepared to the specifled fmish.

The paint shall be applied in a uniform manner and t o the prescribed number of coats and dry film thickness (DfT) given in Painting Schedules without any .runs, sags, marks or other blemishes. Finished application shall be uniform in colour, texture and appearance.

Intermediate and finish paintings shall be applied following final assembly of component pans. For surfaces inaccessible for proper painting and / or inspection, painting shall be applied prior t o final assembly. The contractor and KOC will designate inaccessible areas.

Where a multi-coat paint system is specified t o be used, all intermediate coats shall be of contrasting colour t o differentiate between coats. Colours for intermed~ate coats shall refer t o the paint manufacturer's recommendations.

T m e intervals between coats shall be kept t o t h e minimum recommended by pamt manufacturer in order t o prevent contamination between coats. In case contamination does occur, it shall be removed by washing w~tt i suitable detergent solution and rinsing with clean fresh water.

9.5.2 Airless Spray Application

a) Paint application by airless spraying shall be the preferred paint application process. The use of air spray method shall conform t o the requirement of coating system and shall be subject to K0Cts approval.

b) Spraying equipment, guns, nozzle sizes, orifice sizes & shapes and pressure ranges sP.ali meet the work requirements and the paint manufacturer's recornmendations and shall be free from oil and water contamination.

C) All paint spraying lines and pots shall be cleaned and flushed before the addition of new material.

d) Large surfaces shall be painted with passes in t w o directions a t right angles. Spray overlap of the previous pass shall be by 50%. .

Page 25: KOC Painting STD

9.5.3 Brush Application

Brush application shall be done on areas which cannot be properly sprayed e.g. for welds, edges, bolts, nuts, corners, crevices etc., and for touch-up maintenance where spray application is not practical.

Stripe coating of sharp edges, corners and welds can be done before application of flnish paint t o ensure that these areas receive the mlnlmJm specifred film thickness.

Brushes shall be of a type, size and shape which permits proper application of paint and meets manufacturer's recommendations.

Brush application shall be done such that a uniform coat, with no deep or detr~mental brush marks, is obtained. Runs and sags shall be avo~ded.

T h ~ s method of applcation can be used, subject t o KOC's approval, for painting large areas of relatively flat steel surfaces and where high film build is generally not t o be attained. Roller application will ride over high spots and mlss edges and shall not be used for painting corners, bolt heads, etc. Care mils? be taken t o choose the correct roller pile length, depending on the type of paint and degree of roughness of the surface.

9.6 PI iming

9.6.1 Priming shall be done on prepared surfaces before rusting occurs or within 4 . hours of blast cleaning, whichever is sooner. The only relaxation allowable to this requirement is where the following three (3) conditions are existing.

a) The work t o be primed is fully enclosed.

b) The ambient temperature is above 1 I°C.

C) The relative humidity is below 75%.

9.6.2 All acid - descaled steel surfaces shall be primed as soon as the surface is dry and while it is still warm.

9.6.3 In order t o facilitate shop or site handling procedure, holding (shop) primer of 25 microns may be applied on steel surface. If applied, however, this shall not replace the function or pan of the film thickness specified for the priming coat. Shop or welding primers shall be compatible with the specified painting system.

Page 26: KOC Painting STD

DOC. NO. KOC-P-001 1 P a ~ e 26 of 55 REV. 2

Zmc silicate primers shall be applied to abrasive blasted surfaces only. In order to protect the porous primer film from salt or chemical contamination, rt shall be sealed with a tie coat as soon as practicable after complete curing has occurred. The tie coat shall achieve sound adhesion to the zinc siicate primer and be compatible with the finishing coat.

,hop Painting

3 0 p painting of items may be carried out by the contractor as below, subject KOC's approval.

3) The contractor shall be responsible for paint condition on arrival of such items 'on-site' and shall carry out any paint damage repair needed.

b) The contractor shall comply with all aspects of this Standard and related aspects of KOC's safety regulations.

Completely Fabricated Items

a) Full surface preparation and painting works shall be done prior to transportation to site.

b) All painted items shall be protected!packed to avoid any coating damage during transportation. Care shall be taken in handling and installat~on to minimize coating damage.

Partially Fabricated or Non-Fabricated ltems

a) These items may be prepared / primed and further coated before transportation to sire with the approval of KOC.

b) The painting used shall have enough durability t o withstand the 'on-site' construction period before further painting occurs.

Repair of Darnages'Defects

New painted surfaces are likely to require repair and maintenance in the following cases:

a) f o r painted areas which have been damaged by other adjacent field activities or during handlingltransportation of off-site painted items.

b) For areas which suffer paint defects e.g. disbonding, insufficient film thickness, blisterin& etc.

The type of coating materials used for repair and maintenance shall be identical to, or compatible with the original material.

Page 27: KOC Painting STD

The selection of suitable surface prsparation shall depend on the size of areas t o be painted, the type of repair painting materials t o be used and the Safety regulations involved. The following order of preference shall be adopted.

a ) Dry blast cleaning t o the required visual standard ( S a 2% or Sa 3) and su r face profile.

2) Power tool cleaning r o standard St3 (only where blast cleaning is not practical or permitted).

Hand tool cleaning t o standard St2 (only for minor touch up!repair work)

Surface preparation of defective or damaged areas shall be extended over the surrounding sound coating for a minimum of 25 mm on all sides and a further 25 mm of sound paint work shall be lightly blasted t o e t ch the surface.

Surfaces t o be painted that become contaminated with oil, grease, salts, e t c . shall be cleaned with a proprietary solventidetergent solution and rinsed ~ ~ 2 1 t h fresh clean water.

Repair works shall be in accordance with the specified painting system t o restore the f ~ l m thickness and shall cover the prepared surface and the etched p a n t work. For colour codmg and/or cosmetic reasons it may be necessary t o extend the f ~ n ~ s h coat over a large surrounding area.

It is mandatory tha i all defective work be corrected t o the satisfaction of KOC's representative. Work shall not be deemed complete until the foregoing bas been achieved.

INSPECTION AND TESTING

General Requirements

lnspectlon and testing a t all s tages of surface preparation and paintingkoating a p p l c a t ~ o n shall be conducted by the contractor. The contractor shall provide all necessary inspection equipment and perform such inspections as necessary t o assure t h a t t h e painting I coating complies with t h e requirements of this Standard.

Surface preparation and painting /coat ing application m a y be subjected t o inspection and approval a t any s t age by KOC.

KOC inspector shall have the right to inspect at all times a n y tools, materials or equipment used in t h e performance of surface preparation and paint application to ensure the compliance with t h e requirements of this Standard.

Page 28: KOC Painting STD

Materials and Equipment lnspection

Abrasive material shall be inspected to ensure compliance with the requirements of this Standard. (see clause 8.5.2)

Painting / coating materials shall be inspected to ensure compliance with the requirements of clause 7.0 and the specified painting schedules (Appendix 3) of this Standard.

Equipment for blast cleaning and paint application shall be inspected to ensure the compl~ance with the requirements of this Standard (see clauses 6.3, 8.5.3 and 9.5) and paint manufacturer's recommendations.

lnspectionrresting Equipment

The contractor shall heve the necessary equipment and tools for inspection and testing of environmental conditions, surface preparation and painted.'coated surfaces. All this equipment shall be approved by KOC prior to starting any work. The contractor shall provide calibration certificates for all measurement and test equipment for KOC's review.

Environmental Conditions Testing

Prior to commencing any blast cleaning 1 paint application work, ambient temperature, metal surface temperature and relative humidity (RH) shall be measured. Readings shall comply with clauses 8.2.1 and 9.4.1. For works in confmed areas, the oxygen deficiency and gas testing shall be performed.

Other environmental conditions, e.g, wind speed, wave tide and sandy or rainy weather, shall be checked before the commencement of any work.

Blasted Surface Inspection Resting

Visual lnspection

a) Metal substrate shall be checked t o ensure spatter / protrusions removal, cleanliness etc. prior to blast cleaning.

b) Blast cleaned surfaces shall be visually inspected (surface magnifier may be used) t o ensure the absence of all types of imperfections and contaminants and for the conformance with the specified visual standard mentioned in the painting / coating schedules (Appendix 3).

- Surface Profile Testing

On dry blast cleaned surfaces the profile height shall b e spot checked by means of surface profile comparator or by replica tape and a calibrated

Page 29: KOC Painting STD

micrometer in accordance with ASTM D4417 or NACE RP0287 t o ensure the compl~ance with p a m n g schedule requirements.

Contammants Free Testing

When requested by KOC, a Potassium Ferrocyanide paper test shall be carried out t o confirm the absence of contamination of the blast cleaned surface by soluble iron salts. This shall be done in accordance with BS 5493 Appendix G.

Painted Surface lnspectionrresting

Visual Inspection

All painted surfaces shall be visually inspected t o ensure the absence of skips, overspray, sags, foreign panicles contamination, air pockets, drips, holiaays and s n y other palnt defects. The repair of damagedldefected coating shall be done In accordance wtlh clause 9.8 of this Standard.

Curing of Inorganic Zinc Srlicate Primer Test

a) Z ~ n c silicate primed substrate shall be tested for adequate curing prior to 0vercoa:ing (see clause 9.6.4). The test shall be performed as follows:-

Rub the applred coating with a clean tissue or piece of cloth. There should be no trace of paint on the cloth. The cloth should then be soaked In cleaners as recommended by the paint manufacturer; and again rubbed on the coatrng. After about thirty seconds there should be no trace of zinc on the cloth. If there is any greyness, then the zinc silicate IS not fully cured and shall not be overcoated.

b) The manufacturer's recommendations 1 instructions shall be fully adhered when performing this test.

Paint Film Thickness Test

a) The paint shall conform t o the system and t o the minimum film thickness as specified in the painting schedules.

*

b) The wet film thickness ( WTT 1 shall be spot measured as an initial indication of the expected dry film thickness IDFT). The measurement shall be in accordance with ASTM D1212.

C) The DFT of individual coats end of the total painting system shall be measured in accordance with ASTM D l 186 or SSPC-PA2. There shall be at least one area each for horizontal, vertical and curved surfaces. For internal painting in storage tanks, the film thickness shall be measured at ten (10) randomly selected areas.

Page 30: KOC Painting STD

dl A minimum of five (5) readings shall be taken in each area. Additional readings shall be taken, if there is any change in personnel, application equipment, spray nozzle size, thinning of the paint, etc.

e) The (DFT) shall be measured by using an approved coating thickness gauge suitable for the given type of painting system and thickness range.

f) The gauae shall be calibrated prior any measurement. The calibration shall be repeated at least once an hour if working on the same surface, and before measuring film thickness on the insides of angles and at points nearer than 15 mm from an edge.

Paint Adhesion

When requested by KOC, a spot adhesion test may be carried out using a suitable Adhesion Tester. The paint adhesion recorded must be at least eqilal to the specifled adhesion by the paint manufacturer for the type of paint and or system. The paint adhesion testing shall be in accordance wlth ASTM D3359 or ASTM D4541.

Hohday Detection (Porosity Check)

All coated metal surfaces shall be subjected to visual inspection for holidays, pinholes and overspray. For special coatings where pinholes cannot be allov,~ed, a full scan holiday test shall be done, using suitable equipment for each type of coating as high voltage can cause damage to coatings. The acceptable level of pinholes shall be subjected t o KOC's approval. Holiday detection test shall be carried out in accordance with NACE RPO188.

QUALITY ASSURANCE

The Contractor / Manufacturer shall operate quality systems to ensure that the requirements of this Standard are achieved. The quality systems shall be preferably based on IS0 9000 series of standards and the contractor / manufacturer shall demonstrate compliance by providing a copy of the accredited certificate or the quality manual. Verification of a contractor's I manufacturer's quality system is normally part of the pre-qualification procedure and is, therefore, not detailed in the core text of this Standard."

DOCUMENTATION

General

All correspondence, drawings, instructions, data sheets, design calculations, or any other written information shall be in English language. In case of dual languages, one language shall be English.

All dimensions, units of measurement, physical constants, etc. shall be in SI units, unless otherwise specified.

All documents (texts, specifimtions, data sheets, etc.) shall be provided with electronic files in the approved software I MS Word, Excel, AutoCAD, etc.).

Page 31: KOC Painting STD

A n y design calculations shall be submitted in the approved and widely used software agreed by KOC.

Work Proposal

The contractor shall submit his proposal for all aspects of work, for the approval of KOC prlor t o the commencement of any work. This will include the following:

a ) Information on work location, materials selection, equipment to be used, items to be coated, surface preparation, painting schedule to be used, etc.

b) Manufacturer's technical data sheet, material performance cenifcates and test approvals shall be provided for each paint 1 coating product.

C) f d ~ t e r ~ a i safety dsta sheets and safety precautions to be taken

d ) lnspect~on and tes; plans and procedures, and the equipment to be used.

e) S p e c ~ f c repair proposals t o satisfy the requirements of clause 9.8 for both extensive and minor repair.

Work Records~Reports

The contractor shall operate a comprehensive recording!reponing system on all sspects of the painting work includmg inspection/testing work. The data shall be set out on painting work recordldata sheet within 24 hours of carrying out a spec~fic work. Appendrx 1 shows a sample of this recordjdata sheet.

Final Report

A report shall be subm~ned on completion of the painting works. The fmal repon shall include a summary on all aspects covered e .g . , surface preparation, painting systems used and inspection and testing records performed.

PAlNTlNGlCOATlNG SCHEDULES

The painting I coating schedules (A-E) are attached t o this Standard in Appendix 3. The requirements for surface preparation and paintinglcoating systems are listed for categories of onshore / offshore structure, equipment and other facilities.

The paintinglcoaring schedules explained in Appendix 3 are:

Schedule A - External PaintingICoating Systems for Onshore Storage & Processing Equipment.

Page 32: KOC Painting STD

Schedule 0 - Painting Systems for Onshore Structural Steel works.

Schedule C - Painting Systems for Mechanical, Electrical and Instrumentation Equipment .-

Schedule D - ?ainting.lCoating Systems for Offshore Structure and Equipment.

chedule E - Internal Painting Systems for Storage and Processing Equipment.

14.0 COLOUR SCHEDULE

The finishing colours t o be applied to various equipment and facilities shall be in accordance wirh colours mentioned in colour schedule of Append~x 2. S~!e::~ng different colmrs is subject to KOC's approval.

Page 33: KOC Painting STD

75.0 APPENDIX 1

PAINTING RECORD 1 DATA SHEET -- --

........ Proposed by ................. ... ....... Checked by ........................ Date:.

........................................... Item being painted. ............... .. ..................... Location.

Substrate Material.. ........................................................................ . .

A. Surfact Preparation

....................... Surface Cleanliness (Visual Standardi

Surface Condition .......................

S;*!~:E Prc'li~ He!;?! . . . . . . . . . . . . . . . . . . . . . . . cf,:,c:c-l

Ambient Temperature ('C) .......................

C o v a m ~ n a n t s Free Test . . . . . . . . . . . . . . . . . . . . . . .

....................... De.0. Point ( T I

....................... R ~ ; i i i d € Humidity (C/o)

SLI:~B:E Temperature ('C) .......................

Cleaning Method(s) .....................

...................... Abrasive type

Abrasive S ~ e v e S ~ t e ......................

B. Paint Application Equipment

Primer 2nd Coat 3rd Coat 4 th Coat

Brush Roller /Con. Spray ' A~rless .............................. .... ............................... Conventiona! Gun ....................................................................

A~rless TIP S z e 'Angle (thou'deg' ............................. ... .................................. Pump Ratio ................._.........................,,.......................

.................................................................... Supply Air Pressure (psi)

C. Painting Conditions

Relative Humidity (%I

Surface Temperature t°Cl

Ambient Temperature PC)

Dew Point ( " a

.................................................................... Other weather Conditions

Page 34: KOC Painting STD

PAINTING RECORD / DATA SHEET (Contd. .. 1

0. Paint & Coating Materials

............................... Manufacturer

TypeXode Bstch No. Product No No of t o m Cur~ng Per~od

Primer ............. .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Intermediate ............. ....................................................................

Finish ............. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Colour Codmg

Over Coa?~ng

T ~ m e Interval ......................................................................

T o ~ a l \ V R ......................................................................

To?al D R ......................................................................

Adhesion Test ......................................................................

P~nhole Test ......................................................................

Material Safety Data Sheet ( for information 1

DOC. NO. KOC-P-001

-

Remarks :

Page 35: KOC Painting STD

APPENDIX 2A - . . - - . . - -- -

COLOUR SCHEDULE (table 1 I

Item

Stora e 81 Processing Equipment: &Pressure Vessels, Exchangers, Heaters Columns, Skirts, Saddles and Piping

Rotating Equipment - ElectricallMechanicaI Equipment Instrumentation Equipment Control Panels/Equipment Support

Pipe Works, Valves and Fittings

All valves/devices used for over pressure protection (e.g., Safety valves).

Overhead Travelling Crane

Structural Steel Works

Hazards - Firelsafety systems

Gas Cylinders (Industrial)

Gas Cylinders (Medical)

Safety Signs

Grey

Refer to Table 2

KOC-P-017

Blue

Yellow - red

Aluminium

Rritish Standard No.

-.... - ----P

BS 4800

Remarks

Alirminium colour shall be "Non Leafing" grade.

BS 381 C Ref. No. 107

BS 4800 Shade 08-E-51

BS 4800

Refer to KOC-P-017 for colour coding arrangement and application for piping.

Refer to Table 2 BS 381 C

Refer to Table 3 DS 349 1 Refer to Table 4 RS1319

Refer to BS 5378 RS 5378 - - - - . . . - - - - - - - -

Page 36: KOC Painting STD
Page 37: KOC Painting STD
Page 38: KOC Painting STD

. -- -

[-DOC. NO. KOC-P-001 1 Page 38 of 55 I REV. 2

APPENDIX 2C

cOLOUR IDENTIFICATION OF GAS CYLINDERS FOR INDUSTRIAL GAS VIDE BS 349 (Table 3) (Contd ...)

Methyl Ctrlotrde C H L I

Neon - -- Ne - --

N~tro~en - - . --. . . .

N r Oxygen - - - . . - - Or

Phosyer re & I - --

--- Propane (Comrner call

- - - - . -. Sulphur 0:oxldtt SO:

Ch een

- - - - - - - - - S~gnal Red - - - - - *

b ~ h t Brunsw~ck GI een

41 1 ) Black I - Gbss -- - 630 I & a k . Gbss

None . P ~ L O C ~ Hue & 103

Note: For dour+ White and E I k k , (u) reference number is quoted in BS 381C.

Page 39: KOC Painting STD

IEV. 2

APPENDIX - -- 20

COLOUR IWNflFlCATION FOR MEDICAL - - - - - GAS-VlD+RS - -- 1319 - (Table 4)

I I Vl)ua End I

Oxvaen I 0 2

Nitrous Oxide _. . N70

Cyctopropm ---.-

C3Hn -- - Carbon Dioxide C02 Ethylene C7H4 Helium - He

Nitroaen NZ Oxygen & Carbon Dioxide (mixtures) 1 0 7 + C07

Oxygen and Helium M i m e s 0 2 + He

Air (Medial) AIR Oxygen and Nitrous Oxide mixlures 0 2 + N 7 0

W h l t ~ - French nlue - - - - - - - - light Orange

-~ rench Grey - -- Dark Violet - - -- - - - - M~ddle Rrown

--

R i x k - - --

White and

BS 381C I-...-- C

Illack Gloss - 166 f rnnch Rlue GlossIMatt -~

1.1ght Orange - 557 GlosslMatt - - -

rrench Grey -----

630 Gloss Dark Violet 796 Gloss

- - Middle Drown 41 1 Gloss - - French Grey

-- ----- 630 Gloss

Black Gloss

Rlack I I Gloss

French Grey -. - - - - - - 630 Gloss

. - -- French Wue 1 66 Gloss

I 1 French Rlue I 166 I I I

NOTE: For White and 81ack. no reference number k quoted in BS 381C.

Page 40: KOC Painting STD
Page 41: KOC Painting STD
Page 42: KOC Painting STD
Page 43: KOC Painting STD
Page 44: KOC Painting STD
Page 45: KOC Painting STD

OOC. NO. KOC-P-002 I Page 45 of 55 I Rev. 2 - . - - -- - - - - - . -

APPENDIX --- 38

SCHEDULE 6: PAlNTlNG SYSTEMS FOR ONSHORE - - - - STRUCTURAL -- - - -. - STEEL - WORKS

I-: 1 - G,&Q. Lbddcn, Nmdrdl. Fmclng, Stdrwavs. Wdkwnv, Stdr treads, Cable trays, Duct inn rmd Platforms. 2 - ~encrd Concrete I Not Concrete Encased Structrmd Steel Work.

SCOPE

Ladders. platforms. handrails, stair treads. open grid flooring s ted grating.

SPECIFICATION

Hot dtr, galvantnnq anti Top cnattnq

Hot dip galvani~ing Plqarat on, - Vtwal standard Sa 2% - BS 729 rr,qrrtr~rncnts Coating- Hot dtp ~alvan17c shall b~ car r t4 OII~ In accordancr, wvth RS 729 The mtntmum coattnq woqht shall be 61 0 ~rarnslrn' surface

Top coating Top coatvnq of galvanrwd surface maybe r r q r ~ t r d for colour c d m g or for rna intmanc~ of smrra l weathered t t m s &qal;rtio% In accordance wi th clarrse 8.12 of this Standard. Interm(H1~ale - Two-pack High-build Epoxy FAjsk Recoatable Acrylic Polyurathane in the reqtrirmf colorrr.

REMARKS

Wh~rc? not galvanlsed. rnc! system 'R2' for all axccpt handrails which shall be A 1 - 1.

Page 46: KOC Painting STD
Page 47: KOC Painting STD

SCHEDULE - C: PAINTING SYSTEMS --- FOR MECHANICAL, - . - - - ELECTRICAL - - - - - - AND - - INSTRUMENTAllON - - - - -- EQUIPMENT - - -

Item: Rotating Equlpmcnt lhmps, Compressors. Motors. etc.), Elr?ctrical E q t t i p m n t m d Equipment's Supparts.

SCOPE

Pumps, Compressors. Motors. Fans etc.

- - .-.- - .. - ---.. . - - SPECIFICATION MIN. THICKNESS

DFT IMICRONI - - - - . . . - - . - .-

- A s f o r A l - 1 , A l - 3 , A1 4 a n d A l - B s y s t c m s - Machinery and drivms. instrrtrnents Pi associal4 valves may

he finish coated tn accordance wcth man~rIactttrc?r's staridard coatinn syslmns.

- Manttfactrtrcs shotrld provide d~ ta i l s of the p r o m s d PAINTING

systems for fttttrre maintcmance and fopair. - The pan t system mttst bc? capable of wtthstanding the

c?nvtronrncntal cnndtttons for pcrrtod nf 5 vcnrs to Ri3 pm BS 3900 H 3 scale of drylrw of ntstinq.

Movi Parts: F F ~ ~ S Z ~ I T X P ~ ~ , Couplings etc.

Electrical Equipment Motors, Switchmars, Standard Equipment , Transformers 1 Rectifiers

Preprat ton- VI~II~I Standard Sa3

- S ~ ~ r f a c o prollle 25-35 micron Coattng Syz1c.m- Shail i ) (?a~ for system A 1-1

- This type of eq~ripment shall be prc?pard, prim& (t finished in accordance wi th the man~tlact~rrcr's standartl.

- The system mttst be canahle of wtthstanding the environmcnfal cnncfitions for period of 5 ycars to Ri3, per BS 3900 H3 scale o f d q r w 01 rusttnq.

Housings and Equipment Supports. Pr9arjat;bni - ~tsr~aTstandard Sa 2% - Surlace proltle 25-35 micron Pnmitnt:

coc rtch Epoxy Intr?rrndiale: ' fw&&d High buitd MI0 F w x v Ftnrsh: Ar.iviZ Modif id Polyurethane

Control Pands As lor C3 Svstem

REMARKS

Total patnting system to be shop appl id.

Total painting system to be shoo applied

Manufacturer's standard shall be sttbiect t o KOC approval.

- Housings to be finish coated in sdlers works.

- Shop fabricated supports shan he patntcd in workshop.

Page 48: KOC Painting STD

APPENDIX 30

NGtCOATING SYSTEMS FOR OFFSHORE STRUCTURE 81 EQUIPMENT (EXTERNAL SUR_FACES - ATMOSPHERIC ZONE, SPLASH ZONE AND SUBSEA)

hems: Structural Steel, Tanks. Vessels. Piping, Valves , Plant Equipment.

Dl: Atmospheric Zone

- Pnmd surface to be tree of zinc salts prlw to 1- coatrru.

- Inorganrc Ztnc Srbcate pruned surface shall be rested lor w r e e of cure pror to over coarmq. ISM clause 10.6.2)

- Prtriwd surfaces to be f rw of rmc salts prmr to funsh coalmy.

- Inorgmrc Zmc Sllrcate pr~nwd surface shall be leslt?d foc dqrue of cure p r w to ovw coarmg. l s w clausel0.6.2J

- Second ccktt to ba appked as a trust prior to lull Cwlrn().

- S m o as 01-1 - Allerndi~ve plyruents to Al shall be used m zone 1

;vws lscw clause 6.5.1 & 7.1 5). Slllcorl Alu~nrwnl l~nrslr coal nwy no1 tully cure url l~l equrpmcrbl 6 In servce.

Page 49: KOC Painting STD

APPENDIX 3 ----

SCHEDULE O 1Contd.. . 1

SCOPE

- CS I Low alloy s t d sttrfaces. - Uninsrrlated

- Up to 550°C

- Stainless steels AlSl 300 and 400 series and duplex t y m . - Up to 120ec

- ----- -Ad.. --

SPECIFICAT ION

Propara1 Inn: - - - ~ l s ~ r n i stindard Sa 3 - S~rrfacc! proltlc 5 0 nvcrons First coat: AI~Meini spray Finlsh:

t;?mperatrrre Al Silicone

hcparatlo? IT1stcai st~r~cfard Sa 3 Prrrn~rig- /6orclawc Zinc Silicate Tle coat- Two-pack Epoxy Fincsh: Two gack hiqh bttild M I0 Epoxy f2 coats1

Fqariyio": - Vlsr~al standard Sa 3 - Srrr lxe profrle 5 0 micron Prirningi hi%<antc Zinc Silicate ~intsh: Twollack Epoxy tie coat

~ryara t ron : - V ~ w a i standard Sa 2% - In accordance wlth clattse 8 1 1 Prrmtng li(q11 I~celd Epoxy for stainless stclcls Ftnl5hl Rrcoatahlr Acrylic Polyr trclthanc

1 !iO

70

Total 1 70

7 5

25

7x75

Total 250

75

25

Total 1 0 0

Total 700 -

REMARKS

ShRH not be used far services opetatkg hr wea zone 1.

- Primcd srtrface to be f r w of 7inc salts prior t o f incsh coatinn.

- Inorqanrc Zinc Silicate primed swfacc? shall be t ~ d d for dcqrcv! of cure prior to over coating. lsce clartse 10.6.2)

As above 'Dl -5' remarks.

Under no drcumlPtrnces shall 7inc conlaininn paints hr? r t s 4 on starnl~ss slael s~trfaccs

Page 50: KOC Painting STD

SCHEDULE D lcontd.. . I

CS slruclures and Jelt~es.

Galva~wtnl stccl structure Harldrall

Galva~~lred steel structure Gra1111y

. -. -. -- - . . . . . . .

SPECIFICATION

Pre@fmon. - --- - Vtsual st~~rdard Sa 2% - In accordawe w11lr clause 8.11

01 I~US Sldllddrd Coatmc_l Two coals ol Foster Allas hual reusidrlcu 57" - 73" or approvcd

FIJ GI ; Coal Tar Epoxy 13 coals)

wN.7HICKNESS OFT IMICRQNI

Same as ' 0 1 -7' above.

Galvarured surlaces must be as per BS 729.

Page 51: KOC Painting STD

APOENOIX 30 ----

SCHEDULE 0 (Contd.1

Deck - Heavy Duty Non-sl~p

Deck - Light Duty Non-slip

Preparation; - VISBI~I s?aridard Sa 2% - S t l r l a c~~ p r ~ l t l o 25 35 micron Priming; Ztnc r ~ c h 2 pack Epoxy Finish: -- .-

S ~ k a sand fill4 m o d i f i d q m x y c k d d ~ n g covered wtth non -spark ing aggregate, sweep away e x c ~ s s SF!; Two pack epoxy

P_r,p:at"" - V~sual standard Sa 2% - Surface profda 25-35 micron Priming: zn: r ~ c h 2 pack Epoxy Finish: Two pack Epoxy c o v e r ~ ! with non- sparking aggrcgalc?

5 0

Total 3100 (3.1 mm)

50

250

Total 300

-. -

Page 52: KOC Painting STD
Page 53: KOC Painting STD

DOC. NO. ROC-P-001 I Page 53 of 55 -- - ---- - - - -. REV. 2 -

APPENDlX 3E ---

SCHEDULE E: lNTERNAL --- PAINTING SYSWMS -- . - - FOR - - STORAGE -- - A- AND PROCESSING -- - -- FOUlPMENT -

It-: Tanks - k&strlrJIB~~tlSlopIt)rmln.IBrbckish water. Desalter wash water and Fire water tanks. Wetldry crude tmks and Test tmks. Gmerdffresh wster Services. SeparMors. Drains sump vessel. Drains flash vessel and Desdters.

Wet crude storefln and Test tanks (fixed or floating roof) inclrrding in tmal structures and piping inside and or~tside.

.I

Wet crude starme snd Test tanks (fixed or floating roof1 incldin(l Interns1 structures and piping inside and outside.

IndustrisflBaflastl SloplDemin. /Brackish water, Desalter wash water (md fire water tanks (inckrdmg internal structures and piping inside and outside).

Dry crude tanks

f'r_oparat Ion- Vlzr~al Standard Sa 2%

- s~~rface prof~lc 75 mtcron Pr~m~_ng!In_tfrmc.dtat~lFtn~sh: 'fi;rw coats ol Coai f m Epoxy (Amme cur~d)

P'eparation: - Vtsrd SiSndard Sa 2% - surface profile 75 mlcron. Priming: m m t d e Epoxy primer Finish: Twocoats of high build Coal Tar Epoxy

Reparat ioz 31CuXStandard Sa 2% - surface proftle 7 5 micron. Rimingl~nyrmediateIF~nis~ - coats Cod f i r Ei)oxv IAmine cured)

The shell plates may be sr thwt to coating as per systc?m €2. i f rcquird bv KOC-MV-007, Data Sheet.

MIN. THICKNESS or T (MICRON) - - - - ---

3x150

Total 4 50

Total 350

3x150

Total

F~hrc & t ss lining in ~ccnrdance w ~ t h KOC-P- 002 Part 2.

Entire floor plt~s 3 mcters of the loww shdl corssc or 4 mar. expw,ted water I e v ~ l + 0 .5 mc.tc.rs ) whichcvcr is gredtcr. Rdnr to KOC-MV-007 for information on arms to he coated I not coated bv coal tar m x v .

Same as "E 1 - 1 " above.

Fibre glass lining in accordance with KOC-P- 002 Part 2.

Entire floor plus 0 .5 meters of the loww shell course.

Fibre glass lining in accordmw w ~ t h KOC P- 002

Fnt~rc. floor plr~s 0 5 meters ol ttic 1owc.r shell cot~rsc. . - . . . . - - - . - - - - - -

Page 54: KOC Painting STD
Page 55: KOC Painting STD

ACKNOWLEDGEMENT

This Standard h a s been approved by t h e S tandards Technical Committee ( STC consisting of t h e following :-

!,':. Ali ti. Babe ( Standards Div.) Chairman MI. Mohd. Ernam ( Ins?.& Corr. Div.) Deputy Chairman Mr. S. Kumar ( Standards Div.) Secretary1 Member Dr. Mohammad llyas ( Standards Div.) Member Mr. Khalid S. AI-Ali ( Maint. Proj. Div.) Member Mr. Henry S, Hill ( Maint. Ping. Div.) Member Mr. J a s s e m Al- Ouraini ( PMD- North ) Member

The dre9 c4 thls Standard h a s been circulated t o t h e KOC User Depanmen t s for thelr rEvli.i*i E-1s c c r n m e x s werE rrzeived from the following :-

ENGIKEERING GROUP PROD.& EXPORT OPERATIONS GROUP

Gen. Supdt . Engg. Services Gen. Supd t . Prod. Services Gen. S ~ p 3 t . Proj. Mgmt ( N & W 1 Gen. Supdt . Prod. O p n s ( N&W 1 Gen. S~ipdr. Proj Mgmt ( S& E ) Gen . Supdt . Prod. O p n s ( S)

MAJOR PROJECTS GROUP INDUSTRIAL SERVICES GROUP

Ge7 S,>31 Engg Projects ( N&E 1 Gen. Supdt . Ahmadi Services

MAINTENANCE GROUP

Gen. Supd t . Maint. S v c s . Gen. Supdt . Maint. ( N&W )

LOSS PREVENTION GROUP

Gen. Supdt . Consv. & Insp. Gen . S u p d t . Fire & S a f e t y

DWIDED ZONE GROUP

Supd t . Proj. Engg. & Facilities Div.

This KOC Standard for " Painting a n d Coating of Metal Su r faces - New Construction " has been amended by the Task Force ( TF-PC101 ) comprising of the following m e m b e r s :-

Mr. S. Uumar - S t a n d a r d s Div. - Member Tel. No. 61407

Dr. Muayyad Ajjawi - (Ex) S t a n d a r d s Div. - M e m b e r