Table 1 Inspection and Testing Summary

Work Stage Assessment Assessment Method Test Equipment Notes

Safety Procedures
HSE rules Observation Visual, documentation, Method Compliance with HZL HSE Requirements
Statement
Working practices Visual, documentation, Method Check requirements for working on live stations and operating equipment
Statement
Equipment condition Equipment safety checks Replace faulty equipment
Ventilation Check VOC and air flow rate
Protection
Sensitive equipment Observation Visual Ensure all protection in place
Adjacent structures/ Ensure all protection in place. Isolate work area. Remove vehicles to safe
vehicles area
Raw Materials
Paint Conformance to specification Visual, documentation, Paint Technical Flow cup type B No. 4 Packaging, labelling, shelf life, batch number etc
data sheets, performance test results
viscosity check
to ISO 2431
Abrasives Conformance to specification, Documentation, physical/chemical Standard Wire Sieves Reject if wetted by salt water, rain or condensation or moisture content
cleanliness, particle size. analysis, particle size distribution to ISO too high.
ISO-8504-2 11125-2 Reject any work blasted with wet abrasive
See note 1 for details
Climatic Conditions
Weather Monitor climatic conditions Observe and measure variables Ref. Sections
Air temperature Measurement Monitor air temperature Digital Thermometer Allow time for temperature to stabilize
Surface temperature Monitor surface temperature Contact Thermometer
Humidity Monitor humidity to ASTM E337 Whirling/Sling or Psycro-Dyne Read relative humidity from Hydrometric Tables
Hygrometer
Dew point Measure directly or calculate Direct reading digital Dewmeter, Confirm by charts or conversion calculator
Lighting Measure >500 lux
Surface Preparation
Personnel protection Conformance to HSE Observe and confirm conformance Check operators have proper protective clothing.
Equipment regulations Observe and confirm conformance Check equipment electrical earthing, safety valve ‘dead man’s handle’
operation.
Climatic conditions Monitor all variables as above As above As above Stop work when conditions are outside acceptable limits
Ventilation for Size of enclosure. Capacity of Monitor dust levels. Measure air part Stop work if dust levels become excessive .
enclosed spaces air moving equipment. flow Air 6x per hour
 Work Stage Assessment Assessment Method Test Equipment Notes
Observation Visually examine and compare with Inspection Mirrors. Illuminated Reject surface having large embedded particles that cannot be removed.
Surface cleanliness relevant parts of ISO 8502 Magnifier. Pictorial Standards Tightly adherent fine particles are acceptable. Removing particle by wire
brushing is not acceptable.
See note 2 for details
Surface cleanliness (cont.) Observation Contaminant Pick-up ‘Sellotape’ test –ISO-8502-3
Soluble salts Chemical analysis Bresle Method to ISO 8502-6 Bessle Sampler, Confirm cleaning has been adequate
Test papers ‘Quantab’ Indicator Papers Qualitative checks for Cl, Fe and S etc.
See note 3 for details
Surface profile Observation, comparison Visually examine, compare with Surface Comparator, Keane-
standards to ISO 8503 Tator, Rugotest
Anchor pattern Observation, measurement Measure record values to ASTM Digital /Mechanical Profile Measure profile height
D 4417 Gauges
Surface roughness Replication Surface replica to ASTM D4417 Textex Tape and Micrometer Provides permanent record of surface profile
Coating Application
Climatic conditions Monitor all variables as above As above As above Stop work when conditions are outside acceptable limits
Application temperature range as specified by Manufacturer
Recoat intervals will depend on ambient temperature
Ventilation for Size of enclosure. Capacity of Check LEL, TLV or MAC values. Product documentation. Control vapour to 10% of LEL.
enclosed spaces air moving equipment. Monitor vapour concentrations. Measure Explosimeter For some paints having mixed solvents, it is difficult to ventilate to below
air part flow Personal Air Sampling. the TLV. Applicators working in tanks and vessel must wear breathing
Apparatus
See note 4 for details
Application of Coatings Visual Inspector to check conformance with Details to be included in ITP and in daily record
datasheets
 Work Stage Assessment Assessment Method Test Equipment Notes
Inspection
Wet Film Thickness Measurement Use gauges in accordance with Wet Film Comb. Wet Film Wheel Spot check during application to ensure specified film thickness is being
ISO 2808 Method 7 A/B maintained
Dry Film Thickness Measurement Use gauges in accordance with SSPC PA Magnetic and Electromagnetic Calibrate instruments at least twice daily using standard foils.
2 and Eddy Current Gauges Use statistical methods for determining acceptability
ISO 2808 Method 6 See note 5 for details
Destructive test using special inspection ‘PIG’ Paint Inspection Gauge Destructive test on any substrate to confirm DFTs (Not for production
instruments painting)
General appearance Observation Visual inspection Optical magnifier Reject if appearance and condition are unacceptable
See note 6 for details
Degree of cure Observation Solvent swabbing Appropriate solvent Rubbing for 1 min. should not soften coating to fingernail scratch
Adhesion Pull Off Measurement for New Pull-off tests to ASTM D 4541 Mechanical and Hydraulic Acceptance: Pull-off force as specified in performance testing Report of
Coating Systems ISO 4624 Adhesion Testers Paint, Typically 3-10 N/mm2 . Tests to be done on cuopons

45 oCross cut test 45 oCross cut test For checking internal surfaces and local repairs.
Cross-cut and peel tests to ASTM-3359 For repairs test adhesion between first coat and substrate and between
coats. Acceptance: Classification 5A or 4A
See note 7 for details

Film integrity/ Conductivity Holiday Testing to High Voltage Spark Tester Calibration: High voltage - 5-6V per 1μ coating thickness
porosity NACE RP0188-99 See note for details
Notes to Table 1
1. Blasting Abrasive Quality
Abrasive must come from a recognized supplier and be certified in respect of cleanliness and particle size
distribution. If there is any doubt about the quality of the blasting grit, the Contractor shall provide a
specification covering sieve grading, chemical analyses and physical properties. If such a specification is
not available, the Contractor shall take two samples, of minimum 1 kg each, from each of abrasive and
arrange for analysis by an independent third party. Specification and/or analysis results shall be submitted
to HZL for comparison with accepted values.

2. Surface Cleanliness
The Contractor shall visually examine the surface to ensure that dust or dirt has been removed.

The Inspector shall not accept a blasted surface contaminated by large embedded abrasive particles that can
not be brushed off using a stiff brush. If such contamination is detected, no further blasting shall be
performed, using the same batch of abrasive. Tightly adherent embedded fine particles, however, need not
be a cause for rejection.

Work may be allowed to continue using a different batch, make or type of abrasive approved by HZL.

When using copper slag abrasive under high ambient temperature condition, the visual standard Sa 2½ may
not be obtained due to embedded fine particles causing a different shade. If there is any doubt on the
acceptability of the prepared surface, the Contractor shall provide a dedicated visual standard for Sa 2½
using copper slag under these conditions.

3. Soluble Salts
Soluble salts on a steel surface are taken up in distilled water using a Bressle Sampler. The Bressle titration
method shall be used to measure the chloride content. From titration measurements, the recommended
maximum salt contamination for immersed surfaces or for tank and vessel coatings is 20-40mg/m 2
chloride. Note the value for maintenance work is higher at 60-80mg/m2

4. Ventilation
Before and during blasting and coating work in enclosed spaces, adequate ventilation shall be established.
During coating operation, the vapor concentration shall be monitored at regular intervals using approved
equipment and should never exceed 10% of Lower Explosion Limit. This is considered adequate for
personnel health protection, avoidance of explosion hazards and to ensure adequate evaporation of solvent
from the paint. The TLV (Threshold Limit Value) or MAC (Maximum Allowable Concentration) of the
paint used must be known. Ventilation shall be such as to maintain, wherever practical, a safe atmosphere
below the TLV.

5. Materials Safety and Handling Data Sheets

Vendors are required to supply SHOC cards for each generic paint product in the total coating system.

6. Dry Film Thickness (DFT)

Guidelines for the number of DFT measurements for external coatings to be made after each coat may be
usefully based on the ‘80-20 Rule.’ This rule suggests that:

- the measured thickness must not be less than 80% of the specified DFT and
- a maximum of 20% of the total area painted may be below the specified
DFT The following statistical measurement procedure for the Rule is suggested:

1. Select a number of randomly chosen and continuous 10m2 areas in such a way that 5% of the
entire control area is covered.
2. In each area, select a minimum of five 50cm2 sized test fields.
Take three DFT readings in each field and calculate the mean value to be as one single measurement
 Acceptance criteria:
- No more than 20% of the total of single measurements to be less than the minimum
specified DFT
- The lowest single measurement should be at least 80% of the minimum specified DFT
The DFT of different layers of a paint system may be measured using a paint inspection gauge
using calibrated cutters and microscope. This however is a destructive test and not suitable for
production painting.

For internal coating systems use a 90:10 rule and apply the same procedure as above.

7.0 Adhesion Testing

Pull off adhesion testing in accordance with ASTM D 4541 ISO-4624 and cross cut testing in accordance with
ASTM D3359 shall be carried out on test panels to ensure the coating system meets the performance
requirements. The panels will then be used as a check to compare the cross testing results done on the
actual structure.
Cross cut testing shall be carried out at the following frequencies. For external coatings and repair work 1
per 100m2 with a minimum of 2 per structure. For internal coatings and repairs the frequency shall be 1 per
10m2 with a minimum of 2 per structure. For repairs only cross cut testing shall be used and this will be
carried out on the structure.
Adhesion testing is not applicable to GRE lining or pipeline repairs.

8. Visual Inspection

Each coating applied shall be inspected visually. The paint system applied should have the correct shade,
degree of gloss and evenness and be free from tackiness after drying/curing and free from cracks, holidays,
runs, sags, wrinkles, brush or roller marks or other defects that may deleterious to the quality of the
coating. Finishing coats shall be even in colour and gloss.

9. Integrity Testing

For internal coating systems 100% of the surface shall be tested using a metallic brush type holiday
detector in accordance with NACE RP 0188-99. Special attention shall be paid to welds, edges and
irregular surfaces. For external surfaces, random inspection, which shall be representative of the entire
surface shall be conducted.

A high voltage spark detector shall be used for all heavy-duty systems including glassflake, GRE, high
DFT epoxies and pipeline coating repairs. Testing shall be in accordance with NACE RP 0188 and
RP0274 (for pipeline coatings). The type of brush shall be suitable for the surface being inspected. The
voltage
setting shall be according to the Manufacturer’s recommendations or as given in the coating system
specification. Generally the detector voltage is set at 5-6V for every micron of coating thickness.

1.1 Reporting
The Inspector or Contractor shall record and report daily all inspection results as stated in the Method
Statement. If work is carried out within the Sultanate of Oman, standard Daily Report Sheets as shown in
appendix-B shall be used for reporting. Such a report shall contain the following minimum information:

1. General
- Date, project and job identification, Contractor and Inspector names
- Inspection location and times
- Safety Aspects

2. Ambient Conditions
- Air and substrate temperatures, relative humidity, dew point
- Presence of wind or dust, sunlight or shade
- Access and illumination conditions
3. Surface Preparation
- Condition of surface before cleaning, cleaning method, abrasive used, nozzle sizes
and pressures
- Standard achieved surface profile (microns)

4. Coating Application
- Manufacturer, type, and batch number, amounts of paint and thinners used,
overcoating times
- Application method, equipment used, spray nozzle sizes
- Inspection tests, WFT/DFT, holiday etc. including instruments, calibration details
- Repair