COMPLETE SITE DETAILS OF BHARAT PETROLEUM CORPORATION LTD. REF. DWG. NO.

REFERENCE DRAWING TITLE

BINA REFINERY, BINA
B109-000-17-44-00001 OVERALL PLOT PLAN
B857-000-81-45-00001 OVERALL PLOT PLAN

B957-999-81-45-00001
N55000

N NOTES :-

N50000

Take off point

Terminal point

N45000

AREA CHART -
N40000
TOTAL AREA 795.6 HECTARE

NATURAL POND AREA 8 HECTARE

E
0.0 M WID
LT 20
PLANT AREA INCLUDING FUTURE & OPEN AREA 579.5 HECTARE

N BE
GREE GREEN BELT AREA IN REFINERY COMPLEX 208.1 HECTARE

GREEN BELT REQUIRED (33%) 285.43 HECTARE

E40000

E50000

E55000
E45000
N35000
GREEN BELT IN BDT COMPLEX ( COMPENSATED FOR
12.43 HECTARE
REFINERY AREA)

ADDITIONAL AREA REQUIRED FOR GREEN BELT 65 HECTARE

400R

DE

(BO 09.25
65
. 6/4
WI

RL)
=4
CH
FL
GR

0M
EEN
BE
LT

.
200

200
. 0M
WI
DE

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+

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14.5m

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400F LEV
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(BO 1.44
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The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that

X
PLE
they will not be reproduced, copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.

OM
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5 6

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RW RW RW
3 4 C-9C
1 2
DG HOUSE

SWGR ROOM

RW RW RW

VE-9C
F CUR
RW RW RW

TP-1 O
RW RW RW

909.03
CH 4/
RW RW RW
POND

RW RW RW
RW RW RW
RW RW RW
DET-2

RW RW RW
RW RW RW
RW RW RW RW RW RW RW RW RW RW RW RW RW RW RW RW RW RW

RW RW RW RW RW RW RW RW RW RW RW RW RW RW RW RW RW RW RW RW RW RW RW RW

RW
FOR CONTINUATION B957-999-81-45-00002

RW
21 19 17 15 13 11 9 7 5 3 1

RW
22 20 18 16 14 12 10 8 6 4 2

UP

RAMP
RAMP

UP

4800
HV SWITCH GEAR

LV SWITCH
GEAR ROOM

SRR / RACK
ROOM

HYDROGEN
GREEN

(40X25)
GR
EE
RW RW RW RW RW RW RW RW RW

E-49109.00
E-49054.00
N
N-49710.00

BE
LT
POND

20
N-49618.00

0.
SULPHUR

0
TANKS

M
W

P.S.
LIQUID SULPHUR

ID
LOADING GANTRY

ROAD NO.0B
SULPHUR YARD

BRIDGE
WEIGH
CHAIN LINK FENCING

GREEN BELT 200.0 M WIDE

416.300

BRIDGE
WEIGH
GRE
EN
BEL
T2
00.
0M
WID
E

B957
G 29.11.24 ISSUED FOR ENGINEERING/ PPRRC Anil UF/NS AK/SKN
S. NO. F 14.11.24 UPDATED & ISSUED FOR INFORMATION Anil UF/NS AK/SKN
E 10.04.24 REVISED & REISSUED FOR PRE-PROJECT ACTIVITY NS AK SKN

B857
D 03.04.24 ISSUED FOR PRE-PROJECT ACTIVITY NS AK SKN
C 01.03.24 ISSUED FOR PPRC NS AK SKN
B 02.02.24 ISSUED FOR CLIENT'S COMMENTS NS AK SKN
A 30.01.24 ISSUED FOR COMMENTS NS AK SKN

REV. DATE DESCRIPTION BY CHKD APPD PEM

BHARAT_PETROLEUM_CORP._LTD.
Hkkjr iSVªksfy;e dkWjiksjs'ku fyfeVsM

Page 720 of 1510 : B933-011-CC-MR-6101-2-RFQ : Rev. A

chuk iSVªksdsfedy ,oa BINA_PETROCHEMICAL_&
fjQkbZujh ,DliSU'ku ifj;kstuk REFINERY_EXPANSION
¼ch-ih-vkj-bZ-ih-½ PROJECT_(BPREP)

LkEiwZ.k {ks= foU;kLk

SCALE JOB NO. UNIT DIVN. DEPT. DWG. NO. REV.
1:5000 B957 999 81 45 00001 G

3-1641-0500 REV.4 / 06.03.2024 A0-1189 x 841

 LIST OF ATTACHMENTS DOCUMENT No.
FOR TRAYS & TOWER B933-011-80-46-LL-6101
INTERNALS Rev-A
(ENGINEERED BY EIL) Page 1 of 3

LIST OF ATTACHMENTS
FOR
TRAYS & TOWER INTERNALS
FOR
CRUDE COLUMN
(11-CC-00-2001)

PROJECT : BINA PETROCHEMICAL & REFINERY EXPANSION

PROJECT (BPREP)

OWNER : BHARAT PETROLEUM CORPORATION LIMITED

EPCM : ENGINEERS INDIA LTD.

JOB NO. : B933

A 13.12.24 ISSUED WITH MR BB UT JA/IK

Rev. Prepared Checked Approved
Date Purpose
No by by by

Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved

Page 721 of 1510 : B933-011-CC-MR-6101-2-RFQ : Rev. A

 LIST OF ATTACHMENTS DOCUMENT No.
FOR TRAYS & TOWER B933-011-80-46-LL-6101
INTERNALS Rev-A
(ENGINEERED BY EIL) Page 2 of 3

S. NO. DESCRIPTION Document No. Rev.

1.0 Job Specification
Job Specification for Tray & Tower Internals
1 B933-011-80-46-SP-6101 A
for Crude Column
Technical Compliance Statement for Tray &
2 B933-011-80-46-TCL-6101
Tower Internals for Crude Column
Vendor Data Requirements for Trays &
3 B933-011-80-46-VDR-6001 A
Tower Internals
Mechanical Detail Sheet for Trays & Tower
4 B933-011-80-43-CA-6101 A
Internals
Tower Attachment Drawings (i.e. TSRBB
5 **
Drawings)
General arrangement & details of Vapor
6 B933-011-80-46-SK-6101 A
Horn for crude column
Document at S. No. 5 above, i.e. Tower Attachment Drawings for Crude Column shall be provided
within 04 months after release of PR.
2.0 Standard Specification
Installation procedure for trays and tower 6-14-0003
1
internals
Specification for fabrication of bolting bar & 6-14-0007
2
support ring for trays & tower internals
Standard specifications for trays and tower
3 6-14-0008
internals

Packing, marking & shipping specifications 6-14-0009

4
for trays and tower internals

Standard specification for review of site

5 6-14-0016
installation of column internals
Specification for Preparation of TSR/ BB/
6 6-14-0018
GA Drawings of Trays
3.0 Standards
1 Internal Flanges 7-12-0018
Construction tolerance for welded supports
2 7-14-0001
for tray / tower internals
Method of beam end sealing for bubble cap,
3 7-14-0005
valve and sieve trays
4 Details of special clamps assembly 7-14-0012
Detail of 2thk and 3thk SS/CS clamp
5 7-14-0013
assembly (excluding 410 S material)
6 Details of Integral beam 7-14-0112
Details of Integral beam with
7 7-14-0113
interrupter bar
Details of Integral beam with
8 7-14-0114
interrupter angle
9 Details of Integral beam 7-14-0115
10 Details of Integral beam 7-14-0116
11 Details of Integral beam 7-14-0117
12 Details of Integral beam & interrupter plate 7-14-0118
Details of Integral beam with interrupter
13 7-14-0119
angle
14 Details of Inlet weir 7-14-0120
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved

Page 722 of 1510 : B933-011-CC-MR-6101-2-RFQ : Rev. A

 LIST OF ATTACHMENTS DOCUMENT No.
FOR TRAYS & TOWER B933-011-80-46-LL-6101
INTERNALS Rev-A
(ENGINEERED BY EIL) Page 3 of 3

15 Details of Integral beam with inlet weir angle 7-14-0121

16 Details of Integral beam with inlet weir angle 7-14-0122
17 Details of Integral beam with inlet weir plate 7-14-0125
18 Details of Integral beam with inlet weir angle 7-14-0128
19 Details of Integral beam with inlet weir angle 7-14-0129
20 Details of Integral beam with inlet weir plate 7-14-0130
21 Details of valve pitch (MR2/MR6 valves) 7-14-0132
22 Details for stud/pin welding 7-14-0136
23 Standard for Developed Plate Length 7-14-0137
24 Details of inlet weir sealing arrangement 7-14-0138
25 Details of rectangular washer for clamp 7-14-0140
26 Details of drain holes in exit / inlet weir 7-14-0142
27 Details of downcomer bracket and spacers 7-14-0143
28 Details of joints for downcomer 7-14-0144
29 Details of deck plate stiffener 7-14-0145
30 Details of loose beam 7-14-0151
31 Details of loose beam with interrupter bar 7-14-0152
32 Details of loose beam with interrupter angle. 7-14-0153
33 Details of loose beam with inlet weir angle. 7-14-0154
33 Details of loose beam with inlet weir angle. 7-14-0155
35 Details of loose beam with inlet weir plate. 7-14-0156
36 Details of Anti-Jump Baffle 7-14-0160
37 Details of exit weir adjustability 7-14-0161
38 Details of exit weir blocking 7-14-0162
39 Details of vapor equalizer 7-14-0164
40 Details of side seal pan/recess seal pan. 7-14-0165
41 Details of center seal pan/recess seal pan. 7-14-0166
42 Details of side seal pan 7-14-0167
43 Typical Detail of Sturt Support Arrangement 7-14-0173
44 Typical Detail of Trays 7-14-0202
4.0 Standard Inspection Test Plan
Positive Material Identification at supplier
1 6-81-0001
work
2 Inspection & test plan for bolting material 6-81-0007
3 ITP for Trays & Tower Internals 6-81-0015
5.0 Specification
Specification for Quality Management
1 6-78-0001
System requirement from Bidder
Specification for Documentation
2 6-78-0003
Requirements from Suppliers
Standard specification for health, safety and
3 environment (HSE) management at 6-82-0001
construction sites

Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved

Page 723 of 1510 : B933-011-CC-MR-6101-2-RFQ : Rev. A

 MECHANICAL
COST ANALYSIS
DETAIL
DATA
SHEET Document No.
FOR TRAYS 6556-11-16-46-CAD-01
6556-11-16-46-CAD-01
B933-011-80-46-DS-6101
6743-16-46-CD-6870
6922-05-43-CD-7620
Rev.
Rev. A
A Sht
REV
A xxAOfSht
xx
Sht
Sht
xx 18
7Ofof
ofxx
13
20

CLIENT BPCL - BINA PROJECT BPREP EIL JOB NO B933

COLUMN NO. 11-CC-00-2001
SERVICE CRUDE COLUMN
VESSEL INSIDE DIAMETER 3500 7000 7000
TRAY NOS. 1 to 6 & CT above #6 (Note-2) 7 to 15 & CT#1 (Note-6) 16-18, 31-33 & 44-46
TOTAL NO. OF TRAYS 6+1 9+1 3+3+3
TRAY SPACING 600 (750 for tray #1 & 900 for CT) 600 (750 for tray #7 & 1100 for CT#1) 900 (1050 for #16 & 31,900 for #44, 750 for #45-46)

NO. OF PASSES Four One Four

TYPE OF TRAYS Valve Valve Valve
TYPE OF VALVES 50% MR2 & 50% MR6H 50% MR2 & 50% MR6H 50% MR2 & 50% MR6H
NO. & DIA. OF HOLES OR VALVES/TRAY (Note-3) 3800 3800
VALVE/HOLE PITCH (Note-3) ~ ∆ 80 ~ ∆ 70
TYPE OF D/C AND UDFC Straight / 60 (Note-10) Straight / 40 (Note-11) Straight / 60 (Note-13)
WEIR HEIGHT EXIT / INLET 70 / 100 on tray #6 50 / - 70 / 100 on trays #18, 33 & 46
SIDE/CENTRE 2227 / 3491 3798 / - 3978 / 6996
WEIR
EXIT

LEN.

OFF CEN. INSIDE/OUTSIDE 3279 / 3045 -/- 6435 / 6197

GASKET REQUIRED SP below # 1 (Note-4) SP below # 7(Note-8) SP below #16, 31 & 44 (Note-8)

LOCK NUTS REQUIRED FOR TRAY NOS. All Trays & SP Trays #7-11& All SP Trays 18, 33 & 46

DECK 70x35 Note-7 Note-7

BEAM SIZES
(Depth x Lip)

SIDE UDF 100x85 (Loose) Note-7 Note-7

CENTRE UDF 150x85 (Loose) Note-7 Note-7
OFF CENTRE UDF 150x85 (Loose) - Note-7
MAJOR BEAM (LOOSE) - Note-7 Note-7

TRAYS SA240TP410S SA240TP410S SA240TP410S

CLAMP PLATE/WASHERS SA240TP410S SA240TP410S SA240TP410S
MATERIALS

BOLTING SA 193 B6X / SA 194 Gr 6 SA 193 B6X / SA 194 Gr 6 SA 193 B6X / SA 194 Gr 6
VALVES, BUBBLE CAP/RISER SA240TP410S SA240TP410S SA240TP410S
GASKET/ SEALING FOIL Woven Expanded Graphite Tape Woven Expanded Graphite Tape Woven Expanded Graphite Tape
D/COMER PIPE - - -
GASKET WASHER Soft Graphite Soft Graphite Soft Graphite

TRAY DECKS/UDF/ D-COMER 3.0 / 3.0 / 3.0 Note-7 Note-7

MAJOR BEAM/LOOSE BEAM -/5 Note-7 Note-7
THICKNESSES

VALVES, BUBBLE CAP/RISER MR2=1.5 / MR6H=2.0 MR2=1.5 / MR6H=2.0 MR2=1.5 / MR6H=2.0

GASKET/SEALING FOIL 3 3 3
BOLTING/CLAMP PLATE M10 / 3.0 M10 / 3.0 M10 / 3.0
WASHER (CIRCULAR/RECT.) 3.0 3.0 3.0
D/COMER PIPE - - -
GASKET WASHER 2.0 2.0 2.0
NOTES
1 All dimensions are in mm unless otherwise specified.
2 For details of Chimney Tray above Tray No. #6, refer Sheet 4. 10. UDFC of Tray #1 shall be 75 mm.
3 For trays #(4-6) provide 400 valves (200 MR2 + 200 MR6H) & for trays #(1-3) 11. UDFC of Tray #7 shall be 50 mm.
provide 200 valves (100 MR2 + 100 MR6H). Remaining valves to be blanked with
blanking strips. Provide 150mm high baffles on trays#(1-3) to block the active area 12. 150x150x3thk. Shear clips shall be provided at all beam end location for tray #1 to #11 & CT
and allocate valves as per the optimized pitch. above #6.

4 For detail of Seal Pan below tray #1 refer Sheet 3. 13. UDFC of Tray #16, #31, #44 shall be 75 mm.
5 4 Nos. Vapour Equalizers in the Off centre and Centre Downcomers of 4-Pass Trays 14. For trays#1-6, provide one stiffener of 50mm height and 3 Thk. at centre of all downcomers first
# 1-6 of size 6"NB or equivalent area shall be provided as per EIL Std. 7-14-0164, piece along the length.
Details-1.
6 For details of Chimney Tray CT#1 (above Tray No. #15), refer Sheet 8.
7 For details of Tray Arrangement Dwg, beam depths, and thk refer Sht 5,6 & 9 .
8 For detail of Seal Pans below trays #7,16,31,& 44, refer Sheet 7. Draw-off Pan below
Seal Pan of Tray # 7 shall be of welded construction and in Column Fabricator's
scope.
9 4 Nos. Vapour Equalizers in the Off centre and Centre Downcomers of 4-Pass Trays
( 16-18, 31-33 & 44-46 )of size 8"NB or equivalent area shall be provided as per EIL
A 13.12.24 ISSUED FOR BIDS BB UT JA/IK
Std. 7-14-0164, Details-1.
REV DATE PURPOSE BY CHKD APPVD

Format No. 3-0543-4006 Rev. 0 Copyrights EIL – All rights reserved

Page 724 of 1510 : B933-011-CC-MR-6101-2-RFQ : Rev. A

 MECHANICAL
COST ANALYSIS
DETAIL
DATA
SHEET Document No.
FOR TRAYS 6556-11-16-46-CAD-01
6556-11-16-46-CAD-01
B933-011-80-46-DS-6101
6743-16-46-CD-6870
Rev.
Rev. A
A Sht
REV
A xxAOfSht
xx
Sht
Sht
xx 27
6Ofof
ofxx
13
20

CLIENT BPCL - BINA PROJECT BPREP EIL JOB NO B933

COLUMN NO. 11-CC-00-2001
SERVICE CRUDE COLUMN
VESSEL INSIDE DIAMETER 7000 7000
TRAY NOS. 19-30, 34-43, 47-59 & CT # 2 & 3 (Note-2) 60
TOTAL NO. OF TRAYS 12 + 10 + 13 + 2 1
TRAY SPACING Note-6 600
NO. OF PASSES Two Two
TYPE OF TRAYS Valve Valve
TYPE OF VALVES 50% MR2 & 50% MR6H 50% MR2 & 50% MR6H
NO. & DIA. OF HOLES OR VALVES/TRAY 4000 4000
VALVE/HOLE PITCH ~ ∆ 70 ~ ∆ 70
TYPE OF D/C AND UDFC Straight / 40 (Note-6) Straight / 40
WEIR HEIGHT EXIT / INLET 50 / - 50 / 100 on Tray 60
WEIR

SIDE/CENTRE 3978 / 6991 3978 / 6991

LEN.
EXIT

OFF CEN. INSIDE/OUTSIDE -/- -/-

GASKET REQUIRED For SP below Tray 19, 34 & 47 -
Trays 19,34,47 and SP below Tray
LOCK NUTS REQUIRED FOR TRAY NOS. Trays 60
19,34 & 47

DECK Note-3 Note-3

BEAM SIZES
(Depth x Lip)

SIDE UDF Note-3 Note-3

CENTRE UDF Note-3 Note-3
OFF CENTRE UDF - -
MAJOR BEAM (LOOSE) Note-3 Note-3

TRAYS SA240TP410S SB127

CLAMP PLATE/WASHERS SA240TP410S SB127
MATERIALS

BOLTING SA 193 B6X / SA 194 Gr 6 SB164

VALVES, BUBBLE CAP/RISER SA240TP410S SB127
GASKET/ SEALING FOIL Woven Expanded Graphite Tape Woven Expanded Graphite Tape
D/COMER PIPE - -
GASKET WASHER Soft Graphite Soft Graphite

TRAY DECKS/UDF/ D-COMER Note-3 Note-3

MAJOR BEAM Note-3 Note-3
THICKNESSES

VALVES, BUBBLE CAP/RISER MR2=1.5 / MR6H=2.0 MR2=1.5 / MR6H=2.0

GASKET/SEALING FOIL 3 3
BOLTING/CLAMP PLATE M10 / 3.0 M10 / 3.0
WASHER (CIRCULAR/RECT.) 3.0 3.0
D/COMER PIPE - -
GASKET WASHER 2.0 2.0
NOTES FOR REFERENCED STANDARDS AND SPECIFICATIONS REFER SHT 1
1 All dimensions are in mm unless otherwise specified.

2 For details of Chimney Tray CT# 2 & CT#3, refer Shts 11 & 13 respectively.

3 For details of Tray Arrangement Dwg, beam depths, and thk refer Sht 10 & 12.

4 For detail of Seal Pans below trays #19,34,& 47, refer Sheet 7

5 UDFC of Tray #19, #34 & #47 shall be 50mm.

6 Tray spacing for trays #20-30 is 600mm, for #35-43 is 600mm, for #48-59 is 600mm,
for tray #19 is 750 mm, for tray #34 is 750mm, for tray#47 is 750mm, for CT#2 is
1300, & for CT#3 is 1100mm.

A 13.12.24 ISSUED FOR BIDS BB UT JA/IK

REV DATE PURPOSE BY CHKD APPVD

Format No. 3-0543-4006 Rev. 0 Copyrights EIL – All rights reserved

Page 725 of 1510 : B933-011-CC-MR-6101-2-RFQ : Rev. A

 BHARAT PETROLEUM CORP. LTD.
BINA PETROCHEMICAL &
REFINERY EXPANSION
PROJECT (BPREP)

Page 726 of 1510 : B933-011-CC-MR-6101-2-RFQ : Rev. A

 The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that
they will not be reproduced, copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.

NEW DELHI
ENGINEERS INDIA LIMITED
PROJECT (BPREP)
REFINERY EXPANSION
BINA PETROCHEMICAL &
BHARAT PETROLEUM CORP. LTD.

REV.
DATE
REVISION
BY
CHK
APPROVED
APPROVED
SPECIFICATION NO.
REV.

1-1641-0503 REV.0 A3-420x297

Page 727 of 1510 : B933-011-CC-MR-6101-2-RFQ : Rev. A

 Page 728 of 1510 : B933-011-CC-MR-6101-2-RFQ : Rev. A
BHARAT PETROLEUM CORP. LTD.
BINA PETROCHEMICAL &
REFINERY EXPANSION
PROJECT (BPREP)
 Page 729 of 1510 : B933-011-CC-MR-6101-2-RFQ : Rev. A
BHARAT PETROLEUM CORP. LTD.
BINA PETROCHEMICAL &
REFINERY EXPANSION
PROJECT (BPREP)
 Page 730 of 1510 : B933-011-CC-MR-6101-2-RFQ : Rev. A
BHARAT PETROLEUM CORP. LTD.
BINA PETROCHEMICAL &
REFINERY EXPANSION
PROJECT (BPREP)
 The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that
they will not be reproduced, copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.

NEW DELHI
ENGINEERS INDIA LIMITED
PROJECT (BPREP)
REFINERY EXPANSION
BINA PETROCHEMICAL &
BHARAT PETROLEUM CORP. LTD.

REV.
DATE
REVISION
BY
CHK
APPROVED
APPROVED
SPECIFICATION NO.
REV.

1-1641-0503 REV.0 A3-420x297

Page 731 of 1510 : B933-011-CC-MR-6101-2-RFQ : Rev. A

 Page 732 of 1510 : B933-011-CC-MR-6101-2-RFQ : Rev. A
BHARAT PETROLEUM CORP. LTD.
BINA PETROCHEMICAL &
REFINERY EXPANSION
PROJECT (BPREP)
 Page 733 of 1510 : B933-011-CC-MR-6101-2-RFQ : Rev. A
BHARAT PETROLEUM CORP. LTD.
BINA PETROCHEMICAL &
REFINERY EXPANSION
PROJECT (BPREP)
 The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that
they will not be reproduced, copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.

NEW DELHI
ENGINEERS INDIA LIMITED
PROJECT (BPREP)
REFINERY EXPANSION
BINA PETROCHEMICAL &
BHARAT PETROLEUM CORP. LTD.

REV.
DATE
REVISION
BY
CHK
APPROVED
APPROVED
SPECIFICATION NO.
REV.

1-1641-0503 REV.0 A3-420x297

Page 734 of 1510 : B933-011-CC-MR-6101-2-RFQ : Rev. A

 Page 735 of 1510 : B933-011-CC-MR-6101-2-RFQ : Rev. A
BHARAT PETROLEUM CORP. LTD.
BINA PETROCHEMICAL &
REFINERY EXPANSION
PROJECT (BPREP)
 The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that
they will not be reproduced, copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.

NEW DELHI
ENGINEERS INDIA LIMITED
PROJECT (BPREP)
REFINERY EXPANSION
BINA PETROCHEMICAL &
BHARAT PETROLEUM CORP. LTD.

REV.
DATE
REVISION
BY
CHK
APPROVED
APPROVED
SPECIFICATION NO.
REV.

1-1641-0503 REV.0 A3-420x297

Page 736 of 1510 : B933-011-CC-MR-6101-2-RFQ : Rev. A

 The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that
they will not be reproduced, copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.
300 1860 202

SCH

VANES
3''
PIPE 40S
1000 E
60° K
THK 12

WEAR PLATE
SECTION D-D
THKL
12
200 (WEAR PLATE)
2262
1868

TOP
BOTTOM
PLATE
DETAIL D1

PLATE
THKL
12 THKL
12
200

200
200

STIFFENERS
SECTION K-K
SECTION E-E
THKL
12 THKL
12

SIDE PLATE

SUPPORT PIPES ISOMETRIC VIEW FOR VAPOR HORN

DETAIL D1
15x45
182 THKL
12

CHAL

END PLATE
250
200

12
THK
R300

SECTION F-F
02 100 12
(TYP)
100
20 THK

STIFFENERS
200 1450 200 1050 R300 200 650

THK
R300
R300
SECTION J-J
02
(TYP) 100
12
TYPL
200 SECTION H-H
02 (TYP)
100
THK
12 SECTION G-G
02 THK
12
(TYP)
100
TYPL
150
3x150=450
20 12

STIFFENERS
STIFFENERS
STIFFENERS
6x200=1200
20 THK 12 4x200=800
TYPL
200
20 150
THK
12 (TYP) THK

PLUG 20
30 (TYP) (TYP)
300

SECTION
MANHOLEL-L
OLDL
30''
MH2 WEAR PLATE

WEAR PLATE PLUG WELDING DETAIL

WEAR PLATE
HEIGHT (TYP)
300

NEW DELHI
ENGINEERS INDIA LIMITED
PROJECT (BPREP)
REFINERY EXPANSION
BINA PETROCHEMICAL &
BHARAT PETROLEUM CORP. LTD.

REV.
DATE
REVISION
BY
CHK
APPROVED
APPROVED
SPECIFICATION NO.
REV.

1-1641-0503 REV.0 A3-420x297

Page 737 of 1510 : B933-011-CC-MR-6101-2-RFQ : Rev. A

 The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that
they will not be reproduced, copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.
VANES PIPE 40S
SCH
300 3''

E
E
1860 202
THK 12

WEAR PLATE
SECTION D-D
1000
12 60° K

THKL
200 (WEAR PLATE)
2262
1868 DETAIL D1

TOP
THKL

BOTTOM
PLATE
PLATE
STIFFENERS SECTION K-K SECTION E-E
200
THKL
12 200
THKL
12

SIDE PLATE

SUPPORT PIPES ISOMETRIC VIEW FOR VAPOR HORN

THKL
12

DETAIL D1
CHAL
15x45
182 THKL
12

END PLATE
THK
12 250
200
R300

(TYP)
SECTION F-F
200 1050 02 100 12
100
20 STIFFENERS
THK

THK 12
200 1450 R300 THK
12 R300 THK
12
TYPL
150
200 650
R300

(TYP)
SECTION J-J
SECTION H-H
SECTION G-G
02 100
6x200=1200
20
TYPL
200 THK STIFFENERS
02
12 (TYP)
100
4x200=800
TYPL
200
20 THK
12 02 (TYP)
100
3x150=450
20 STIFFENERS
THK
12

STIFFENERS
150 30 (TYP) PLUG 20

SECTION
MANHOLEL-L
OLDL
(TYP) (TYP)
300

WEAR PLATE
30''
MH2

WEAR PLATE PLUG WELDING DETAIL

WEAR PLATE
HEIGHT

NEW DELHI
60
°

ENGINEERS INDIA LIMITED

12
12
THK

THK

PROJECT (BPREP)
REFINERY EXPANSION
BINA PETROCHEMICAL &
BHARAT PETROLEUM CORP. LTD.

REV.
12
THK

DATE
REVISION
BY
CHK
APPROVED
APPROVED

30
SPECIFICATION NO.
REV.

1-1641-0503 REV.0 A3-420x297

Page 738 of 1510 : B933-011-CC-MR-6101-2-RFQ : Rev. A

 JOB SPECIFICATION FOR DOCUMENT No.
TRAYS & TOWER INTERNALS B933-011-80-46-SP-6101
(ENGINEERED BY EIL) FOR Rev-A
CRUDE COLUMN Page 1 of 10

JOB SPECIFICATION
FOR
TRAYS & TOWER INTERNALS
(ENGINEERED BY EIL)
FOR
CRUDE COLUMN

PROJECT : BINA PETROCHEMICAL & REFINERY EXPANSION

PROJECT (BPREP)

OWNER : BHARAT PETROLEUM CORPORATION LIMITED

EPCM : ENGINEERS INDIA LTD.

JOB NO. : B933

A 13.12.24 ISSUED WITH MR BB UT JA/IK

Rev. Prepared Checked Approved
Date Purpose
No by by by

Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved

Page 739 of 1510 : B933-011-CC-MR-6101-2-RFQ : Rev. A

 JOB SPECIFICATION FOR DOCUMENT No.
TRAYS & TOWER INTERNALS B933-011-80-46-SP-6101
(ENGINEERED BY EIL) FOR Rev-A
CRUDE COLUMN Page 2 of 10

1.0 INTENT

This specification defines the additional requirements for Residual Engineering,

Material Procurement including bought-out components, Fabrication, Assembly at
shop, Inspection/Testing, Packing, Supply and Installation of Trays and Tower
Internals.

Fabrication, supply and installation shall include all the components such as valve
trays / chimney trays, lattice girders, major beams, feed pipe distributors, vapor horn
(inlet feed device) etc. collectively called as Tower Internals. These Tower internals
are required for Crude Column (Item No. 11-C-00-2001). This column belongs to
CDU unit of Bina Petrochemical and Refinery Expansion (BPREP) Project for M/s
BPCL, India. A brief description of Internals required for this column is as follows:

S. Item Description Column

Detail of column Internals MOC
No. (Column No.) I.D. (mm)
Four pass Valve trays #1-6 SS 410S
3500 and Seal pan below #1
Chimney tray above tray #6 SS 410S
One pass Valve trays #7-15 SS 410S
and Seal Pan below #7
Chimney trays SS 410S
- CT#1 above tray #15
Four pass Valve trays #16- SS 410S
18 and Seal Pan below#16
Two pass Valve trays #19- SS 410S
30 and Seal Pan below #19
Chimney tray CT#2 above SS 410S
CRUDE
tray #30
1 COLUMN
Four pass Valve trays #31- SS 410S
(11-CC-00-2001)
7000 33, Seal Pan below tray
#31
Two pass Valve trays #34- SS 410S
43 and Seal Pan below #34
Chimney tray CT#3 above SS 410S
tray #43
Four pass Valve trays #44- SS 410S
46, Seal Pan below tray
#44
Two pass Valve trays #47- SS 410S
59 and Seal Pan below #47
Two pass Valve trays #60 Monel (SB127)

2.0 GUIDELINES FOR SUBMITTING OFFERS

2.1 Vendor to note that no correspondence shall be entered into or entertained after offer
submission.

Trays & Tower Internals shall be procured mandatorily from any of the EIL approved
vendors as per list included in this specification. Complete Trays and Tower Internals
for column shall be procured from a single vendor only.

Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved

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 JOB SPECIFICATION FOR DOCUMENT No.
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(ENGINEERED BY EIL) FOR Rev-A
CRUDE COLUMN Page 3 of 10

2.2 Vendor shall submit quotation only for those items, which he can supply strictly as
per MR specifications and for which Trays/Internal Supplier for this column is already
registered with EIL. Any product for which Trays /Internal Supplier is not listed with
EIL, offer shall be liable for rejection.

2.3 No technical details of any nature shall be included in the offer with respect to
Internals detailed in this specification. If the offer contains any technical deviations or
clarifications or stipulates any technical specifications (even if in line with the MR
requirements), the offer shall be liable for rejection. However, for items where the tray
/ internal supplier has entered into MOU with EIL, he may state that the deviations
are as per MOU with EIL.

2.4 The submission of prices by the vendor shall be construed to mean that he has
confirmed compliance with all technical specifications of the corresponding item(s).

2.5 Vendor to ensure submission of “Technical Compliance Statement” as per Doc. No.
B933-11-80-46-TCL-6101 has been filled-in, signed, stamped and submitted on
Letterhead of Internals Supplier along with offer.

2.6 Ensure that Unit Rates for addition/deletion for Trays and tower internals have been
quoted.

2.7 Column Fabricator shall obtain offers from Trays/Internals Supplier for Crude Column
Trays and shall submit Technical Compliance Statement from these suppliers to EIL
alongwith the main offer. Order can be placed only among the tray vendors, whose
Technical Compliance Statement have been furnished with the offer.

2.8 While quoting following shall be ensured/noted.

2.8.1 Vendors shall quote item-wise prices as per MR format for the column.

2.8.2 Vendors, after studying the contents of this specification and attachments to
requisition, may decide to obtain clarifications before making their offer. Any
ambiguity shall be discussed and concluded at the pre bid stage only and once
having done so, the offer shall be in strict compliance to the requirements and
technical specifications of this package i.e. various technical
specifications/drawings/documents as referred to in this specification and other
attachments of requisition.

Any deviation to this and referred specifications should have prior approval of Owner
/ EIL. All such deviations shall be raised at pre bidding stage (i.e. before submission
of bid). Clarifications/ deviations listed in the bid documents shall not be considered
during offer evaluation.

2.8.3 Design and Engineering of Trays and tower internals for Crude Column has been
carried out by EIL and design data has been furnished in the form of Mechanical
Detail Sheet for Trays & Tower Internals (Doc. No. B933-011-80-46-DS-6101).
Vendor to carry out residual engineering and prepare Detail / GA Drawing for Trays.

2.8.4 Any missing document shall be obtained prior to submitting offer.

Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved

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 JOB SPECIFICATION FOR DOCUMENT No.
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(ENGINEERED BY EIL) FOR Rev-A
CRUDE COLUMN Page 4 of 10

2.8.5 The “Nozzle Orientation Drawing” and “Tower Attachment Drawing” for the column
shall be given to successful Vendor at Post Order Stage. These drawings are
mandatorily required to be followed during Residual Engineering of internals.

3.0 SPARES
Following Spares shall be supplied:
3.1 Mandatory Spares shall be supplied as per clause 7.1 of Specification No. 6-14-0008.

3.2 Erection & Commissioning Spares:

i) Erection & Commissioning spares shall be supplied as per clause 7.2 of
Specification No. 6-14-0008.
ii) In addition to above following plates shall also be supplies as erection &
commissioning spares. These plates may be used for minor modification work, if
required at site.

Item Size MOC Qty.

Plate 2m x 1m x.3.0mm thk SA240TP410S 01 No.

Plate 2m x 1m x.5.0mm thk SA240TP410S 01 No.

Plate 1m x 1m x.3.0mm thk SB127 (Monel) 01 No.

3.3 Unused Erection & Commissioning Spares after completion of the Site work shall be
handed over to the Owner.

4.0 SCOPE OF WORK/SUPPLY

4.1 TRAYS & TOWER INTERNALS (ENGINEERED BY EIL)

EIL has carried out the Hydraulic Design and Mechanical Design of trays/ internals
for this column and details have been furnished in the form of Mechanical Detail
Sheets for Trays & Tower Internals. Tray Vendor’s scope of work/supply for this
column includes Residual Engineering, Fabrication, Inspection/Testing, Packing,
Supply and Site Installation as per Mechanical detail sheets and other documents
enclosed with this requisition.

4.1.1 All supporting/fixing arrangement (i.e. Tray Support Rings / Bolting Bars etc.) required
to be welded to column for the fitment of Internals shall be designed by EIL & detail
Drawings (Issued for Construction) for the same shall be furnished to successful
vendor at post order stage. These shall be Procured, Fabricated, Supplied and
Installed by Vendor (Column fabricator).

4.1.2 VAPOR HORN FOR NOZZLE “F” (ENGINEERED BY EIL)

The supply of Vapor Horn is excluded from the scope of Internal supplier and is kept
in the scope of Column fabricator. EIL has carried out the Hydraulic and Mechanical
Design of Vapor Horn at Nozzle F – (42” NB) and detail for the same has been
enclosed with this requisition in the form of Drawing (No. B933-011-80-46-SK-6101).

Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved

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 JOB SPECIFICATION FOR DOCUMENT No.
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(ENGINEERED BY EIL) FOR Rev-A
CRUDE COLUMN Page 5 of 10

Vendor’s (i.e. Column Fabricator) scope of work/supply for Vapor Horn includes
Fabrication, Inspection/Testing, Supply and Installation as per Job Specification /
Mechanical Data Sheet, Approved GAD and other documents enclosed with this
requisition.

Material of Vapor Horn shall meet all requirement of Shell MOC, as indicated in the
Job Specification / Mechanical Data sheet of the Crude Column.

4.1.3 Feed Pipes for Nozzle ST (Stripping Steam), CR1 (PA Return), CR2 (PA Return),
CR3 (PA Return) & R (Reflux) & their supporting arrangement shall be Fabricated,
Supplied & installed by Column Fabricator. The schematic details for the Feed Pipes
are provided in MDS of the Crude Column.

Column fabricator to carry out complete detailing of feed pipe & supporting
arrangement and get it approved from EIL.

4.2 Fabrication, Supply & Installation of all the trays & tower Internals as mentioned
above at Clause 1.0 of this specification including all tray components, girder
components, beams etc. as detailed out in “Mechanical Detail sheet for Trays &
tower Internals” attached with the requisition shall be in the scope of “Tray & Internal
Supplier” only.

5.0 SPECIAL TECHNICAL REQUIREMENTS

In addition to various requirements indicated in the requisition & its attachments,

following shall also be applicable.

5.1 Following change regarding ITP (Spec No. 6-81-0015 Rev-1), “Inspection and Test
Plan for Trays and Tower Internals” is made.

i) S. No. 3.5:- Refer DP of Welds, 100 % DP test shall be carried out for welds of
load bearing components while 10 % random DP test shall be carried
out for welds of other locations.

5.2 Vendor to note that all internals shall be designed to pass through the manhole size
as indicated in Vessel Design Data. Maximum diagonal dimension of the components
shall be restricted to Vessel manhole ID – 12mm clearance.

5.3 Lock-nuts wherever specified, are to be provided on all edge clamps (except at
manways), downcomer & seal pan boltings.

5.4 All lattice girders and major beams at bolting bar location shall be provided with
locknuts irrespective of locknut location specified in the EIL drawings.

5.5 Approximate bolting/clamping pitch to be adopted shall be as below:

Ungasketed Internals - 120 to 140 mm

Gasketed & Stiffened Internals - 80 to 110 mm
and Manways

5.6 For gasketed construction, all clamps & boltings shall be provided with gasket washer
along with metallic washer. Size of gasket washer shall be same as of metallic

Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved

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 JOB SPECIFICATION FOR DOCUMENT No.
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(ENGINEERED BY EIL) FOR Rev-A
CRUDE COLUMN Page 6 of 10

washer except hole diameter, which shall be 9.0 mm for gasket washer instead of
11.0 mm for metallic washer. Also, all internal pipe or conduit flanges shall have
suitable gaskets.

5.7 The load bearing members (beams) which require butt welding of two or more parts
shall be provided with splice joint.

5.8 In the event of conflict among the various documents attached with the Requisition,
following order of precedence shall apply. However, as a general rule, more stringent
requirement shall govern:

 Statutory Requirements.
 This specification and other job specifications.
 Mechanical Detail Sheets & TSR/BB Drawings
 Datasheets
 Standard specifications, standards, ITPs etc.
 Codes and Standards.

However, all such conflicts shall be referred to Owner / EIL for clarification and the
decision of Owner / EIL shall be final and binding on the vendor without any cost and
delivery implications.

5.9 Trays & Tower Internals shall be procured from EIL approved vendors as per list
given in Clause 12.0 only.

5.10 All SS Material shall be pickled & passivated as per ASTM A380 & EIL Specification
6-14-0008.

6.0 DRAWINGS AND DOCUMENTS

6.1 Vendor to note that all vendor drawings/documents submission shall be strictly as per
EIL Specification No. B933-011-80-46-VDR-6101 attached with the requisition.

6.2 All drawings / documents for Trays & Tower Internals of Internal Supplier shall be
reviewed & signed by vendor (Column Fabricator), prior to submitting to client/EIL for
code Approval.

6.3 Vendor to note that EIL shall NOT PROVIDE any GA Sketches/Layout Sketches for
trays. Tray Vendor shall prepare GA Drawings based on the EIL Specification No. 6-
14-0018 (i.e. Guidelines for preparation of General Arrangement Drawings) and other
relevant standards enclosed with this requisition and submit as per approved DCI.

6.4 Preparation & Submission of Document Control Index (DCI):

a). Vendor shall prepare Document Control Index (list of drawings / documents,
which are to be submitted to EIL along with the submission dates for each
drawing) within 07 days of placement of FOI. Vendor shall strictly adhere to this
drawing submission schedule. Successful bidder shall submit DCI and all the
vendor data through vendor portal only. The detail guidelines for uploading the
documents on vendor portal are available on the site itself.

Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved

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 JOB SPECIFICATION FOR DOCUMENT No.
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(ENGINEERED BY EIL) FOR Rev-A
CRUDE COLUMN Page 7 of 10

b). Vendor to note that unscheduled documents (documents which are not listed in
DCI) shall not be accepted by EIL. All vendor drawings/documents shall be
submitted as scheduled document only.

All subsequent submissions of drawings / documents must contain Compliance

Statement with respect to incorporation of each EIL comment. All subsequent
submissions without revisions clearly marked & compliance statement shall not be
entertained by EIL. Any delay because of this shall be to vendor’s account.

6.5 All drawings shall be prepared on standard drawing sheets with scale chosen such
that all dimensions and details are legible. All drawings shall contain title block with
minimum essential information such as Vendor’s name, Client’s name, Consultant’s
name, Project, Equipment No., Drawing No. and Drawing description. For trays and
liquid distributors GAD’s in ‘A3' size is preferred.

7.0 MATERIAL

All materials shall conform to those specified on the respective Mechanical Detail
sheets for trays. All the materials unless specified otherwise in the requisition for the
fabrication & supply of sheets/plates, bolting etc. shall be in vendor’s scope of supply.
No substitution of material will be permitted without prior approval from EIL. In case of
substitution of material, vendor shall clearly indicate the reason for requiring such
change and giving chemical & physical properties for the alternate material with their
complete standard specification number.

8.0 INSPECTION/TESTING

8.1 EIL shall be the inspection agency for equipment and its indigenous components. All
fabrication activities in vendor shop shall be under EIL inspection and charges for the
same shall not to be included in quoted price. If any components are procured from
abroad, the inspection shall be carried out by TPIA. Quoted price shall include
charges for TPIA only.

For acceptable third party inspection agencies (TPIA), refer commercial documents.

8.2 The Owner’s inspectors / authorized representatives shall have free entry to the
Vendor’s shop at all times where and while the work is being performed. All
reasonable facilities shall be offered to Inspectors to satisfy them that the materials
are being furnished in accordance with the specifications.

8.3 The Vendor shall notify the Client sufficiently in advance of any fabricating operations
to permit the Client’s Inspector to arrive at the Vendor’s shop.

8.4 Any rejection made by Inspector shall be final. Approval/ Inspection by the Owner
and/or his designated representative shall, in no way relieve the Vendor of his
responsibility to meet all the requirements of the Purchase Order.

8.5 Vendor shall prepare a detailed ITP based on the EIL-ITPs for Shop / Site activities
and obtain Client/EIL approval.

Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved

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(ENGINEERED BY EIL) FOR Rev-A
CRUDE COLUMN Page 8 of 10

8.6 Trial assembly of one tray/Internal of each type and size shall be carried out as floor
mock-up inside the fabricator’s shop. Trial assembly shall be witnessed by Client/EIL
representative.

9.0 GUARANTEE

Guarantees shall be as per Clause 11.0 of “Standard Specification for Trays & Tower
Internals”, Specification No. 6-14-0008.

10.0 PACKING & FORWARDING

10.1 Packing and forwarding of Trays and Tower Internals shall be done by Tray vendor in
accordance with EIL Standard Specification No. 6-14-0009 (Packing, Marking &
Shipping Specification for Trays / Tower Internals).

10.2 All components shall be marked with proper Item Nos. to facilitate identification at site
and same shall be as per vendor’s duly approved General Arrangement Drawings.

It will be, however, vendor’s responsibility to ensure that the packing of Trays / Tower
Internals & Associated Internals is adequate for the mode of transportation actually to
be adopted.

10.3 Vendor shall recommend guidelines for safe storage of equipment / items at site for
the period of 6 months or till completion of job as per execution plan, whichever is
later. Equipment / items shall normally be stored at site in the original boxes as
supplied by the vendor, under covered hard stand.

10.4 Material Test Certificates, Test reports, Inspectors’ approval Certificates, release
notes, etc. and two sets of assembly and fabrication drawings are to be enclosed
along with shipment of internals.

10.5 All spares shall be separately packaged and supplied, so as to preserve them in new
condition. These packages shall be clearly tagged with the respective item Nos. and
marked as “Spares”, so as to identify them as and when needed.

11.0 INSTALLATION AT SITE

Vendor (i.e. Column fabricator) shall get the Trays and Tower internals
installed at site by Supplier of Trays & Tower Internals. However, overall
responsibility lies with the Vendor (i.e. Column fabricator). Following is a broad list of
activities to be carried out by vendor at site. Any other work not specifically listed but
required for completion of job shall also be in vendor's scope.

11.1 Survey of column inside and checking the levelness of support rings, cleats, location
of bolting bars to ensure that the same are as per column drawings and within
tolerances specified in Standard 7-14-0001. In case these are not within permissible
tolerances, the same shall be reported to Engineer-in-Charge for necessary
rectification/modification. If desired by Engineer-in-Charge, the same may have to be
carried out by column fabricator to the satisfaction of Engineer-in-Charge.

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(ENGINEERED BY EIL) FOR Rev-A
CRUDE COLUMN Page 9 of 10

11.2 Installation of Trays as per Installation Procedure 6-14-0003 and strictly as per
General Arrangement Drawings for each column under surveillance and stage-wise
inspection of Engineer-in-Charge. All requirements of the drawings shall be complied
with in totality.

11.3 Carrying out minor adjustments, modifications, seal welding of chimney trays, seal
plates etc. wherever necessary during installation.

11.4 Checking of installed Trays and filling of "Installation Reporting Formats" and getting
these counter checked by Engineer-in-Charge as per "Specification for Review of
Installation of Tower Internals". These shall be submitted to Engineer-in-Charge.
Dimensions indicated by installation agency in the “Installation reporting formats”
shall be 100% checked and verified before the same are forwarded to Engineer-in-
Charge.

11.5 Providing following infrastructure facilities and all necessary help/manpower to

Engineer-in-Charge and/or specialist during checking/review of tray installations.

i) Exhaust fan at the column to free it of welding gases, fumes etc. before entry of
EIL-personnel into the column.
ii) Proper lighting arrangement (24V) inside the column.
iii) Rope ladder inside the column in case Trays are not easily approachable from
column manhole.
iv) Any other Access platform and ladders required temporarily for access on certain
portions in addition to permanent platforms/ladders provided by others.
v) Suitable scaffolding and other inspection aids required inside the column.
vi) Water manometer for levelness checking.
vii) Hose pipe connection etc. for supply of water and Teflon tape for sealing
threaded joints.

11.6 Carrying out various leak tests for Seal Pans/Chimney Trays etc. as per requirements
of drawings/specifications. These shall be witnessed by Engineer-in-Charge.

11.7 Attending to Punch List points and carrying out necessary rectifications/
modifications.

11.8 After inspection of the Trays by vendor and Engineer In-Charge, same shall be
inspected by EIL- Specialist and Owner also, before final box-up.

11.9 General Notes

11.9.1 Installation of Trays shall be carried out in the column after Column gets erected.
Tray Installation in horizontal condition is not allowed.

11.9.2 All column interior walls, debris etc. shall be cleaned thoroughly prior to installation
work.

11.9.3 All consumables like electrodes etc. shall be in the scope of vendor. All welding shall
be done by qualified welders only. The electrodes/filler material to be used shall be
compatible with the metallurgy of component and shall be used only after prior
approval of Engineer-in-Charge.

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CRUDE COLUMN Page 10 of 10

11.9.4 It shall be ensured that trays are not used as working platform inside the column. Any
damage caused to these shall be repaired / replaced by vendor free of charge.

11.9.5 While installing the tray decks, vendor shall ensure that valves fitted in the tray decks
are not damaged during handling/installation of trays inside column. All valves shall
be checked for verticality of valve legs so that they do not come out on lifting.
Damaged valves, if any, shall be replaced by vendor from "Constructional Spares"
available at site.

11.9.6 A proposed Welding Procedure Specification (WPS) for any welding to be done at
site shall be submitted to Client/EIL Inspector for his approval. On approval, a
Procedure Qualification Test (PQT) shall be conducted which shall be witnessed by
Client's inspector. On acceptance of all tests as per ASME Section IX, a final WPS
along with Procedure Qualification Record (PQR) shall be submitted. Site welding
shall start only after approval of final WPS/PQR and qualification of welders as
ASME Section IX. Client/EIL Inspector may accept previously qualified WPS/PQR at
his sole discretion.

11.9.7 Opening and closing of manholes shall be in vendor’s scope. Further, Gasket
required for Manholes shall also be in Vendor’s Scope.

12.0 LIST OF EIL APPROVED VENDORS FOR TRAY & TOWER INTERNALS

12.1 TRAYS & TOWER INTERNALS (Item category - 12LA)

S. No. Vendor Remark

i) M/s Godrej & Boyce Mfg. Co. Ltd. (Mumbai)
M/s Munters India Humidity Control Private
ii)
Limited (Thane)
M/s Kamal Encon Industries Limited
iii)
(Yamuna Nagar)
M/s Koch Engineered Solutions India Pvt.
iv)
Ltd. (Baroda)
v) M/s Sulzer India Private Limited (Pune)
vi) M/s Swan Enterprises Pvt. Ltd. (Chennai)

Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved

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 TECHNICAL COMPLIANCE STATEMENT DOCUMENT No.
FOR TRAYS & TOWER INTERNALS B933-011-80-46-TCL-6101
Rev-A
(ENGINEERED BY EIL)
Page 1 of 2

TECHNICAL COMPLIANCE STATEMENT

FOR
TRAYS & TOWER INTERNALS
(ENGINEERED BY EIL)
FOR
CRUDE COLUMN

PROJECT : BINA PETROCHEMICAL & REFINERY EXPANSION

PROJECT (BPREP)

OWNER : BHARAT PETROLEUM CORPORATION LIMITED

EPCM : ENGINEERS INDIA LTD.

JOB NO. : B933

A 13.12.2024 ISSUED WITH MR

BB UT JA/IK
Rev.
Date Purpose Prepared by Checked by Approved by
No

Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved

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 TECHNICAL COMPLIANCE STATEMENT DOCUMENT No.
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Rev-A
(ENGINEERED BY EIL)
Page 2 of 2

Annexure-I
Sheet 1 of 1

TECHNICAL COMPLIANCE STATEMENT

(TO BE SIGNED BY VENDOR'S PRINCIPAL CORPORATE LEVEL SIGNATORY ON COMPANY LETTERHEAD)

I, ON BEHALF OF M/s_____________________________________________ CONFIRM THAT

THE PROPOSAL OF TRAYS & TOWER INTERNALS (ENGINEERED BY EIL) FOR CRUDE

COLUMN (Col. No. 11-CC-00-2001) QUOTED BY M/s

______________________________FOR BINA PETROCHEMICAL & REFINERY

EXPANSION PROJECT (BPREP) AGAINST MATERIAL REQUISITION

/TENDER/PACKAGE No. B933-011-CC-MR-6101 IS IN TOTAL COMPLIANCE TO THE

FOLLOWING:

A. SCOPE OF SUPPLY AND WORK

B. MECHANICAL DETAIL SHEET FOR TRAYS & TOWER INTERNALS
C. EQUIPMENT DATA SHEETS
D. BATTERY LIMIT/INTERFACE REQUIREMENTS
E. TECHNICAL AMENDMENT IF APPLICABLE
F. ANY OTHER DOCUMENT ATTACHED AS PART OF MR

AS WELL AS ALL THE TECHNICAL SPECIFICATION AND NO DEVIATION,

VARIATION OR RESERVATION WHATSOEVER HAS BEEN MENTIONED IN THE
TECHNICAL OFFER. IT IS FURTHER AGREED THAT THE TECHNICAL DETAILS
FURNISHED IN OUR OFFER WILL BE REVIEWED BY EIL/CLIENT DURING
DETAILED ENGINEERING STAGE AFTER ORDER AND ANY CHANGE REQUIRED TO
MEET THE REQUIREMENTS OF ENQUIRY SCOPE AND SPECIFICATION INCLUDING
AMENDMENT(S) (IF ANY) WILL BE INCORPORATED BY US WITHOUT ANY PRICE AND
TIME IMPLICATION.

(SIGNATURE WITH SEAL) (SIGNATURE WITH SEAL)

TRAY & TOWER INTERNAL SUPPLIER COUNTER SIGNED BY BIDDER

Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved

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 Document No.
VENDOR DATA REQUIREMENTS B933-011-80-46-VDR-6101
FOR Rev. A
COLUMN -TRAYS (ENGINEERED) Page 1 of 2

VENDOR DATA REQUIREMENTS

FOR
COLUMN -TRAYS (ENGINEERED)

A 13-DEC-2024 ISSUED FOR BIDS BB UT JA/IK

Rev. Date Purpose Prepared by Checked by Approved by
No.

Format No. EIL-1642-1924 Rev.1 Copyright EIL - All rights reserved

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FOR Rev. A
COLUMN -TRAYS (ENGINEERED) Page 2 of 2

VENDOR DATA REQUIREMENTS

The following drawings/documents marked " " shall be furnished by the bidder.

TRAYS & TOWER INTERNALS (ENGINEERED) TYPE I

POST ORDER
S. WITH WITH
N DESCRIPTION FOR FOR DATA REMARKS
BID
O. REVIEW RECORD BOOK
(FINAL)
1. General Arrangement Drawings for Trays &
Tower Internals
2. Bill of Material
3. Material Test Certificates @

4. Inspection Records / Data (including WPS/ @

PQR)
5. List of Spares
6. Fabrication Schedule @

7. Site Installation Reporting Format (attached

with 6-14-0016) dully filled and signed

Notes :
1. "TICK" denotes applicability.
2. Post order, drawing / document review shall commence only after approval of Document Control Index (DCI).
3. All post order documents shall be submitted / approved through EIL eDMS portal.
4. Final documentation shall be submitted in hard copy (Six prints) and soft ( two CDs/DVDs ) in addition to
submission through EIL eDMS.
5. Refer - 6-78-0001: Specification for quality management system from Bidders.
6. Refer - 6-78-0003: Specification for documentation requirement from Suppliers.
7. All drawings & documents shall be submitted in A4 or A3 paper sizes. Documents in higher paper size shall
be submitted in exceptional circumstances or as indicated in the MR/Tender.
8. Post order- The schedule of drawing / data submission shall be mutually agreed between EIL & the bidder /
contractor / supplier during finalization of Document Control Index (DCI).
9. "@" indicates submission of documents to Inspection Agency.
10. Bill of Material shall form part of the respective drawing.

Format No. EIL-1642-1924 Rev.1 Copyright EIL - All rights reserved

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PAINTING MANUAL

INSPECTION & ADVISORY SERVICES

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REVISION SHEET

EDITION : NOVEMBER 2020

DOCUMENT NO. : SOP/09/11 – Rev-2

2 Vijay Sankhare Ashish Dane Deepak P. 20.11.2020 Amendment of Tank

Chandramore External surface Painting
Specifications For Crude
tanks of Refinery as well
as COT, Internal painting
of Crude tank for COT,
Building and RCC
structure painting, TSA
coating, inclusion of
performance formats,
Removal of Camouflaging
etc.
1 Sonali Palekar Ashish Dane Mohan Mate 10.12.2018 Formatting revised as per
IMS, New painting
specification for U/G CBD
lines, Equipment Specific
painting system, ATF
Service paint, Separate
painting specifications for
maintenance & prject
works
0 Ashish Dane Ashish Dane Narendra Pandey 27.06.2013 Nil
Rev No. Prepared By Reviewed By Approved By Date of issue REMARKS

BHARAT PETROLEUM CORPORATION LIMITED, (BINA REFINERY), BINA

DISTRICT- SAGAR, MADHYA PRADESH- 470124

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PREFACE

Bharat Oman Refineries Limited has number of static equipment and structures. Painting of these
equipment & structures is essential to enhance their life as well as to improve aesthetics of unit.
The painting technology is growing more rapidly day-by-day and it has attained a higher position in
almost all areas where nothing is said to be complete without painting as far as material world is
concerned. Present practices of painting leave a lot of scope for improvement of quality control in
respect of surface preparation, selection of paints and workmanship. In view of the same need was
felt to revise the existing painting manual to include new painting specification, capture latest
technological advancement and prepare more user friendly painting manual. Through this manual,
an attempt has been made to provide the knowledge about the latest painting practices including
surface preparation, types of paints and equipment specific painting for internal painting of
equipment. The time-bound painting as suggested in this manual shall be adopted for obtaining
good quality painting and overcome the ageing or adverse effects of environment.

Improvement is a continuous process and if at any stage, anything is to be revised due to

advancement in paint technology, will also be incorporated in future. We take this opportunity to
thank all those who directly or indirectly helped us in our endeavor of continuous improvement.

Deepak P. Chandramore

JSVP (Inspection & Advisory Services)

Date : 20th November 2020

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CONTENTS
SR.NO DESCRIPTION PAGE NO
1.0 INTRODUCTION 5
2.0 SCOPE 5
3.0 GENERAL INFORMATION 5
4.0 CODES & STANDARDS 18
5.0 PHILOSOPHY & GUARANTEE 19
6.0 RESPONSIBILITIES 20
7.0 HEALTH & SAFETY 20
8.0 TOOLS & EQUIPMENT 21
9.0 STORAGE 21
10.0 SURFACE PREPARATION 22
11.0 PAINT APPLICATION 26
12.0 MAINTENANCE PAINTING 41
13.0 PAINT MATERIALS 42
14.0 PAINT SYSTEMS 48
15.0 TEMPERATURE INDICATING PAINT 68
16.0 FIRE RETARDANT PAINT 68
17.0 COLOR CODE FOR PIPING 70
18.0 INSPECTION & TESTING 77
19.0 PAINT PERFORMANCE EVALUATION 83
20.0 GENERAL INSPECTION GUIDELINES 85
21.0 PACKAGING & LABELING 86
22.0 RECORDS & REPORTS 86
23.0 PROCEDURE FOR DFT MEASUREMENT 87
24.0 EXTERNAL PAINTING OF TANKS 93
25.0 CRUDE OIL TANKS PAINTING 94
26.0 SPECIFICATION FOR TSAC 117
27.0 BUILDING & RCC STRUCTURE PAINTING 129

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1.0 INTRODUCTION

In our day-to-day life we come across many equipment/items which are either painted / coated. The
paints at different locations i.e. house hold items or in industry, have their own significant role to play.
In majority of the cases in household items the painting/coating is used for decorative purpose while
in industry, corrosion protection is of prime consideration.

In Refinery, plant equipment/structures/piping are exposed to low and moderate to severe corrosive
atmosphere, leading to direct and indirect losses for an industry. To prevent such losses, proper
maintenance must be done by applying protective paint/coating on plant machineries. Timely
inspection and preventive maintenance will help in making equipment safer to use for longer periods
of time.

2.0 SCOPE

This document outlines the procedure of painting works at Bharat Oman Refineries Limited. It gives
requirement and recommendation for the surface preparation and the application of external painting
and coating of metallic components exposed to atmospheric condition (irrespective of whether it will
be insulated). This manual does not restrict the use of any improved paint system but same shall be
referred to Inspection Dept. prior to use. This document also covers the following:

• Painting of all new pipelines/ structures and equipment during erection.

• Repairing/ Re-painting over existing equipment/ pipe lines/ structures.

• Internal painting of above ground storage tanks & vessels.

• Painting/coating of underground piping

3.0 GENERAL INFORMATION

3.1 Definition of Paint/coating

Paints are commonly called ‘Surface coatings’. A paint may be defined as a solution or suspension
(emulsion) of pigment, binder, and mineral solvent (or water) that on drying forms an adhering film on
the surface. It is applied for protection and / or decoration or to perform some other specialized
function.

Generally, the term “Paint” and “Coating” may be used interchangeably, but coating has become
more commonly associated with specialized application. In wider perspective, painting is a part of
coating.

Coating can be single or multi component, metallic, non-metallic and has many process by which
application is done like Hot dip galvanizing, Electroplating, Sputtering etc.

For industrial purpose paint/coating is generally carried out for corrosion protection purpose.

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3.2 What is Paint / Coatings:

Paint is mechanical mixture or dispersion of pigments or powder, at least some of which are normally
opaque with a liquid or medium known as the resin (vehicle), applied to a surface that dries or cures
to form an aesthetically pleasing protective film. The film thickness may range from few microns to 0.5
mm.
The paint mainly consists of Resin (Vehicle), Pigments, Special additives & solvent that evaporates
shortly after application. Following block diagram represent paint system.

PAINT

Mechanical mixture or dispersion of

Resin Pigment Special Additives Solvent

cial Additives
Function of ingredients

Film formation, Decorative, Opacity, Modify property Improve application

continuity & color, Resistance to of either vehicle property
adhesion corrosion or pigmentation

3.2.1 Resin (vehicle)

Resin portion of the paint will normally consist of non-volatile portion which will remain as part of the
paint film & a volatile portion which will evaporate, thus leaving the dry film. The dried film will
therefore consist of pigment & non-volatile resin.

Commonly, paint is designated by their resin components (such as vinyl, chlorinated rubbers, epoxies
etc.) The chemical & atmospheric resistance of the paint is dependent on the specific properties of
the film former i.e. resin/vehicle. Many paints are available in the market with different resin having
different application.

Vinyl resin, Epoxy resin, Polyester resin, Acrylic resin, Rubber based resin, Chlorinated resin,
Urethanes etc. are the few important resins which are used in paint generally for industrial
application.

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3.2.2 Pigments

Pigments are finely divided, insoluble solid particles that are dispersed in the binder/resin and remain
suspended in the binder after film formation. The role of pigments in the paint coatings is

• To provide color and reinforcement

• To hide the surface

• To decrease the permeability of the film

• To provide rust inhibiting characteristics and

• To protect the film from the effect of ultraviolet light and weathering.

Pigments used in the paint industry may be divided into two broad groups’ viz. Main pigments and
Extenders. Main pigments determine the function of the coating (primer, undercoat, topcoat etc.)
They once again may be divided in to three categories viz. Inhibitive pigments, Inert pigments,
Metallic pigments.

3.2.2.1 Inhibitive pigment

The main inhibitive pigments used in paints are red lead, lead silicochromate. Zinc chromate, zinc
phosphate, calcium plumbate etc. They are mainly used in primers. The mechanism of inhibition of
corrosion differs from one pigment to another.

3.2.2.2 Inert pigment

The main inert pigments used in the paint industry are red iron oxide, micaceous iron oxide, titanium
dioxide etc. They have very good hiding property.

3.2.2.3 Metallic pigment

Metallic pigments normally used are aluminum pigment and zinc dust. Aluminum pigments are used
because of their excellent properties such as brilliance, durability, high covering and hiding power and
high resistance to atmospheric corrosion. Aluminum pigments are mainly produced by wet milling in
white spirit. There are two major classes of aluminum pigments used in coatings: “leafing”
and “non - leafing” pigments.

Leafing aluminum pigments have been surface treated (e.g. with stearic acid) so that they have a
very low surface tension. When a coating containing leafing aluminum pigment is applied as a result
of their low surface tension, flakes orient at the surface. This gives a bright metallic appearance and,
furthermore, acts as a barrier to permeation of oxygen and water vapor through the film. As a result of

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this barrier development, leafing aluminum pigments are used in corrosion protection topcoats for
steel structures.

Non leafing aluminum pigments are used more to produce aesthetic metallic effects in paints,
particularly automobile finishes.

Zinc dust is used as pigments in anticorrosive primers. Zinc rich primers can provide an effective
longer life to a paint system when applied over well prepared surface. It is used with organic as well
as inorganic binder.

3.2.2.4 Extenders

Extenders are inert pigments usually inexpensive and of low refractive index, that are added to the
paint to modify its properties and to reduce costs. As most of them being white in color extenders may
be used for any one of several reasons outlined here, lowering the paint cost, increasing pigment
volume, flattening, and tooth for primers, better brushing, consistency control and better suspension.
Most widely used extenders are silica, mica, talc, china clay etc. and their specific purposes are as
follows:

• China clay increases the toughness of a paint film because of its plate like structure.

• Talc reduces the settling tendency of pigment because of its acicular nature.

• Mica reduces the permeability of a paint film to moisture because of its lamellar nature.

3.2.3 Solvents

The most important property of solvents is to reduce viscosity so that coating can be applied either by
brush, roller, dipping, or spraying. Besides this most important property, the solvent controls setting
time of paint, leveling or flow, gloss, drying time, durability, sagging tendencies etc.

3.2.4 Additives

This group of raw material is used in relatively small amounts to give coatings certain necessary
property. Additives compositions are not normally revealed by manufacturer. Cobalt & manganese
naphthanates are used as dryers for alkyds & other oil based coatings to facilitate surface & thorough
drying. These drying additives are added to the paint less than 0.1%.

3.3 Mechanism of protection by Paints/Coating

As the process of corrosion is based on an electrochemical reaction between steel and its
environment, corrosion protection is achieved by coatings through any one of the following
mechanisms.

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• Suppression of anodic reaction

• Suppression of cathodic reaction

• Introduction of high electrical resistance between the metal and the environment so as to
prevent flow of corrosion current (barrier mechanism).

3.3.1 Suppression of anodic reaction

The anodic reaction may be suppressed by either applying zinc rich primer over the metal or applying
a primer containing an inhibitive pigment like zinc chromate, zinc phosphate etc. The zinc rich primer
may be an organic type wherein a high percentage of zinc powder (above 90 %) is incorporated in
organic binder like epoxy or chlorinated rubber. Zinc, being anodic to steel protects the steel by
sacrificing itself. Zinc supplies electrons and suppresses the anodic reaction of steel thus protecting
steel. The other type of zinc rich primer is the inorganic zinc ethyl silicate primer where zinc powder is
incorporated in an inorganic ethyl silicate binder. Here also the mechanism is the same i.e. sacrificial
protection. The inorganic system due to the higher conduction of inorganic binder compared with
organic binder is more effective in getting sacrificial protection and also it can withstand higher
temperatures compared to organic systems.

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The other way of suppressing anodic reaction is by applying a primer containing inhibitive pigments
like zinc chromate, zinc phosphate, calcium plumbate, red lead, lead silico chromate or lead
suboxide. These pigments passivate the metal by providing ions which react with the metal and
reduce its tendency to corrode.

3.3.2 Suppression of cathodic reaction

Suppression of cathodic reaction is difficult with paint film of normal thickness as they are easily
permeable to both moisture and oxygen. Hence this is achieved by providing paint films of very high
thickness (high build coating) and having very low MVTR (Moisture Vapor Transmission Rate)
examples - epoxies. This role is played by the undercoat in a paint scheme. Employing micaceous
iron oxide (MIO) as pigment in the undercoat still reduces permeability.

3.3.3 Barrier Mechanism

This is the most general and popular mechanism of protection by paints, which is achieved by
applying a barrier film of very high electrical (ionic) resistance between the metal and the corrosive
environment. The barrier film impedes the movement of ions thereby preventing flow of corrosion
currents. The ions cannot pass between anodic and cathodic areas and hence corrosion is
prevented. Highly cross-linked polymer films have the highest ionic resistance, e.g., epoxy, polyester,
polyurethane, phenolic etc. Obviously ionic resistance increases with paint film thickness.

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A paint scheme consisting of a primer, undercoat/s and topcoat, utilizes the advantages of all the
three types of mechanisms of protection described above and provides protection in a corrosive
environment. This also justifies the recommendation of multi coat systems to a severe environment.

3.4 Selection procedure/Criteria for Paint-coatings

The main criteria for selection are the Environment/Atmosphere around the structure or item to be
protected. Following points should be considered for selection of paint/coatings:

• Environment/Atmosphere is wet / dry. If wet, is it by fresh water or salt water.

• Chemical exposure/contamination due to acid/alkali.

• Environment/Atmosphere uniformity throughout the structure.

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• Environment/Atmosphere predominantly a weathering subject to heat, cold, daily or seasonal

temperature changes, precipitation, wind (flexing), exposed to sunlight or detrimental solar
rays.

• Importance with respect to Decorative appearance or Corrosion protection.

3.5 Common Industrial Coating/Resins

The most & widely used coatings are Vinyl resins, Epoxy resins, Alkyd Resin, Acrylic resin, Rubber
based resin etc. Following is the brief information about the above coatings.

3.5.1 Vinyl Resins

• Resins are polymers of either Polyvinyl chloride or polyvinyl acetate.

• This exhibits exceptional resistance to corrosive agents, chemical, water, alcohol, acids &
alkali.

• Coatings obtained from these resins are unaffected by strong or weak acids (except formic
and acetic acids); by strong or weak alkalis (except ammonia which diffuses through the film);
by many corrosive liquids such as mixtures of sulfuric acid and potassium dichromate,
aquaregia etc. or by oxidizing or reducing agents; by petroleum hydrocarbons, alcohols,
grease or water.

• Coating is highly resistant to corrosion by chlorides (salt spray).

• Droplets of plastic binder float in a water emulsion. When the solvent evaporates, the droplets
merge and polymer cross link to form paint film.

• Vinyl paints are highly corrosion resistant and applied to ships, hulls, immersed structures in
marine environments and in industrial areas, where all types of chemical fumes are met with.
Also suitable as linings for beer cans, juice can etc. as inner food can coatings, for concrete
swimming pools and other masonry surfaces.

• Limitations are: (i) a low-solid solution is only possible (around 30%) making the covering area
per litre of paint low and hence paint is costlier per unit area of surface; (ii) Poor adhesion to
metals (improved by adding maleic anhydride in the structure or by a blast primer); (iii)
decomposition possible at elevated temperatures; (iv) PVA has poor chemical & UV
resistance and does not weather well. Vinyl stabilizing additives are required to gain UV
resistance; (v) these are poor quality latex coatings for exterior application: look for 100%
acrylics instead.

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3.5.2 Epoxy Resins

• These are more correctly called epichlorohydrin bisphenol resin. These have excellent
durability, hardness & chemical resistance.

• Most of the epoxy resins used in surface coatings is made from bisphenol A and
epichlorohydrin in varying proportions depending upon the property desired. The most popular
type epoxy resin is the DGEBA-diglycidyl ether of bisphenol-A.

• Coatings based on epoxy resins are two-pack systems one containing the resin part and the
other the hardener or curing agent part. Just before application, these two are thoroughly
mixed and applied within the given pot lifetime. After application, they cross-link at room
temperature to give dry films of good thickness per coat and outstanding properties.

• Epoxy resins form a hard, durable finish which is highly moisture and alkali resistant, with
excellent adhesion to most surfaces.

• Epoxies typically have low water vapor permeability; though more permeable formulations are
available as primers.

• They can provide good corrosion protection for steel, durable protection for interior concrete
floors, and make good primers for concrete.

• They are not normally used as finish coats because of their relative impermeability, and they
should be top coated in any other exterior applications because they chalk with exposure to
ultraviolet light. Their hard surface can interfere with adhesion of subsequent coating systems,
so top coat are best applied before epoxy has fully cured.

3.5.3 Acrylic Resins

• These thermoplastic resins, obtained by the polymerization or co-polymerization of acrylic &

ethacrylic esters, may be combined with melamine, epoxy, alkyd, acrylamide etc. resulting into
film having excellent resistance to water, acids, alkalis, chemicals & other corrosives.

• Acrylic latex may mean a blend of acrylics and vinyl or styrenes, or may be 100% acrylic.

• Use only 100% acrylic for exterior application if given a choice. Like other “latex paints”, they
are suspended in an emulsion of water, and cure by merging and cross linking of polymers as
the water evaporates.

• Acrylic resins are among the most reliable for resistance to fading and chalking and for
maintaining a flexible paint film.

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• Acrylics are also highly vapor permeable, making good finish coatings for wood and concrete
(Where you want moisture to be able to pass out of structure).

• Acrylics make a good all-around choice for finishing of most exterior building surfaces, and the
water based solvents make them useful where volatile organic solvents (VOCs) are a concern.

3.5.4 Alkyd Resins

• Alkyds are commonly used as exterior primers and enamels, have good surface penetration
and adhesion, can be applied on variety of substrates, but are not as resistant to wear and
moisture, nor as color fast as many of the newer resins.

• Alkyd resins are essentially polyesters of polyhydroxy alcohols and polycarboxyl acids,
chemically combined with acids of various drying, semi-drying and non-drying oils in different
proportions.

• The most resins for oil based paints, enamels and varnishes are alkyds. For many years,
alkyds set the standard for high quality exterior paint.

• They continue to cure and shrink over prolonged period, however, adding stress to the paint
film, which can contribute to problems if the substrate is not sound or if there are many layers
of old paint under the new coat.

• Alkyds also tend to absorb moisture, and are not alkali resistant, which are potential problem
on fresh concrete surfaces.

3.5.5 Phenolic Resins

• Phenolic resins are made from phenols and para-substituted phenols reacted with
formaldehyde. They have one free methylol group and are of two types of Novolac and
Resole.

• Novolac type resin is made by reacting substituted phenols with formaldehyde and a small
excess of phenol such as para-phenyl phenol, para-tertiary butyl phenol and para-tertiary amyl
phenol in presence of acid catalysts. Air-drying paints are employed in blends with alkyds and
other resins to get paints for floors, deck paints, machinery enamels and other maintenance
and industrial finishes.

• The resole type is made by reacting substituted phenols with an excess of formaldehyde in the
presence of an alkaline catalyst. Product is a baking finish useful for electrical insulating
varnishes, trade sales coatings, floor varnishes and for architectural finishes.

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• They have excellent resistance to organic and mineral acids and unusual heat resistance.
Resistance to water immersion and weathering is exceptional. Coatings for interior of storage
tanks for wine, beer, milk, cheese and other food products are of this type.

3.5.6 Amino Resins

• Amino resins are a special type of synthetic resins possessing outstanding properties. There
are two important types-urea formaldehyde type and melamine formaldehyde type. These
resins are seldom used alone. Normally they are blended with other resins-mostly with alkyds
to provide improved varieties of binders.

• Urea and formaldehyde are reacted to give dimethylol urea, which on reaction with butanol
gives butylated dimethylol urea. Subsequent reaction with amine gives urea formaldehyde
polymer. Melamine on reaction with formaldehyde and butanol gives melamine formaldehyde.
• Alkyd-amino paints are used for high-grade modern finishes like automatic topcoats. They
provide high build, good gloss, hardness and gloss retention for longer periods. Urea-alkyd
resins have good resistance to moisture, acids, alkalies, grease and other chemicals and are
also durable. They have high resistance to discolouration and are used for radiators, stoves,
washing machines etc.

3.5.7 Chlorinated Rubber

• Chlorinated rubber is an important film-forming resin that is available in a wide range of

molecular weights, ranging from 3500 to 20,000. It is prepared by chlorinating rubber latex to
the extent of 65-67% chlorine. The resin is in powder form and soluble in aromatic
hydrocarbons. Films made from these resins are very brittle and so a large amount of
plasticizers have to be used in the formulation. Normally chlorinated paraffins are used. Now
drying alkyds can also be used as plasticizers.

• Paints formulated from these resins possess very high corrosion and chemical resistant
properties and have high durability. These paints are used successfully for ships hulls,
immersed structures, polluted industrial atmospheres and other marine environments; also
used for buildings, masonry, swimming pools and road markings.

• These are thermo-plastic coatings and are cheaper than epoxies as protective coatings.

3.5.8 Urethane Resins

• Urethanes and polyurethanes have been developed into wide range of products.

• They are basically very long chain polymers that can be formulated to extremely durable
finishes.

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• Early polyurethanes based on aromatic materials deteriorated badly in Ultra violet light (but
are still in normal use in deck coating systems). Newer urethanes based on aliphatics are
much more durable, with better ultraviolet resistance.

• There are several methods for curing different urethanes and polyurethanes, which may result
in single components and two components system. They make excellent clear sealers and
finishes for wood and are extremely useful in elastomeric formulation for waterproofing
concrete decks.

• The moisture curing varieties utilize hazardous solvents effectively limiting their use to outdoor
or very well ventilated areas.

• Two-pack polyurethane coatings are based on hydroxy functional resins and isocynate
adducts. These are mixed at the time of use and the resultant finish is a tough solvent,
chemical and corrosion-resistant coating, curable at room temperature like epoxy. The
hydroxy functional resin may be alkyd, polyester, polyether, epoxy or acrylic. Alkyd-based
coatings find use in wood finishing.

• Polyester-based finishes are applied for high durability transport finishes including marine and
aircraft and automobiles. Acrylic-based polyurethanes find application in car refinishing,
appliance finishes and for corrosion protection in industrial atmosphere.

3.5.9 Silicone Resins

• Silicone resins are based on an inorganic silicon-oxygen structure which has organic radicals
attached to the silicon atoms. Silicon-Oxygen and Silicon-Carbon bonds are particularly stable
and this has a beneficial influence on the behaviour of semi-organic silicone resins making
them exceptionally resistant to thermal decomposition and oxidation and hence they are very
much used in heat resistant coatings of very high temperature ranges in the order of 540°c.

• These silicone resins are also used to modify other film-formers such as alkyds, polyesters,
acrylic or epoxy, to enhance their thermal stability and durability, the range of modification
being 15% to 40%, though higher level of modification of alkyds is possible for special heat-
resistant applications. Pure silicone surface coatings are used, where very high heat-resistant
properties are required.

• Silicone resins are made from intermediates known as silanes, which are monomeric
chemicals containing silicon combined with various organic groups and usually one to three
atoms of chlorine. The most commonly used silanes are the methyl and phenyl chlorine
compounds. The organo chloro silanes are liquids soluble in aromatic hydrocarbons and are
easily hydrolyzed to hydroxyl-bearing monomers known as silanols. Silicone resins are sold as
50% or 60% solution in xylene or toluene. They are nearly water white in colour. Some are air-

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drying and some are baking type (1-3 hrs at 148-250 °C). The raw materials – chlorosilanes
and silanols are also available in market to make tailor-made resins.

• Silicone resins tend to be expensive, but should last longer than other coatings.

• Application is similar to acrylic coatings, but silicones can achieve similar performance in a
thinner application.

3.6 Materials

All paints and paint materials used shall be obtained from approved Manufacturers. All material shall
be supplied in the Manufacturer's original containers, durably and legibly marked with the description
of the contents. This shall include the specification number, the color reference number, the method
of application for which it is intended, the batch number, date of manufacture, the shelf-life /expiry
date and the Manufacturer's name or recognized trade mark.

Different brands or types of paints shall not be inter-mixed.

The storage and preparation of paints and other coating materials shall be in accordance with the
Manufacturer’s instruction.

Samples for testing the paint being used may be taken by the owner at any time. Should a sample fail
to meet the required specification, the Contractor shall remove this paint from areas already covered
and recoat them with paint that meets the specification.

3.7 Paint approval

The paint (or range of paints) to be used shall be approved by owner.

3.8 Painting contractor responsibilities

The painting Contractor shall be responsible for:

• The quality of workmanship, which shall be performed in accordance with this document and
all other relevant documents such as site regulations, safety rules, referred standards and
codes, etc.

• Obtaining the Owner's assurance that the equipment is certified safe and available and that all
appropriate tests are completed before starting any painting work.

• The protection of all equipment, structures and any other areas from mechanical damage,
environmental damage, damage caused by abrasives during blast cleaning, paint droppings,
or overspray.

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• The earthing of electrical equipment.

• Taking all necessary precautions to avoid interference with the execution of work of other
contractors.

• The characteristics of the paints and paint materials obtained from the paint Manufacturer.
The characteristics shall be obtained via the provision of separate technical, and health and
safety data sheets.

• Control of waste resulting from the Contractor's painting and coating activities, in accordance
with site regulations and specific contract requirements.

• Maintaining workshop facilities, tools and equipment in a good, clean condition. Spray guns,
brushes, rollers, paint pots and the like shall be regularly cleaned and shall be suitable for
their purpose.

• Preparation of appropriate work planning, which shall be in agreement with that of the Owner.

4.0 CODES AND STANDARDS

4.1 The applicable codes and standards reference in this specification shall be as follows:

Code Description
IS:5 Color coding
IS: 101 Methods of test for ready mixed paints and enamels.
IS 2379:1990 Indian standard for pipeline identification- Color code
ASA A13.1-1981 Scheme for identification of piping system:ANSI

4.2 Surface Preparation Standards

Following standards shall be followed for surface preparations -

• Swedish Standard - SIS-05 5900-1967 (Surface preparations standards for Painting Steel
Surfaces).

• Steel Structures Painting Council, U.S.A. (Surface Preparation Specifications (SSPC-SP).

• British Standards (Surface Finish of Blast-cleaned for Painting) BS-4232.

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• National Association of Corrosion Engineers, U.S.A., (NACE).

4.3 The paint manufacturer instruction shall be followed at all the times. Particular attention shall be
paid for the following:

• Instruction for storage to avoid exposures as well as extreme temperatures.

• Surface preparation prior to painting.

• Mixing & thinning.

• Application of paint and the recommended limit on time interval between coats.

5.0 PHILOSOPHY & GUARANTEE

• Generally, external Painting Frequency shall be as per below table

Sr. Area Items Frequency(yrs)

Piping 8
1 Unit Equipment 8
Structures 8
Piping 8
2 Offsites Tankages As per M&I schedule
Structures 8
Piping 4
3 P&U Equipment 4
Structures 4

• On receipt of recommendations from Inspection on damage of paint over any painted surface.
• Any new structure/ pipeline provided as an outcome of any modification/ MOC.
• Structures of all pump houses, sheds in units & offistes, etc are included in above.
• Internal paintings of tanks and vessels to be done as per inspection recommendations during
Shutdown or available opportunities based on requirement.

GUARANTEE

• Contractor shall stand guarantee for painting system as follows

a. For surfaces painted after Blasting as surface preparation 5 years

b. For surfaces painted after Manual Cleaning as surface preparation 4 years

c. Paint material shall be procured from approved manufacturers who also will stand
guarantee as above clause.

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d. For Guarantee against coating of Crude tank at COT, Vadinar and BORL, refer section 25

• For all internal lining / painting works, manufacturer’s laboratory test statement / Laboratory
Paint performance certificates to be checked for specified services at design / operating
conditions. Material shall be procured from only those approved manufacturers who will meet
the above stated criteria.

6.0 RESPONSIBILITIES

• Section Heads and the Engineer in-charges are responsible for quality work execution/
inspection of material/ confirming Batch Certificates on quality/ expiry date of paints/
measurement/ Bill certification etc.

• Maintenance planning section is responsible for identifying painting application contractor

through tendering process for the material supply and application.

• Operation section is responsible for issuing necessary work permits for execution.

• Inspection will issue applicable repair procedure.

7.0 HEALTH AND SAFETY

Most of the volatile organic solvents used in paints causes health and fire hazards. They are harmful
for the respiratory system, eyes and skin and also are potentially explosive. Hence, the following
general precautions are necessary while handling and application of paints.
• Inhalation of solvent vapors or paint mist, contact with liquid paint with skin and eyes should
be avoided.
• Suitable approved respirators or face masks should be used during paint application and
handling.

• Since solvent vapors are heavier than air, they tend to accumulate at the bottom of tanks or of
confined spaces. Care should be exercised while entering areas where this might have
happened.

• Food and drink should not be stored or consumed where paints are stored and smoking
should be prohibited in such areas.

• All fire safety precautions are to be followed in areas where paints are stored and where paint
application is done.

• Cans holding liquid paints are to be handled carefully and should not be kept near or above
any hot surface or object.

• All scaffoldings, etc. erected for painting must be to the satisfaction of BORL safety
requirements. Safety belts with lifelines are mandatory requirements, while painting at
elevated locations.

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• If a Fire involving paint does occur, avoid sparks from electrical appliances or caused by metal
to metal contact.

• Do not extinguish with water, as paint solvents float on water, & help Fire to spread.

• Use a dry chemical, foam or CO2 extinguisher.

• Protect from the fumes with breathing apparatus.

8.0 TOOLS & EQUIPMENT

• All tools, brushes, rollers, spray gun, abrasive material, hand power tools for cleaning and all
equipments, scaffolding materials, shot/wet abrasive blasting, water blasting equipments & air
compressors etc. required to be used shall be suitable for the work and all in good order and
shall be arranged by the contractor at site and in sufficient quantity.

• Mechanical mixing shall be used for paint mixing operation in case of two pack systems
except that the Engineer-in-charge may allow the hand mixing of small quantities at his
discretion.

9.0 STORAGE
All paints and painting materials shall be stored only in rooms to be arranged by contractors and
approved by EIC for the purpose. All necessary precautions shall be taken to prevent fire. The
storage building shall preferably be separate from adjacent building. A signboard bearing the words
“PAINT STORAGE” – HIGHLY INFLAMMABLE” shall be clearly displayed outside.
• As a rule, paint shall be stored in a well-ventilated room.
• All paint and thinner shall be stored in such a way that the manufacturer’s labels can be
readily identified.

• Paint stocks shall be controlled so that they can be used within their effective period of use.

• For storage areas, provide prescribed protective measure and signs.

• Paint exceeding the prescribed quantity shall not be stored.

• Care shall be taken while storing and handling to avoid breakage or marked deformation of
containers.

• When paint is stored outdoors, it shall be protected by using plastic/ tin sheets or other
appropriate measures, in order to prevent damage to containers or changes in the quality of
the paint.

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• When paint is temporarily stored in the working area, the amount equivalent to one day’s use
or less shall be stored. Paint shall be protected from rain, snow etc. using plastic/tin sheets.

10.0 SURFACE PREPARATION

10.1 General
For optimum paint performance surfaces to be painted 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 paint is applied.

If the surface has been exposed to a polluted, e.g. salt-laden, atmosphere, it shall be washed down
with clean, fresh water prior to blasting or power tool cleaning.

After preparation of the substrate surface, any grit, dust etc. shall be removed and a layer of primer
shall be applied before any corrosion or recontamination occurs, normally within 4 hours after
blasting.

Surface preparation shall be carried out by dry blast-cleaning wherever possible.

The external surface of R.C.C. chimney to be painted shall be dry and clean. Any loose particle
of sand, cement, aggregate etc. shall be removed by scrubbing with soft wire brush if
necessary acid etching with 10-15% HCL solution for about 15 minutes shall be carried and
surface must be thoroughly washed with water to remove acid & loose particles then dry
completely before application of paint.

10.2 Surface preparation by blast cleaning.

10.2.1 General

Before blast cleaning any oil, grease and dirt shall be removed either by means of a suitable solvent,
by steam cleaning, with an alkaline cleaning agent if necessary, or by water jetting. Excessive layers
of rust shall be removed by chipping. Weld spatter and sharp edges shall be removed.

10.2.2 Blast cleaning equipment

The compressed air supply used for blast cleaning shall be free from water and oil. Adequate
separators and traps shall be provided, installed in the coolest part of the system. They shall be
emptied regularly to prevent carryover of water and oil. Accumulations of oil and moisture shall be
removed from the air receiver by regular purging.

Air compressors shall not be allowed to deliver air at a temperature above 110 °C.

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Abrasive blast cleaning equipment shall be an 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.

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.

10.2.3 Abrasives

Abrasives for use in blast cleaning carbon steels & low alloy steels are specified in ISO 8504-2.
Suitable abrasives types are:
1. Chilled iron grit or shot.
2. Steel and malleable iron grit or shot.
3. Non-metallic abrasive (Aluminum oxide, Garnet)

NOTE: Abrasives detail for stainless steels and non-ferrous metals are given in 10.4. Copper slag
and Sand shall not be used. The abrasives shall be free from oil, grease, moisture etc. Re-used
abrasive shall be clean, sharp and free from contaminants.

The blast profile shall be that recommended by the paint Manufacturer. Roughness measurement
shall be carried out by the paint Contractor using instruments approved by the Owner and in
accordance with ISO 8503-2.

The surfaces shall be blast cleaned using one of the abrasives (type 1 or 2) as above at pressure of
7kg/cm2 at an appropriate distance and angle depending of nozzle size maintaining constant velocity
and pressure. The shot or grit of size with appropriate size of G42 grade (maximum) and S250 grade
size of steel shots (maximum) to obtain a desired surface profile of 35-50µ trough to peak or specified
profile in case of steel. The combination of steel grits and shots shall be normally in the ratio of 3:1.
The quality of abrasives shall be free from contaminants and impurities and shall meet the
requirements of SSPC AB1. Compressed air shall be free from moisture and oil. The blasting nozzles
should be venturi style with tungsten carbide or boron carbide as the materials for liners. Nozzles
orifice may vary from 3/16” to ¾”. On completion of blasting operation, the blasted surface shall be
clean and free from any scale or rust and must show a grey white metallic luster. Primer/first coat of
paint shall be applied within 4 hours of surface preparation. Blast cleaning shall not be done outdoors
in bad weather without adequate protection or when there is dew on the metal, which is to be
cleaned. Surface profile shall be uniform to provide good key to the paint adhesion (i.e. 35 to 50
microns). If possible, vacuum collector shall be installed for collecting the abrasives and recycling.

10.2.4 Grades of surface finish

The following four preparation grades (in accordance with ISO 8501-1) are recognized:

• Sa 1 - Light blast-cleaning/ Removal of Loose rust, mill, scale etc.

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• Sa 2 – Commercial blast/Thorough blast-cleaning

• Sa 2½ - Near White metal finish

• Sa 3 - Blast cleaning to visually clean steel/White Metal

10.2.5 Performance & application condition

Blast cleaning shall only be performed in conditions suitable for painting see 11.2.
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 present. Fresh water
may either be mixed with the abrasive in the pressure tank or introduced directly behind or ahead of
the blast nozzle.

To prevent rusting the cleaned surface should be washed off immediately after blast cleaning using
fresh water containing a suitable corrosion inhibitor such as 0.3% wt sodium nitrite with 1.2% wt
ammonium phosphate. It should also be considered to include a suitable corrosion inhibitor in the
water used for blast-cleaning.

The cleaned surface shall be thoroughly dry before any paint is applied. In general it is not necessary
to remove residues of the inhibitor before painting. However, the paint Manufacturer should be
consulted on the inhibitor/primer compatibility.

It is strongly recommended to use Dehumidifiers to maintain the better conditions for painting and
effective results, for internal painting of all types of tanks, vessels etc or as directed.

10.3 Surface preparation by hand & power tool cleaning

Manual cleaning using mechanical cleaning tools to remove mill scale and rust, according to ISO
8504-3, should not be used for new construction painting and may be used only if approved by the
Owner.

10.4 Surface preparation of Stainless steel, hot galvanized steel and non-ferrous metals

If stainless steel, galvanized or non-ferrous metal surfaces are to be painted, a suitable pre-treatment
in the form of a light blast cleaning with an appropriate abrasive shall be given to ensure proper
adhesion of the subsequently applied paint system.

Aluminum oxide or other abrasives (free from any chloride or iron/steel contamination) shall be used
for blasting stainless steel.

If blast cleaning is impossible then solvent or steam cleaning with an alkaline detergent agent may be
used for surface preparation.

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If galvanized surfaces are contaminated with zinc salts and/or oil grease, etc., they shall first be
cleaned by a fresh water wash and/or a suitable solvent.

Surface preparation standards

Sr.No Description International Standards (Equivalent) Remarks

Swedish SSPC- NACE- British
standard SP- USA USA Standard
SIS-05- BS-4232
900
1 Manual or hand tool ST.2 SSPC-SP- This method is
cleaning, Removal of 2 applied when the
loose rust, loose mill surface is
scale and loose paint, exposed to
chipping, scrapping, normal
standing and wire atmospheric
brushing. Surface conditions hence
should have a faint other methods
metallic sheen cannot be
2 Mechanical or power adopted and also
tool cleaning for spot cleaning
Removal of loose rust during
loose mill scale and maintenance
loose paint to°ree painting.
specified by power tool
SSPC-SP-
chipping, de-scaling, ST.3
3
sanding, wire brushing
and grinding, after
removal of dust, surface
should have a
pronounced metallic
sheen.
3 Blast cleaning (air & water) There are four common grades of blast cleaning

3.1 White metal Where extremely

Blast cleaning to white clean surface can
metal cleanliness. be expected for
Removal of all visible SSPC-SP- prolong life of
SA 3 NACE#1 First Quality
rust. Mill scale, paint & 5 paint system.
foreign matter 100%
cleanliness with desired
surface profile.
3.2 Near white metal The minimum
Blast cleaning to near SSPC-SP- Second requirement for
SA 2½ NACE#2
white metal 10 Quality chemically
cleanliness, until at resistant paint

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Sr.No Description International Standards (Equivalent) Remarks

Swedish SSPC- NACE- British
standard SP- USA USA Standard
SIS-05- BS-4232
900
least 95% of each systems such as
element of surface area epoxy, vinyl,
is free of all visible polyurethane
residues with desired based and
surface profile. inorganic zinc
silicate paints,
also for
conventional
paint systems
used under fairly
corrosive
conditions to
obtain desired life
of paint system.
3.3 Commercial Blast For steel required
Blast cleaning until at to be painted with
least two-third of each conventional
element of surface area paints for
SSPC-SP- Third
is free of all visible SA 2 NO.3 exposure to
6 Quality
residues with desired mildly corrosive
surface profile atmosphere for
longer life of the
paint systems.
3.4 Brush-off Blast
Blast cleaning to white
metal cleanliness,
removal of all visible SA 1 SSPC-
NO.4
rust, mill scale, paint & SP7
foreign matter. Surface
profile is not important

11.0 PAINT APPLICATION

11.1 General

Paints and other coating materials shall be applied in accordance with the paint Manufacturer's
instructions. The surface preparation shall be as described in 10.0
All surfaces shall receive an appropriate paint system as specified in 13.0 and with the following
exceptions:

• Any equipment (e.g. off-the-shelf items) for which the Manufacturer's standard paint system
has been approved for use by owner.

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• Hot-dip galvanized steel, weathering steel and non-ferrous metals, unless specified by the
Owner.

• Any surface specified by the Owner not to be painted.

The painting requirements are often dependent on the temperature of the substrate to be painted. In
selecting a paint system the Operating Temperature of the equipment shall be referred to.

Painting Contractor shall procure the paints from following approved manufacturers only:

1. Akzo Nobel paints

2. Asian Paints PPG Ltd
3. Berger paints Ltd
4. CDC Carboline Ltd
5. Hempel paints
6. Jotun coatings

All the procured paint material along with batch/test certificates shall be offered for BORL inspection
for approval. Remaining Shelf life shall be at least 50% of the total duration at the time of inspection.

11.2 Paint application requirement

The paint shall be applied in accordance with the paint Manufacturer's product data sheet, which shall
include the mix ratio, the method of application, the use of thinners and over-coating times.

The dry film thicknesses shall be as specified in coating system. Areas with inadequate coating
thickness shall be thoroughly cleaned and, if necessary, abraded, and additional compatible coats
shall be applied until they meet the required film thickness.

Painting shall not be performed when the temperature of the surface is less than 3 °C above the dew
point of the surrounding air or when the relative humidity of the air is greater than 85% unless local
conditions dictate otherwise and the Owner is in agreement.

In the following conditions, paints shall not be applied under the following conditions:

• When the surface temperature is greater than 40 °C (unless a higher temperature is agreed
by the paint manufacturer).

• When the air temperature is less than approximately 4 °C, (depending on local conditions).

• When there is the likelihood of an unfavorable change in weather conditions within two hours
after painting.

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• When there is a deposition of moisture in the form of rain, condensation, frost, etc., on the
surface.
• When the available light is less than 500 lux.

If condensation, rain, dust or other foreign materials contaminate the surface of a paint coating which
is not dry to the touch, the paint shall be removed, the surface re-cleaned and fresh paint applied in
accordance with this Document.

Paints shall not be applied within 50 mm of edges which will later have to be welded. Such weld
areas shall be taped for a distance of 50 mm either side of the weld line. Extra coats of paint shall be
applied on the areas where the shape and/or plane of application result in thinly applied coatings, e.g.
at edges, welds, corners etc. To compensate for these effects, stripe coats of paints shall be applied
(normally applied first so that they will be covered by the full coat).

When zinc rich primers are used, care shall be taken to avoid any possibility of over spraying or
dripping onto austenitic stainless steel, duplex stainless steel, nickel alloy or 9% nickel steel
components.

Transport and construction of painted structures shall be carried out only after the drying time
specified by the paint Manufacturer has elapsed. Damage to the paint system shall be avoided by
taking appropriate measures, such as the use of non-metallic slings, etc. for handling and by
minimizing as far as possible handling after painting.

All steel equipment shall be provided with priming or coating system to protect the steel surfaces
during transport, storage, installation and construction.

11.3 Application Method

There are a number of methods by which coatings can be applied. The two principal methods are by
brush and spray. The other methods are paint pad applications, paint mitts, electrostatic spray,
electro coating, dipping and fluidized bed technique. The latter methods are primarily for in plant
application.

The choice of application methods depends on a number of factors. The first is the type of coating.
Most of the oil based coatings can be easily applied by brush but it is the slowest process. Spray
application is the fastest for large flat surfaces. The type of surface is also a factor. For small and
intricate areas, brushing is probably the best method. If the surface is used and pitted, application of
the first coat by brushing is recommended.

Brushing can be done in almost all areas, since the liquid coating is transferred from the brush to the
surface. Spraying however, causes problem with toxic solvents as well as a possible fire hazard due
to fume build up. Spraying in small, enclosed areas is usually not suggested. Cleanup is also a factor.

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Cleaning a brush is the least difficult procedure and cleanup of spray equipment is the most time
consuming and most complicated procedure.

11.3.1 Brush application

Brush application may be used under the following circumstances:

• When areas cannot be properly coated by spraying for any reason, such as material or
environmental considerations.

• For the initial coat of paint to corners, edges, crevices, holes, welds or irregular surfaces prior
to spray application.

• For "touch up" or repairs to localized damaged paint or areas of incorrectly applied paint.

• Where the paint Manufacturer considers the coating material suitable for brush application.

Brushes shall be of a style and quality that will permit the proper application of paint.

Brush applications should be done in two passes that are perpendicular to each other so that a
smooth coat, as near uniform in thickness as possible, is obtained. There should be no deep or
detrimental brush marks. Paint shall be worked into all crevices and corners. Runs and sags shall be
brushed out.

During the application of each coat, all areas such as corners, edges, welds, small brackets, bolts,
nuts, and interstices shall receive additional paint to ensure that these areas have at least the
minimum specified dry film thickness and to ensure continuity of coating.

The two general designs of brush which may be used for steel are conventional wall type brush and
flat brush. Conventional wall type brushes vary in width from 7.5 to 15 cm and bristles varying in
length from 10 to17.5 cm are used for painting steel structures. Small areas require “sash” brushes 5
to 7.5 cm wide. Oval brushes can be used for application of coating around irregular surfaces, such
as rivets, bolt heads, and similar areas.

The flat brush is a new type of brush generally made up of short nylon bristles of 2.5 to 3.75 cm long,
attached to a flat base, about 10 to17.5 cm. This provides much wider coverage on the surface. This
brush holds considerably large quantity of paint than conventional brush and applies paint more
rapidly. It is especially not effective on complex surfaces.

These are two types of brushes used in paint application. Synthetic fibers are satisfactory for most
brushes. Nylon is an excellent synthetic fiber. It is not affected by most solvents. Hog bristle used to

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be a primary material for brush is the best quality bristle. It is expensive and gives better level for
most coatings.

The proper application of a coating by brush depends on the proper handling of the brush. The brush
should be held with the fingers, like holding a pencil. Brushes should not be dipped deep into the
paint. Dipping into the paint approximately 2.5 cm is adequate.

This keeps the paint out of the heels of the brush and prevents dripping of the paint on to the handle.
The coating should be spread over the surface holding the brush at an angle approximately 450 to
the work.

The coating should be spread evenly and quickly over the surface by a number of light strokes using
the wrist and aim to spread brush loaded coating. Once the coating is evenly spread, the coating
should be smoothed by light parallel stripes of the brush regularities in the coating. During brushing
the brush should not be pushed down, this will not improve the brushing procedure. Pushing the
brush too hard, especially on the finish coats, can create brush marks which act as a focal point to
lead to premature coating failure.

When the next brush load of coating is applied the final smoothing stroke should be from the latest
applied coating into the previous brush load so as to spread the overlap between the two areas of
coating. The final strokes of the brush should be always from the last application into the previous
one sweeping the coating into the wet edge of the previous application to prevent lap marks. The
coating can be best smoothened and spread uniformly by using cross strokes. The final strokes
should be parallel and in one direction. Brushing against an edge is to be avoided as this pulls the
coating away causing a thin area on the edge.

The brush is constructed by cementing the bristling ends on a setting up compound then adding a
handle. The setting compound and flat end of the handle are fastened together with a metal ferrule.
Strips or felling are inserted inside and at the bottom of the bristling. Cavity formed in this way help to
hold more paint and reduce the volume of bristling.

11.3.2 Spray application

The large volume of all maintenance and high performance coating is applied in the fastest way by
spray. This is illustrated by relative efficiency of different methods of application in the table given
below:

Method of application Sq. Meter covered in one day

Brush 93
Air Spray 372-744
Airless Spray 744-1115

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By adopting this techniques coating films with uniform thickness and fewer imperfections than other
methods can be obtained. The spray method of coating utilizes a stream. Highly atomized coating
particles are directed to the surface in a uniform pattern. The particle then flow together to form a
continuous and even film. The time duration per day comes to 8 hours and the number of workers to
be deployed can be three. Spray application can be done essentially by two types of equipment.

• Air spray – conventional

• Air less spray

11.3.2.1 Air Spray

Air spray is a process in which compressed air and the coating liquid are brought together in a way
that forms a fine spray. The spray gun is the important component in the spray system as it is the
machine which brings the air and liquid together.

There are two types of spray guns. The most common is the external mix gun. The liquid and air first
contact with each other outside the spray gun. The air jets impinge on the stream of liquid coating
coming out of the gun, disperse it and form fine spray. The air is directed towards the liquid stream
through a specially designed air cap having minimum two to maximum ten to help break up the liquid.

There are two adjustments on most spray guns. One regulates the amount of liquid passing through
the gun and the second controls the amount of air passing through the gun. In most products of spray
guns, the trigger operates both the liquid and the air. There are some spray guns where the air flows
in a continuous stream and only the liquid is controlled.

Compressed air is used to atomize the coating liquid at the tip of the gun and also to apply pressure
to the liquid coating material and force it through the nozzle on the gun. The pressure of air passing
through the gun as well as the pressure on the liquid has a great influence on the type of air spray
and the type of fan developed. If there is only too little air pressure at the gun the stream will not be
broken satisfactorily, resulting in unsatisfactory coating film. The same thing can occur if the air
pressure in the liquid is too high in comparison with the air pressure at the gun.

Basic equipments for atomized spray paints consist of

• Spray gun
• Container for the paint
• Air compressor
• Air regulator or transformer.
• Connections for pipes and hoses
• Air felts and moisture trap

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Spray guns are available to fit any requirement. An air cap at the front of the gun atomizes the paint
and forms the desired spray pattern. Air caps may be interchanged to meet the requirements of
different applications.

A fluid tip of nozzle, located directly behind the air cap directs the paint into the air stream. These tips
vary in material and size according to the value of viscosity of the paint being applied with the speed
and volume requirements of the application. Large orifices nozzles are required for heavy coarse or
fibrous paints.

Smaller orifices are used for thin paints. Because atomization of the paint improves as the nozzle size
decreases abrasive materials contained in the paint require tips made of materials with resistance to
wear.

Air compressor should be capable of supplying 25 cft/min of free air at 100 psi for each gun. If an air
mask is used for spraying on the interim tanks and similar vessels an additional 5 - 10 cft/min should
be added for each operator. Air compressor provides the force for atomized spray painting. A
fluctuating air pressure at the gun usually caused by inadequate compressor capacity can result in
improper atomization of the paint and defective paint films.

Air regulator regulates the air pressure as required. Air filters and moisture traps remove moisture
from the compressed air. These should be installed in the air supply lines between compressor and
the paint container and between compressor and the spray gun. These regulators and filters should
be as close to the tanks and guns as possible.

Pipes and hoses that distribute the compressed air or paints must be adequate in size to handle peak
loads and must be able to withstand any abrasive or chemical effects of the paint.

For best results, the gun should be equipped with 1.27cm ID fluid hose and 0.75 cm air hose. Smaller
hoses should be avoided since they cause excessive pressure losses.

Spraying Procedure

The proper spraying technique is essential to the success of the coating. The following points should
be observed.

• Hold the guns not more than 25 cm from the surface.

• Use a normal fan. It is possible to check this by holding the gun in the proper distance from
the surface and pulling the trigger quickly. With normal spray pattern, the spray will be an
even, smooth. Oblong with no heavy Centre or dry spray at the ends.

• The gun should be pointed perpendicular to the surface.

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• Keep the gun parallel to the surface at all times.

• The term ‘FAN’ describes the spray pattern of the spray gun.

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Air Spray Painting faults and remedies

Trouble Possible Causes Suggested Remedies

Sags Dirty air caps and fluid tips Remove the cap and clean the fluid tip and air
cap carefully
Gun stroked too close to the Stroke the gun 15-20cm from the surface
surface
Gun stroked at wrong angle to Gun should be stroked at right angle to the
the surface surface
Paint thinned out too much Add correct amount of solvent
Streaks Too much air pressure Use least air pressure necessary
Paint too cold Heat paint to get good flow out
Split spray Clean the fluid tip and air cap
Orange Paint not thinned out sufficiently Add the correct amount of solvent
peel
Not depositing a wet coat Check solvent. Use correct speed and overlap of
stroke
Insufficient air pressure Increase air pressure or reduce fluid pressure
Excessive Not triggering the gun at each It should be a habit to release trigger after every
paint loss stroke stroke
Depositing a paint film of Learn to calculate the depth of wet film finish
irregular thickness
Excessive Too high pressure Use least amount of compressed air necessary
build up
Spray fog Spraying past surface of product Release trigger when the gun passes target
Too little material at gun Adjust pot pressure or gun or both

11.3.2.2 Airless Spray

The word airless is used in connection with this type of spray equipment since there is no air used in
the atomization of the liquid coating. The liquid is forced through a very fine orifice by hydraulic
pressure and forms a spray pattern as it expands into the atmosphere. The combination of the
pressure and the small orifice breaks the liquid coating into a very fine mist which is forced on to the
surface to be coated.

The gun for airless spraying is a simple device, consisting of not much more than a handle used to
direct the spray in the proper direction. As previously mentioned, the fan is developed by the shape of
the orifice through which the high pressure liquid is directed. This is the most critical part of the airless
spray gun, and the spray tips must be carefully made and machined to obtain the proper expansion of
the liquid and the formation of the fan.

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There are essential two adjustments to be made in airless spray gun. In order to change the fan size
or shape, it is necessary to change the orifice tip. It is also necessary to change the orifice, depending
on the type of coating that is being sprayed. Very thin liquid will require a very small orifice, while a
heavy, viscous liquid will require a larger opening.

Because of the adjustments needed due to the use of different tips, a number of tips are essential.
The larger the orifice, the greater the flow of material and the greater the speed and coverage that
can be obtained. On the other hand, if a relatively large opening is used with a low - viscosity
material, the rate of discharge may be such that it is impossible to keep up with the speed of the flow.
As a general rule, the best orifice is the smallest orifice that will allow the coating material to pass
through without plugging.

A number of different spray patterns can be obtained. These vary from almost cone shaped patterns
to fans with various widths. These can vary from approximately a 25 ° angle up to a 65° angle. The
finer angles would be used for narrower work, such as on relatively small dimensional structural steel,
while the wide patterns would be used for large board and flat surfaces.

Airless v/s Conventional spray

Air spray Airless Spray

Coverage sq. m/day 372-744 744-1115
Overspray 10-30% Below 10%
Pin holing Possible Unusual
Thickness µ Min 20-25 50-60
Max 100-110 200-220
Material loss on application Considerable Up to 35% less
Penetration of corners & voids Fair Good
Paint clogging problem Slight Considerable
Safety during cleaning Excellent Fair
Coating contamination from air source Possible None
Wind loss Considerable Negligible
Gun distance from surface 15-20 cm 35-40 cm
Film build per coat Lower Higher
Versatility More Less
Thinning before spray Usual Sometimes
Hoses to spray gun 2 1
Compressors Large Small
Portability Fair Excellent

Hydraulic - type pressure pumps are used to supply the pressure on the liquid. It may be operated by
either air or an electric motor. Most of the pumps are actuated by air cylinder. Generally, it is better to

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have a pump with higher ratio than required. Too low a pressure would not provide the liquid
dispersion required for proper application. Insufficient pressure causes streaks or fingers in the fan
pattern. Adjustment of air pressure usually eliminates these streaks or fingers, when the correct
operating pressure for the particular coating liquid is obtained.

The even spray pattern with no fingers or streaks in the fan is already obtained using spray gun from
the distance of 30 - 35 cm from the surface by 100 % solid epoxy coating. The spray gun and pump
are the most important items of the airless spray equipment. The third is the high pressure fluid line.
The hose is usually lined with fluorocarbon or nylon which will withstand a working pressure of 170
kg/cm2 or more.

Paint cleanliness is critical in order to prevent clogging of nozzles. Any coating material used should
be thoroughly screened or filtered to eliminate this type of problem. It is always advisable to have
extra nozzles or tips so that they can be easily exchanged quickly when they become clogged.

11.4 Precaution to be observed

Normally paints have high density pigments dispersed in low-density polymer binders and hence the
pigments and extenders settle at the bottom leading to caking on storage for long periods, in spite of
using anti-settling agents in the formulation.

This should be checked while opening the drum and corrected before application. The lumps so
formed if any should be broken up by rubbing against the sides of the container and thoroughly mixed
with the liquid portion so that a consistent smooth flowing liquid paint material is obtained. If the
pigment lump does not break and has set as a hard mass, the paint should be discarded.

It is probable that a small amount of skin may be formed on the top of the paint material in some
cases. The skin may be removed before application and the most of the material may be stirred well.
If the quantity of skinning is high or the skin may thick, the paint may be rejected.

11.5 Mixing of two component paint

The base paint shall be stirred and made homogenous. The hardener shall be added to the base
paint in the specified mixing ratio and thoroughly blended using a power stirrer. Viscosity of the mixed
paint shall be adjusted to the required level by adding thinner and thorough mixing so as to maintain
the WFT.

The quantity of paint that can be applied well within the pot life of the mixed paint should only be
mixed.

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11.6 Drying of coated surface

• No coat shall be applied until the preceding coat has dried. The material shall be considered
dry for re-coating when another coat can be applied without the development of any film
irregularities such as lifting or loss of adhesion of undercoats. Drying time of the applied coat
should not exceed maximum specified for it as a first coat; if it exceeds the paint material has
possibly deteriorated or mixing is faulty.

• No paint shall be force dried under conditions which will cause checking, wrinkling, blistering
formation of pores, or detrimentally affect the conditions of the paint.

• No drier shall be added to paint on the job unless specifically called for in the manufacturer’s
specification for the paint.

• Paint shall be protected from rain, condensation, contamination, snow and freezing until dry to
the fullest extent practicable.

11.7 Compatibility of different paints

While applying multi coat system of paint it is always desirable to have first-hand knowledge of
compatibility of different coating systems with one another. A general view of such information is
given in the following tables. This is only a general view. In some cases, specific recommendations
may differ due to some special reasons.

Top Coats
Phenolic Chlorin-
Primer Oleoresi Silicone Coal tar Uret-
Alkyds Oleoresi- Vinyl ated Epoxy
-nous Alkyds Epoxy hane
nous rubber
Oleore-
C C C C NR NR NR NR NR
sinous
Alkyds C C C C NR NR NR NR NR
Silicone
C C C C NR NR NR NR NR
Alkyds
Phenolic
C C C C NR NR NR NR NR
Resins
Vinyl C C NR NR C C C C NR
Chlorin-
C C C C C C NR NR NR
ated rubber
Epoxy NR NR NR NR C C C C C
Coal tar
NR NR NR NR NR NR C C NR
Epoxy
Zinc-rich
NR NR NR NR C C C C NR
Epoxy
Inorganic
NR NR NR NR C C C C NR
Zinc
Urethane NR NR NR NR NR NR NR NR C

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Note:

• C : Compatible,
• NR : Not recommended due to known or suspected problems. Certain combinations marked
“NR” may be used provided a suitable tie coat is applied.

12.0 MAINTENANCE PAINTING

In an operating industry, maintenance painting is very important and crucial because of its regularity
and continuity. The most critical consideration is about the surface preparation which is obviously
difficult to execute. In most operating plants, as it is difficult to do the blasting operation in a running
plant, an alternate route is always looked for, like power tool cleaning or manual cleaning. The
problem with these types of alternatives is that they cannot remove the old paints and also the well
adherent rust from the surface thoroughly or at least to a satisfactory level. Then the problem arises
about painting over that surface. The ideal product required here is a well-established and standard
maintenance coating capable of adhering to old adherent coatings. Keeping in mind these limitations,
the following recommendations for surface preparation and painting on various likely scenarios are
provided.

1. Where the finish paint is intact but area is faded, clean the surface manually to remove the
dust, debris, coke particles / foreign material etc. by water wash, with wire brush or fine emery
cloth. Over the prepared surface, apply finish paint as per coating system, ensuring that
surface is dry.

2. Where finish paint or all the coatings including the primer are damaged, prepare the surface
by power tool cleaning to ST-3. Wherever power tool cleaning is not possible, surface may be
prepared with manual cleaning to ST-2 and apply the complete paint scheme as applicable to
the area.

3. For all the maintenance painting, sequence of painting shall be as below

o Prepare all the surfaces (point 1 and 2 above) & offer for inspection
o Apply coat of primer as applicable in point no. 2
o Then apply finish coat as per applicable system for all the surfaces.

12.1 Measurement of DFT in these cases

While executing this kind of maintenance painting works, the dry film thickness of the existing coating
shall be measured initially during surface inspection stage. Then as the subsequent coatings are
applied, DFT shall be measured after each application and recorded. The DFT of each coating may
be obtained by deducting the rest from the total value.

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13.0 PAINT MATERIAL

Paint manufacturer shall furnish all the characteristics of painted material on printed literature, along
with the test certificates for all specified characteristics given in this specification. All the paint material
shall be of first quality and conform to the following general characteristics as per the given tables:

13.1 – Primers

Sr.
Description P-2 P-4 P-6 F-8 F-9
No
1 Technical Chlorinated Etch Epoxy Self-priming Inorganic
Name rubber Zinc Primer/wash Zinc type surface zinc
Phosphate primer phosphate tolerant high silicate
primer Primer build epoxy coating
coating
(complete rust
Control coating).
2 Type and Single pack, Two pack Two Two pack epoxy A two
composition air drying polyvinyl componen resin based pack air
chlorinated Butyral resin t suitable drying self
rubber based medium polyamide pigmented and curing
medium cured with cured capable of solvent
plasticized with phosphoric epoxy adhering to based
unsaponifiable acid solution resin Manually inorganic
plasticizer, pigmented medium, prepared zinc
pigmented with with zinc pigmented surface and old silicate
Zinc tetroxy with zinc coating. coating
phosphate chromate. phosphate
3 Volume 40+3 10+1 50+1 78+3 60+3
Solids %
4 DFT (Dry 40-45μ 8-10μ 40-50μ 100-125μ 65-75μ
film
thickness)
per coat in
microns
5 Theoretical 8-10 8-10 8-10 6.0-7.2 8-9
covering
capacity in
M2/coat/litre
6 Weight per 1.3+0.05 1.2+0.05 1.4+0.05 1.41+0.03 2.3+0.03
litre in kgs /
litre
7 Touch dry 30 minutes. 2 hrs .. After 30 3 hrs. 30

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Sr.
Description P-2 P-4 P-6 F-8 F-9
No
at 30°C mins. minutes
(Minimum)
8 Hard dry at 8 hrs 24 hrs 8 hrs 24 hrs (5 days) 12hrs
30°C (Max.)
9 Over Min.: 8 hrs. Min.: 4-6 hrs. Min.: 8 Min.: 10 hrs Min.: 12 hr
coating hrs. at 20° &
interval 50% RH
10 Pot life at Not applicable Not 6-8 hrs. 90 minutes 4-6 hrs.
30°C for applicable
two
component
paints
11 Temperatur 60°C NA 80°C 80° C 400° C
e resistance Dry Service Dry Service Dry Dry service Dry
( Minimum) service service

13.2 Finish Paints

Sr.
Description F2 F3 F6 A/B F6C
No.
1 Technical Name Acrylic Chlorinated Epoxy-High Solvent less
Polyurethane rubber based Build finish Epoxy
finish paint finish paint paint. Coating
2 Type and Two-pack Single pack F-6 A :- Two-pack Two pack
composition aliphatic plasticised Aromatic amine cured with
isocynate chlorinated Cured epoxy resin amine
cured rubber based medium suitably adduct
acrylic finish medium with Pigmented catalyzed
paint. chemical and F-6B :- Polyamide epoxy resin
weather cured epoxy resin suitably
resistant medium pigmented
pigments. Suitably pigmented
3 Volume Solids % 40+3 38+2 60+3 99+1
4 DFT (Dry film 30-40μ 30-40μ 100-125μ 200 -500
thickness) per
coat in Microns
5 Theoretical 11-15 11-15 5-6 2-3
covering capacity
in M2/coat/litre

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Sr.
Description F2 F3 F6 A/B F6C
No.
6 Weight per litre in 1.15+0.03 1.15+0.03 1.42+0.03 1.40+0.03
kgs / litre
7 Touch dry at 30 minutes. 30 minutes. 3 hrs. 3 hrs.
30°C
8 Hard dry at 30°C 8 hrs. 8 hrs. 16Hrs 16 Hrs
(Maximum)
Full Cure at 30° C 5 Days.
( For immersion /
hightemp service)
9 Over coating Min.: (12 Min.: Overnight Min.: Overnight Min – 8 Hrs
interval at 30°C hrs.) Max.: 5 days Max – 48 Hrs
10 Pot life at 30°C 6-8 hrs. Not applicable 4-6 hrs. 30 Min
for two
component paints
11 Temperature 80°C 120°C (Dry
resistance Dry service 60°C 80°C service)
( Minimum) Immersion Dry service 50°C
service (Immersion
service)

Sr.
Description F7 F-11 F-12
No
1 Technical Name High build Coal tar Heat resistant synthetic Heat resistant
epoxy coating. medium based two silicone
pack Aluminum paint
Aluminum paint suitable upto
suitable upto 250°C dry 500°C dry temp.
temp.
2 Type and Two pack polyamide Heat resistant synthetic Single pack
composition cured epoxy resin medium based two silicone resin
blended with coal tar pack based medium with
medium, suitably Aluminum paint Aluminum flakes.
pigmented suitable upto 250°C.
3 Volume Solids % 65+0.03 38+3 20+2
4 DFT (Dry film 100-125μ 15-20μ 15-20μ
thickness) per
coat in microns
5 Theoretical 5.2-6.5 10-12 8-10
covering capacity

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Sr.
Description F7 F-11 F-12
No
in M2/coat/litre
6 Weight per litre in 1.4+0.03 0.95+0.03 1.00+0.03
kgs / litre
7 Touch dry at 4 hrs. 3 hrs. 30 Minutes
30°C
( maximum)
8 Hard dry at 30°C 48 hrs. 12 hrs 24 hrs
(Maximum)
Full Cure at 30° C 5 Days NA NA
( For immersion /
high temp
service)
9 Over coating Min.: 24 hrs Min.: 24 hrs Min.: 24 hrs
interval Max.: 5 days
10 Pot life at 30°C 4-6 hrs. Not applicable Not applicable
for two
component paints
11 Temperature 125°C 250°C 500°C
resistance Immersion service Dry service Dry service
( Minimum)

Sr.
Description F-15 F-16 F-17 F18
No
Technical Two-component Inert multi- Novalac epoxy High build Epoxy
Name Epoxy phenolic polymeric phenolic Ceramic Filled
coating cured matrix coating cured tank liner
with coating with
1 Polyamine adduct Polyamine
hardner system adduct hardner
(primer +
intermediate coat
+ finish paint)
Type and Two pack Suitable for Novalac epoxy high build Epoxy
composition ambient under phenolic Novalac Ceramic
temperature insulation coating cured Filled tank liner
2 curing coating of CS with for sustained
epoxy phenolic and SS Polyamine immersion
coating system surface for adduct hardner service in
suitable for high Hydrocarbon

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Sr.
Description F-15 F-16 F-17 F18
No
application under temperature cargoes, refinery
insulation of service distillates, furnace
CS/SS piping oils etc., kept at
elevated
Volume Solids 70±3 70±5 98-100 -
3
%
DFT (Dry film 100-125 100-150 125- 150 150-200µ
4 thickness) per
coat (approx.).
Theoretical 4-5 7.0- 9.0 6.5 - 8 3.5-4.7
covering
5
capacity in
M2/coat/litre
Weight per litre 1.65±0.03 1.3 1.7 -
6 in kgs / litre
(mix paint)
Touch dry at 3 hrs 1 hr 2 hr 2-3 hrs
7 30°C
(Maximum)
Hard dry at 24 hrs 16 hrs 24 hrs 10 hrs
30°C 168 hrs (7 days) -
(Maximum) 168 hrs (7
Full Cure at days)
8
30° C ( For
immersion /
high temp
service)
Over coating Min. 36 hrs Min.16 hrs Min. 16 hrs Min: 12 Hrs
9 interval Max.21 days Max. Not Max.21 days Max: 3 days
applicable
Pot life at 4 -6 hrs 1 hr 1 hr 1-2 hrs
30°C for two
10
component
paints
Temperature -45oC to 125°C up to 650° C -45°C to 150°C 180°C
resistance under insulation & for under
11 immersion insulation &
immersion
service

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14.0 PAINT SYSTEMS

The specific paint system recommended to be applied for different areas of the plant are given in the
following tables which are grouped according to the corrosive nature. The individual paints are code
named as P2, F2, F3 etc. The corresponding names are indicated below and the detailed
specifications of individual paint are provided in the previous chapter.

The paint system should vary with type of environment envisaged in and around the plants. Three
types of environment as given below are considered for selection of paint system. The paint system is
also given for specific requirements.

Code Names for different Paints

PRIMERS: -

P-2 Chlorinated rubber zinc Phosphate Primer

P-4 Etch Primer/Wash Primer
P-6 Two component Epoxy Zinc Phosphate Primer cured with polyamine hardener
F-8 Self-priming surface Tolerant High Build epoxy coating cured with polyamine hardener
F-9 Two component Inorganic Zinc Silicate coating

FINISH COATS/PAINTS

F-2 Two component Acrylic – Polyurethane finish paint

F-3 Chlorinated Rubber finish paint
F-6A High Build Epoxy finish coating cured with polyamine hardener
F-6B High Build Epoxy finish coating cured with polyamide hardener
F-6C Two component solvent free type high build epoxy phenolic
F-7 High build Coal Tar epoxy coating cured with polyamine hardener
F-11 Heat resistant synthetic medium based Aluminum paint
F-12 Heat resistant Silicone Aluminum paint
F-14 Specially formulated Coal Tar epoxy coating cured with polyamine hardener
F-15 Two component Epoxy phenolic coating cured with Polyamine adduct hardener system
F-16 High build cold applied inorganic copolymer based aluminum coating
F-17 Novalac epoxy phenolic coating cured with Polyamine adduct hardener system
F-18 High build Epoxy Novalac Ceramic Filled tank liner suitable for immersion service upto
operating temperature of 180° Cent.

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14.1 PAINT SYSTEM

FOR PROJECT AND MOC’S

14.1.1 Pre-Erection/ Pre-Fabrication & Shop Priming for Carbon Steel, Low Temperature
Carbon Steel & Low Alloy Steel, Steel Un-insulated & insulated New Structures, Piping & Tank.

(Note – For all carbon and Low alloy steel surfaces, after blast cleaning, surface profile shall
be 50 to 70µ).

Sr. Design Temperature Surface Total DFT in Microns

Paint System
No. in°. C Preparation (Min.)
1 -90 to 400 SA 2.5 1 Coat of F-9 65-75

2 401 to 500 SA 2.5 2 Coats of F-12 40-50

14.1.2 Repair of pre-erection/pre-fabrication & shop priming after erection/welding for carbon
steel, low temperature carbon steel & low alloy steel uninsulated and insulated items in all
environments. all weld joints and damages of galvanized steel, carbon steel and alloy steel
structures, piping and equipment after erection on above ground overhead areas at site:

Sr. Design Temperature Surface Total DFT in Microns

Paint System
No. in°. C Preparation (Min.)
1 -14 to 80 ST3 1 Coat of F-8 100

14.1.3 External field paint system for all plant areas except SRB, RODM, ETP, RWTP & Cooling
Tower (for Carbon steel, Low Temperature Carbon steel & Low alloy steel) for un-insulated
structures, piping, equipment, flare line etc.

Surface Paint System Total DFT

Design
Sr. Preparation &Pre- in
Temp. in°.
No. erection/shop Field Primer Finish paint Microns
C
primer (Min.)
SA 2.5 ;1 coat of F-
1 coat of F-9 @
1 -90 to -15 9 @ 65-75μ DFT/ None 65-75
65-75μ DFT/ coat
coat

1 coat of F-6B @
SA 2.5 ;1 coat of F-
1coat of P6 @ 40 100μ DFT/coat + 1
2 -14 to 80 9 @ 65-75μ DFT/ 245
μ DFT/coat coat of F-2 @ 40μ
coat
DFT/coat

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Surface Paint System Total DFT

Design
Sr. Preparation &Pre- in
Temp. in°.
No. erection/shop Field Primer Finish paint Microns
C
primer (Min.)
SA 2.5 ;1 coat of F- 2 coats of F-11 @
3 81 to 200 9 @ 65-75μ DFT/ none 20μ DFT/ Coat 105
coat 2x20=40
SA 2.5 ;1 coat of F- 2 coats of F-12 @
4 201 to 400 9 @ 65-75μ DFT/ none 20μ DFT/ Coat 105
coat 2x20=40

SA 2.5;1 coats of 2 coats of F-12 @

5 401 to 500 F-12 @ 20μ DFT/ none 20μ DFT/ Coat 60
Coat 2x20=40

Note:
1. Primer shall be compatible with finish coat
2. For external surfaces of MS chimney, based on temperature painting scheme as per serial no.
3, 4, 5 in above table shall be followed.
3. For external surfaces of RCC chimney: 2 coats of F-6B @ 100μ DFT/Coat to obtain
2x100=200μ DFT shall be applied after making surface preparation as per guidelines given in
surface preparation chapter 10.0

14.1.4 External Paint system for SRB, RODM, ETP, RWTP & Cooling Tower (for Carbon steel,
Low Temperature Carbon steel & Low alloy steel) for un-insulated structures, piping, tanks,
equipment etc.

Surface Paint System Total DFT

Design Field Primer
Sr. Preparation &Pre- in
Temp. (If required)
No. erection/shop Finish paint Microns
in°. C
primer (Min.)

1 coat of F-6A @
SA 2.5 ;1 coat of F-9 1coat of P6 @ 40 μ 100μ DFT/coat + 1
1 -14 to 80 245
@ 65-75μ DFT/ coat DFT/coat coat of F-2 @ 40μ
DFT/coat

14.1.5 Field paint system for Carbon Steel Storage Tanks (external, except for all crude tanks
in BORL and COT, Vadinar) for all environments.
(Refer Section 25 for Internal and External painting / coating of Crude tanks for BORL, Bina
and COT, Vadinar)

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Paint System Total

Design
Sr. Surface DFT in
Temp. in°. Primer
No. Preparation (Field) Finish paint Microns
C
(Min.)
External shell, wind girders, roof tops of all above ground tank including top side of floating
roof of open tank (except Crude tank) as well as covered floating roof tank and associated
1 structural works, rolling and stationary ladders, spiral stairways, hand rails for all
environments for tanks, LDO, HSD, ATF, Kerosene, Gasoline, motor spirit, DM water,
firewater, raw water, potable water, acids, alkalies solvents and chemicals etc.
1 coat of F-9 @ 65- 2 coat of F-6A @
1.1 -14 to 80 SA2.5 75μ + 1coat of P6 100μ DFT + 1 coat 345
@ 40 μ DFT / coat of F-2 @ 40μ DFT
2 coats of F-11 @
1 coat of F-9 @ 65-
1.2 81 to 200 SA 2.5 20μ DFT/ coat = 2 105
75μ DFT/ coat
x 20 = 40
2 coats of F-12 @
1 coat of F-9 @ 65-
1.3 201 to 400 SA 2.5 20μ DFT/ coat = 2 105
75μ DFT/ coat
x 20 = 40
2 External surfaces of bottom plate (soil side) for all storage tanks except Crude tanks.
3 coats of F-7 @
1 coat of F-9 @ 65-
2.1 -14 to 80 SA 2.5 100μ DFT/ coat 365
75μ DFT/ coat
3x100 = 300
3 coats of F16 @
2.2 81 to 550 SA 2.5 None 125μ DFT/ coat 375
3x125 = 375
External surfaces of bottom plate (soil side) for Crude tanks.(Refer Section 25 As well for
3
more details)
2 Coats of F-15@
1 Coat of F-15@
3.1 -14 to 80 SA 2.5 100 DFT/Coat 300
100 DFT/Coat
2x100 = 200
For underside of the bottom plate (in case tank is not lifted after PWHT) e.g SWS, Amine
4
storage and Underside of Stainless steel Storage tanks like Liquid Sulphur tank
1 coat of Inert Multi 2 coat of Inert Multi
*Withstand Polymeric Matrix Polymeric Matrix
4.1 PWHT SA2.5 inorganic Ceramic inorganic Ceramic 375
temp. Coating.@ 125μ Coating.@ 125μ
DFT/ coat DFT/ coat
* Coating must be approved by EIC before application. Necessary Documents to be submitted by
Contractor as per directions.

Note: All paint coating application including primer shall be carried out at field after erection and
completion of welding

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14.1.6 Field paint system for Carbon steel & Low alloy steel Storage Tanks (lnternal)
(For painting of Crude Tanks at BORL, Bina & COT, Vadinar- Refer Section 25)

Paint System Total

Design Surface
Sr. DFT in
Temperature Preparation Remarks
No. Field Primer Finish Paint Microns
in °C Field
(min.)
Internal surface of cone roof with supporting structures, top shell course, underside of
floating roof, oil side surface of pontoons, support structures and ladders and other CS
internals etc , inside of bottom plate, internal surface of bare shell for 1.5 mtr from bottom,
1
for storing petroleum products and intermediates such as Isomerate, Reformate, NHT /
CCR / DHT feed, HSD, Gasoline, Naphtha, SKO, MS - Motor Spirits, LCGO, MTBE and
Dry Slop.
F-15 should
2 Coats of
be suitable for
1 Coat of F- F-15 @
immersion
1.1 upto 80 SA 2.5 15@ 100 100μ 300
service of the
DFT/Coat DFT/ Coat
products
2X100=200
given.
Underside of floating roof, oil side surface of pontoons, support structures and ladders
and other CS internals etc, inside of bottom plate, internal surface of bare shell for 1.5 mtr
2
from bottom , for storing Crude Oil and Crude + Water Tank (52-TT-CR-15).- Refer
Section 25
*Primer shall
be compatible
2 Coats of with F-6C
1 coat of F-6C @ & F-6C should
2.1 upto 80 SA 2.5 Primer* @ 75 300μ 675 be suitable for
μ DFT/ coat DFT/ Coat immersion
2X300=600 service of
products
given
3 Internal surface of top shell courses for free board height for Crude tanks.
3.1 For Details, Refer Section 25 for Painting of Crude tanks
Internal surfaces of bare shell above 1.5 mtrs from bottom including underside of cone
4 roof and supporting structures for Crude + Water Tank (52-TT-CR-15). – Refer section
25 for more details
2 Coats of
1 Coat of F-15 F-15 @
4.1 upto 80 SA 2.5 @ 100 100μ 300
DFT/Coat DFT/ Coat
2X100=200

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Paint System Total

Design Surface
Sr. DFT in
Temperature Preparation Remarks
No. Field Primer Finish Paint Microns
in °C Field
(min.)
5 Inside surface of pontoon of all floating roofs.
1 Coat of F-
1 Coat of F-8
8 @ 100μ
5.1 Upto 80 ST3 @ 100μ 200
DFT/Coat
DFT/Coat

Internal surfaces of underside of Floating Roof, Bottom Plate, complete shell course for
6 full tank height, including immersed gauge pipe, still well etc. and their supporting
structure ,ladders and other CS internals etc for storing ATF- Aviation Turbine Fuel
*Primer shall
be compatible
with F-6C.
F-6C shall
1 Coats of
comply the
1 coat of F-6C @
requirements
6.1 Upto 80 SA2.5 Primer* @ 75 300μ 375
of EI-
μ DFT/ coat DFT/ Coat
Standard
1X300=300
1541.
Shade of
paint shall be
Off-white
Internal surfaces of underside of Fixed Roof and supporting structure for Internal Floating
7
roof tank for storing ATF- Aviation Turbine Fuel
1 coat of F-9 2 Coats of
@ 65-75μ + F-6A @
7.1 Upto 80 SA2.5 1coat of P6 @ 100μ 305
40 μ DFT / DFT/ Coat
coat 2X100=200
Inside of bottom plate, internal surface of bare shell for 1.5 mtr from bottom, for storing
8 petroleum products and intermediates such VR, VGO, IFO/RFO, HCGO and Black Slop
and other high temp. Hydrocarbons
F-18 shall be
suitable for
3 Coat of F- immersion
8.1 81 to 180° SA 2.5 None 375
18 @ 125 service of the
given
products

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Paint System Total

Design Surface
Sr. DFT in
Temperature Preparation Remarks
No. Field Primer Finish Paint Microns
in °C Field
(min.)
Internal surface of cone roof with supporting structures, top shell course for free board
9
height, underside of roof & support structures .
F-15 shall be
suitable for
3 Coat of F- immersion
9.1 81-180° SA 2.5 None 300
15 @ 100 service of the
given
products
10 Internal surfaces of amine & sour water storage tanks
F15 shall be
2 coats of F- suitable for
1 Coat of F-
15 @ 100 μ immersion
10.1 upto 80 SA 2.5 15@ 100 300
DFT/coat service of the
DFT/Coat
2x100 = 200 products
given
11 Internal surfaces of Potable water , Raw water , Fire water
F6A shall be
suitable for
1 coat of F-9
2 Coat of F- Drinking water
@ 65-75μ +
6A @ 100μ service and
11.1 upto 60 SA 2.5 1coat of P6 @ 305
DFT/Coat should have
40 μ DFT /
=2X100=200 competent
coat
authority
certification.
12 Internal surfaces of DM water and Condensate
2 Coat of F-
1 Coat of *Primer shall
6C @ 100μ
12.1 upto 60 SA 2.5 Primer* @ 65- 465 be compatible
DFT/Coat
75μ DFT/Coat with F-6C
=2X200=400
2 Coat of F-
1 Coat of F-15
15 @ 100μ
12.2 61 to 100 SA 2.5 @ 100 μ 300 -
DFT/Coat =
DFT/Coat
2X100=200

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14.1.7 Coating system for external side of underground carbon steel plant piping & tanks

Desig Paint System Total Re

Sr.
n Surface DFT in m
No
Temp Preparation Field Primer Finish Paint Microns a
.
in °C (min.) rk
1 Carbon steel plant piping (underground)
1 layer of coaltar
One coat of synthetic tape coating @ 2mm
primer conforming to + 1 coat of synthetic
AWWA C 203/2003 fast drying primer + 1
Upto and IS 15337/2003 layer of coaltar tape
1.1 SA 2.5 4 mm
50 standards. The primer coating @ 2mm
shall be compatible conforming to
with the hot applied AWWA C 203/2003
tape and IS 15337/2003
standards
1 coat of synthetic
fast drying primer + 1
layer of coal tar tape
coating @ 2mm +
1coat of synthetic
1Coat of Jotatemp-
51 - fast drying primer + 1
1.2 SA 2.5 250 @ 150μ DFT/coat 4 mm
400 layer of coaltar tape
= 150 μ
coating @ 2mm
conforming to
AWWA C 203/2003
and IS 15337/2003
standards
2 External side of un-insulated underground storage tanks
3 coats of F-7 @
-40 to
2.1 SA 2.5 None 100μ DFT/coat 300
80
3x100=300
3 Coat of F-16 @
81 to
2.2 SA 2.5 None 125μ DFT/coat 375
400°C
= 3 x 125 = 375

14.1.8 Painting under insulation for insulated (Hot, cold & safety) carbon steel, low alloy steel,
low temp carbon steel (LTCS) & stainless steel piping, storage tanks and equipment in all
environment.

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Surface
Paint system Total
Preparation
Sr. Design DFT in
/ Pre Remarks
No. Temp in °C Microns
erection / Primer Finish Paint
(min.)
shop primer
1 Insulated carbon steel, low alloy steel , LTCS piping and equipment & tanks
SA 2.5; 1 3 coats of F-
coat of F9 @ 15 @100μ
1.1 -45 to 125 none 365-375
65-75 μ DFT/coat =
DFT/coat 3x100=300

3 Coats of
SA 2.5; 1
F-12@20μ
1.2 126 to 400 coat of F9 @ none 125
DFT/coat F-12 shall be
65-75 μ
3x20=60 ambient
DFT/coat
temperature
curing type till
3 Coats of operating
SA 2.5; 1
F-12@20μ temperature is
1.3 401 to 540 coat of F12 none 80
DFT/coat attained for full
@ 20 μ
3x20=60 curing.
DFT/coat
2 Insulated stainless steel including Alloy-20 piping
SA 2.5 2 coats of F-
1 coat of F- 15 @ 100 μ
2.1 -30 to 125 None 300
15 @ 100 μ DFT/coat
DFT/coat 2x100 = 200
SA 2.5
1 coat of F-
1 coat of F-
2.2 126 to 550 None 16 @ 125 μ 250
16 @ 125 μ
DFT/coat
DFT/coat
3 Cyclic service of SS, Alloy steel and CS
SA 2.5 1 coat of F-
3.1 -180 to 550 1 coat of F-16 @ none 16 @ 125 μ 250
125 μ DFT/coat DFT/coat
4 No painting is required for insulated Monel, Incoloy and Inconel piping.

Notes:
• The blast cleaning abrasives for SS and Alloy20 surfaces shall be SS grits/shots or
Aluminium oxide grits/shots.

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14.1.9 Internal Protection of water side components of coolers & condenser i.e. Channels box,
Channel Cover, Tube sheets and Float Head cover etc.

Paint system Total DFT

Sr. Design Surface in
Remarks
No. Temp in °C Preparation Primer Finish paint Microns
(min.)
1 coat of F- 2 coats of F-15 For CS
1 Upto 80 SA 2.5 15 @ 100μ @100μ DFT/coat 300 tube
DFT/coat 2x100=200 exchanger
For Non-
ferrous /
1 coat of F-
1 coat of F-15 @ SS /
2 Upto 80 SA 1 15 @ 100μ 200
100μ DFT/coat Duplex SS
DFT/coat
tube
exchanger
1coat of glass
For CS
reinforced
3 80-140 SA 2.5 none 1500 tube
novolac epoxy of
exchanger
1.5mm DFT
For Non-
1coat of glass ferrous /
reinforced SS /
4 80-140 SA 1 none 1500
novolac epoxy of Duplex SS
1.5mm DFT tube
exchanger

14.1.10 Field painting system for GI towers

Surface Paint System Total DFT

Sr. Design
Preparatio in Microns Remarks
No. Temp in °C Primer Finish Paint
n (min.)
1 coat of F- 1 coat of F-2
Shade as per
8 @ 100μ @40μ
1 Upto 80 ST3 140 defence
DFT/coat DFT/coat
requirements
1x100=100 1x40=40

14.1.11 Shop & field paint system for Street poles

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Sr. Description Max Surface Painting system Total DFT

No Temp Preparatio Finish in Microns
Primer
°C n Paint (min.)
2 coats of
1 coats of P-6
1 Street Light Poles 80 ST3 F11 @20 80
@ 40μ DFT
DFT/ coat

14.1.12 Painting scheme for PSV

Paint System Total

Surface
Sr. DFT in
Description Preparatio Remarks
No. Primer Finish Paint Microns
n
(min.)
− LPG service:
RAL 5013
(Cobalt Blue)
1 coat of F- 1 coat of F-2 − Conventional
PSV,PRV,PV SA 2.5 / ST- 8 @ 100μ @40μ type: RAL 3024
1 140
RV,TRV 3 DFT/coat DFT/coat (Luminous Red)
1x100=100 1x40=40 − Bellow Type :
RAL 1026
(Luminous
Yellow) colour

14.1.13 Shop & field painting system for RODM & Effluent treatment plant

Paint System Total

Design
Sr. Surface DFT in
Temperature in Finish Remarks
No. Preparation Primer Microns
°C Paint
(min.)
-14 to 80°.C : All
Blast cleaning
R.C.C. surfaces
to SSPC-SP
such as tanks, Epoxy screed
guide lines and
structures, drains lining shall be
Acid etching
etc.) in Process used as per
1 with 10-15% Epoxy screed lining 3mm
sump, TPI OEM
Hcl acid
separator (Process specification
followed by
and Oil), Aeration and guidelines
thorough water
Tank, Transfer
washing.
sump etc.

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Paint System Total

Design
Sr. Surface DFT in
Temperature in Finish Remarks
No. Preparation Primer Microns
°C Paint
(min.)
Upto 60°.C Natural
C.S/M.S Dual Rubber
media filters - Lining shall be
2 (Internal), SA 2.5 Natural Rubber Lining 4.5mm used as per
Chemical dosing As per IS 4682 Part-1 OEM
tanks(internal such specification
as DAP, Urea and guidelines

14.1.14 Temperature Indicating Paint

Sr. Description Max Surface Painting system Remarks

No Temp Preparati
°C on Primer Finish Paint
Cold
Collector, 2 coat of
1 coat of Silicon Mfg – M/s
Transfer line Therm-O-
Heat Resistant Korthal
1 ,TPR & PG 400 SA 2.5 Signal 7-H-52
Primer 6/7360 P Paints
boiler inlet 2 x 25 = 50 μ
1x70 = 70 μ DFT Netherland
channel at DFT
HGU

14.2 – MAINTENANCE COATING SYSTEM

14.2.1 External Paint system for all plants except SRB, RODM, ETP, RWTP & Cooling Tower
(for Carbon steel, Low Temperature Carbon steel & Low alloy steel) for un-insulated
structures, piping, equipment, tanks, flare line etc.
(For Crude tanks, refer section 25)

Design Paint System Total DFT in

Sr. Surface
Temp. in°. Field Primer Microns
No. Preparation Finish paint
C (If required) (Min.)
1 coat of F-16 @ 1 coat of F-16 @ 125 μ
1 -90 to -15 ST3 250
125 μ DFT/ coat DFT/ coat
1 coat of F-6B @ 100μ
1 coat of F-8 @
DFT + 1 coat of F-2 @
2 -14 to 80 ST3 100 μ DFT 240
40μ DFT
1 x 100 = 100
1x 100 +1 x 40 = 140

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Design Paint System Total DFT in

Sr. Surface
Temp. in°. Field Primer Microns
No. Preparation Finish paint
C (If required) (Min.)
1 coat of F-11 @ 2coats of F-11 @ 20μ
3 81 to 200 ST3 20μ DFT/ Coat DFT/ Coat 60
1x20=20 2 x 20=40
ST3 3 coats of F-12 @ 20μ
4 201 to 400 none 60
DFT/ Coat 3x20=60
ST3 3 coats of F-12 @ 20μ
5 401 to 500 none 60
DFT/ Coat 3x20=60

14.2.2 External Paint system for SRB , RODM, ETP, RWTP & Cooling Tower (for Carbon steel,
Low Temperature Carbon steel & Low alloy steel) for un-insulated structures, piping, tanks,
equipment etc.

Design Paint System Total DFT in

Sr. Surface
Temp. in°. Field Primer Microns
No. Preparation Finish paint
C (If required) (Min.)
1 coat of F-6A @ 100μ
1 coat of F-8 @
DFT + 1 coat of F-2 @
1 -14 to 80 ST3 100 μ DFT 1 x 240
40μ DFT
100 = 100
1x 100 +1 x 40 = 140

14.2.3 Painting under insulation for insulated (Hot, Cold & Safety) carbon steel, low alloy steel,
low temp carbon steel & stainless steel Piping, Equipment & tanks in all environments.

Total
Paint system
Sr. Design Surface DFT in
Remarks
No. Temp in °C Preparation Microns
Primer Finish Paint
(min.)
1 Insulated carbon steel, low alloy steel , LTCS Piping , equipment & tanks
2 Coats of F- F-12 shall be
1 Coat of F-
15@100μ ambient
1.1 -45 to 125 ST3 15@100μ 300
DFT/coat temperature
DFT/coat
curing type till
1 Coats of 3 Coats of F- operating
F-12@20μ 12@20μ temperature is
1.2 126 to 540 ST3 80
DFT/coat DFT/coat attained for full
1x20=20 3x20=60 curing.

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Total
Paint system
Sr. Design Surface DFT in
Remarks
No. Temp in °C Preparation Microns
Primer Finish Paint
(min.)
2 Insulated stainless steel including Alloy-20 piping
SA 2.5 2 coats of F-
ST3 1 coat of F- 15 @ 100 μ
2.1 -30 to 125 300
15 @ 100 μ DFT/coat ONLY SS tools
DFT/coat 2x100 = 200 shall be used for
SA 2.5 surface
1 coat of F-
1 coat of F- preparation
2.2 126 to 550 ST3 16 @ 125 μ 250
16 @ 125 μ
DFT/coat
DFT/coat
3 Cyclic service of SS, Alloy steel and CS
ONLY SS tools
1 coat of F- shall be used for
3.1 -180 to 550 ST3 none 16 @ 125 μ 250 surface
DFT/coat preparation on ss
substrate
4 No painting is required for insulated Monel, Incoloy and Inconel piping.

14.2.4 Coating system for external side of underground carbon steel plant piping & tanks

Desig Paint System Total

Sr. Surface
n DFT in
No Preparatio
Temp Field Primer Finish Paint Micron
. n
in °C s (min.)
1 Carbon steel plant piping (underground)
One coat of synthetic 1 layer of coaltar tape
primer conforming to coating @ 2mm + 1 coat of
AWWA C 203/2003 and synthetic fast drying primer +
Upto
1.1 ST3 IS 15337/2003 1 layer of coaltar tape 4 mm
50
standards. The primer coating @ 2mm conforming
shall be compatible with to AWWA C 203/2003 and
the hot applied tape IS 15337/2003 standards
1 coat of synthetic fast
drying primer + 1 layer of
coaltar tape coating @ 2mm
1Coat of Jotatemp-250 + 1coat of synthetic fast
51 -
1.2 ST3 @ 150μ DFT/coat drying primer + 1 layer of 4 mm
400
= 150 μ coaltar tape coating @ 2mm
conforming to AWWA C
203/2003 and IS
15337/2003 standards

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14.2.4 Internal Protection of water side components of coolers & condenser i.e. Channels box,
Channel Cover, Tube sheets and Float Head cover etc.

Design Paint system Total DFT

Sr. Surface
Temp in in Microns Remarks
No. Preparation Primer Finish paint
°C (min.)
1 coat of F- 2 coats of F-15
For CS tube
1 Upto 80 SA 2.5 15 @ 100μ @100μ DFT/coat 300
exchanger
DFT/coat 2x100=200
For Non-
1 coat of F- ferrous / SS /
1 coat of F-15 @
2 Upto 80 SA 1 15 @ 100μ 200 Duplex SS
100μ DFT/coat
DFT/coat tube
exchanger
1coat of glass
reinforced For CS tube
3 80-140 SA 2.5 none 1500
novolac epoxy of exchanger
1.5mm DFT
For Non-
1coat of glass
ferrous / SS /
reinforced
4 80-140 SA 1 none 1500 Duplex SS
novolac epoxy of
tube
1.5mm DFT
exchanger

14.2.5 Painting system for GI towers

Design Surface Paint System Total DFT

Sr.
Temp in Preparati in Microns Remarks
No. Primer Finish Paint
°C on (min.)
1 coat of F-
1 coat of F-2 Shade as per
8 @ 100μ
1 Upto 80 ST3 @40μ DFT/coat 140 defense
DFT/coat
1x40=40 Requirements.
1x100=100

14.2.6 Painting system for Street poles

Sr. Max Surface Painting system Total DFT in Remarks

No Temp °C Preparati Microns (min.)
Primer Finish Paint
on
1 coats of P- 2 coats of F11
1 80 ST3 80
6 @ 40μ DFT @20 DFT/ coat

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14.2.7 Temperature Indicating Paint

Sr. Description Max Surface Painting system Remarks

No Temp Preparation
Primer Finish Paint
°C
Cold
Collector, 1 coat of Silicon 2 coat of
Mfg – M/s
Transfer line Heat Resistant Therm-O-
Korthal
1 ,TPR & PG 400 SA 2.5 Primer 6/7360 P Signal 7-H-52
Paints
boiler inlet 1x70 = 70 μ 2 x 25 = 50 μ
Netherland
channel at DFT DFT
HGU

14.2.8 Painting scheme for PSV

Paint System Total

Sr. Surface
DFT in
No Description Preparati Finish Remarks
Primer Microns
. on Paint
(min.)
− LPG service: RAL
5013 (Cobalt Blue)
1 coat of F-8 1 coat of F- − Conventional type:
PSV, PRV, @ 100μ 2 @40μ RAL 3024
1 ST-3 140
PVRV, TRV DFT/coat DFT/coat (Luminous Red)
1x100=100 1x40=40 − Bellow Type : RAL
1026 (Luminous
Yellow) colour

14.2.8 Internal Painting of Equipments

Internal
Sr Equipment
Unit Description Surface
No Tag Primer Finish Paint
preparation
3 coats of ( F15)
,
1 CDU 11-VV-VI-120 I F L O Vessel SA 2.5 ---
3 x 100 = 300
microns

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One coat of Two

component clear
primer, based on 3 coats of Glass
same grade of flake Vinyl ester,
2 VDU 12-VV-HI-101 Hot Well SA 2.5
vinyl ester coating 3 x 300 = 900
material @ 75 microns
microns
DFT/Coat.
CFC Solvent 3 coats of (
LPG wash contactor F15),
3 21-VV-HI-203 SA 2.5 ---
TU & Phase 3 x 100 = 300
separator microns
One coat of Two
Three coats of
component clear
Two component
primer, based on
vinyl ester
Clear water same grade of
4 DCU 14-TT-00-101 SA 2.5 based glass
Tank vinyl ester coating
flake coating @
material @ 75
300 microns
microns
DFT /Coat.
DFT/Coat.
Internal coating
of De-emulsifier
tank with
De-Emulsifier Belzona 4311 or
5 DCU 14-VV-117 SA 2.5 ---
Vessel equivalent. (
Total DFT 500
microns)

Two coats of
One coats of
epoxy phenolic
Single stage epoxy phenolic
6 SRU 28-TT-CR-101 SA 2.5 paint F15
sour water tank paint F15
2X100=200
100
microns
28-TT-CR- Sour water tank
7 SRU SA 2.5 Do Do
201A 1
28-TT-CR- Sour water tank
8 SRU SA 2.5 Do Do
201B 2

9 SRU 27-TT-CR-101 Lean amine tank SA 2.5 Do Do

10 SRU 29-TT-CR-013 Amine tank SA 2.5 Do Do

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3 Coat of GA
500 WGF
Polyamine
cured solvent
less epoxy @3
X 100 microns
11 HGU 18-VV-HI-32 Slop Tank SA 2.5 _
OR
GP 400
Phenolic epoxy
Glass flake
coating@ 300-
800 microns
Two coats of
One coats of
epoxy phenolic
16-VV-VW- Injection water epoxy phenolic
12 HCU SA 2.5 paint F15
410 drum paint F15
2X100=200
100
microns
13 RO- 32-ACF- Activated SA 2.5 1 coat of F-9 @ 2 Coat of F-6A
DM 01A/B/C/D carbon media 65-75μ + 1coat of @ 100μ
filter P6 @ 40 μ DFT / DFT/Coat
coat =2X100=200
14 RO- 32-ACF-02 Secondary SA 2.5 1 coat of F-9 @ 2 Coat of F-6A
DM A/B Activated 65-75μ + 1coat of @ 100μ
carbon media P6 @ 40 μ DFT / DFT/Coat
filter coat =2X100=200
15 RO- 32-MB-01 A/B mixed bed SA 2.5 Rubber lined
DM exchanger
16 RO- 32-TT-01A/B Unpolished SA 2.5 2 Coat of F-6C
1 Coat of Primer*
DM Condensate @ 100μ
@ 65-75μ
storage DFT/Coat
DFT/Coat
=2X200=400
17 RO- 32-TT-02A/B polished SA 2.5 2 Coat of F-6C
1 Coat of Primer*
DM Condensate @ 100μ
@ 65-75μ
storage DFT/Coat
DFT/Coat
=2X200=400
18 RO- 32-TT-04A/B Caustic SA 2.5 Rubber lined
DM measuring
Tanks MB CPU
19 RO- 35-CMF-01 Activated SA 2.5 1 coat of F-9 @ 2 Coat of F-6A
DM A/B/C carbon media 65-75μ + 1coat of @ 100μ
filter P6 @ 40 μ DFT / DFT/Coat
coat =2X100=200
20 RO- 35-DG-01 Degasser Tower Rubber lined
DM A/B/C

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21 RO- 35-DMF-01 Dual media filter SA 2.5 1 coat of F-9 @ 2 Coat of F-6A
DM A/B/C 65-75μ + 1coat of @ 100μ
P6 @ 40 μ DFT / DFT/Coat
coat =2X100=200
22 RO- 35-MB-01 mixed bed Rubber lined
DM A/B/C/D exchanger
23 RO- 35-PC-01 A/B Waste disposal Rubber lined
DM tank
24 RO- 35-TT-04 Feed Collection SA 2.5 1 coat of F-9 @ 2 Coat of F-6A
DM tank 65-75μ + 1coat of @ 100μ
P6 @ 40 μ DFT / DFT/Coat
coat =2X100=200
25 RO- 35-TT-05 RO-1 Feed tank SA 2.5 1 coat of F-9 @ 2 Coat of F-6A
DM 65-75μ + 1coat of @ 100μ
P6 @ 40 μ DFT / DFT/Coat
coat =2X100=200
26 RO- 35-TT-06 RO-2 Feed tank SA 2.5 1 coat of F-9 @ 2 Coat of F-6A
DM 65-75μ + 1coat of @ 100μ
P6 @ 40 μ DFT / DFT/Coat
coat =2X100=200
27 RO- 35-TT-07 Degasser Rubber lined
DM storage
28 RO- 35-TT-08 Suck back tank Rubber lined
DM
29 RO- 35-TT-09 A/B Fecl3 Dosing Rubber lined
DM
30 RO- 35-TT-17 RO Cleaning Rubber lined
DM
31 RO- 35-TT-23 A/B Caustic dosing Rubber lined
DM tank
32 RO- 35-TT-101 A/B DM water SA 2.5 1 Coat of Primer* 2 Coat of F-6C
DM storage @ 65-75μ @ 100μ
DFT/Coat DFT/Coat
=2X200=400
33 RO- 35-V-01 saturation SA 2.5 1 coat of F-9 @ 2 Coat of F-6A
DM vessel 65-75μ + 1coat of @ 100μ
P6 @ 40 μ DFT / DFT/Coat
coat =2X100=200
34 ETP 56-ACF- Activated SA 2.5 1 coat of F-9 @ 2 Coat of F-6A
01A/B/C/ carbon media 65-75μ + 1coat of @ 100μ
filter P6 @ 40 μ DFT / DFT/Coat
coat =2X100=200

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35 ETP 56-T-03 A/B spent caustic SA 2.5 1 coat of F-9 @ 2 Coat of F-6A
storage 65-75μ + 1coat of @ 100μ
P6 @ 40 μ DFT / DFT/Coat
coat =2X100=200
36 ETP 56-T-05 A/B PH adjustment SA 2.5 1 coat of F-9 @ 2 Coat of F-6A
tank 65-75μ + 1coat of @ 100μ
P6 @ 40 μ DFT / DFT/Coat
coat =2X100=200
37 ETP 56-T-06 Sour water tank SA 2.5 Two coats of
One coats of
epoxy phenolic
epoxy phenolic
paint F15
paint F15
2X100=200
100
microns
38 ETP 56-T-07 Treated Effluent SA 2.5 one coat of 3 coat of High
tank Inorganic zinc build
silicate coating (F- Coal tar epoxy
9) 1X75=75 (F-7) 3X100 =
microns 300 microns
39 ETP 56-T-08 Sour water tank SA 2.5 Two coats of
One coats of
epoxy phenolic
epoxy phenolic
paint F15
paint F15
2X100=200
100 microns
microns
40 ETP 56-T-09 Contaminated SA 2.5 one coat of 3 coat of High
rain water Inorganic zinc build
silicate coating (F- Coal tar epoxy
9) 1X75=75 (F-7) 3X100 =
microns 300 microns
41 ETP 56-T-10 A/B Wet Slop oil SA 2.5 one coat of 3 coat of High
Inorganic zinc build
silicate coating (F- Coal tar epoxy
9) 1X75=75 (F-7) 3X100 =
microns 300 microns
42 ETP 56-V-101 saturation SA 2.5 1 coat of F-9 @ 2 Coat of F-6A
vessel 65-75μ + 1coat of @ 100μ
P6 @ 40 μ DFT / DFT/Coat
coat =2X100=200
43 N2 38-RAC- air cooler SSPS-SP-10 one coat of 2 coat of High
101A/B Epoxy Zinc build
Phosphate Primer Coal tar epoxy
cured with (F-7) 2X100 =
polyamine 200 microns
hardener (P-6)
1X40=40 microns

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44 N2 39-E-152 A/B condenser SSPS-SP-10 one coat of 2 coat of High

Epoxy Zinc build
Phosphate Primer Coal tar epoxy
cured with (F-7) 2X100 =
polyamine 200 microns
hardener (P-6)
1X40=40 microns
45 N2 38-VV-00-101 LP air receiver SA 2.5 1 coat of F-9 @ 2 coat of High
65-75μ build
Coal tar epoxy
(F-7)
coating(100X2=
200u).
46 N2 39-E-814 A/B, Vaporiser SSPS-SP-10 1 coat of F-9 @ 3 coat of High
39-E-815 A/B 65-75μ build
Coal tar epoxy
(F-
7)coating(100X3
=300u).
47 Refin 37-G-101 A/B side stream filter SA 2.5 1 coat of F-9 @ 2 Coat of F-6A
ery 65-75μ + 1coat of @ 100μ
CT P6 @ 40 μ DFT / DFT/Coat
coat =2X100=200
48 Flare 40-VV-00-103 Water seal drum SA 2.5 - 3 Coat of
Novalac epoxy
phenolic coating
cured
with Polyamine
adduct hardener
(F-17 ) 3 x 200 =
600
49 UB Day oil tank SA 2.5 Two coats of
One coats of
epoxy phenolic
epoxy phenolic
paint F18
paint F18
2X100=200
100
microns
50 UB DM water SA 2.5 2 Coat of F-6C
1 Coat of Primer*
storage @ 100μ
@ 65-75μ
DFT/Coat
DFT/Coat
=2X200=400
51 CFB 31-TT-CR-001 Condensate SA 2.5 2 Coat of F-6C
1 Coat of Primer*
C storage @ 100μ
@ 65-75μ
DFT/Coat
DFT/Coat
=2X200=400

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52 CFB TT-CR-2201 HSD storage SA 2.5 Two coats of

One coats of
C epoxy phenolic
epoxy phenolic
paint F15
paint F15
2X100=200
100
microns
53 CFB 31-GN-00- side stream filter SA 2.5 1 coat of F-9 @ 2 Coat of F-6A
C 101A/B 65-75μ + 1coat of @ 100μ
P6 @ 40 μ DFT / DFT/Coat
coat =2X100=200
54 CFB 31-VV-VW-04 Flash tank SA 2.5 1 coat of F-9 @ 2 Coat of F-6A
C /05/06 65-75μ + 1coat of @ 100μ
P6 @ 40 μ DFT / DFT/Coat
coat =2X100=200
55 BDT 70-TT-TB-01 LPG bullet SA 2.5 Two coats of
One coats of
A/B/C/D/E/F epoxy phenolic
epoxy phenolic
paint F15
paint F15
2X100=200
100
microns

15.0 TEMPERATURE INDICATING PAINT

• This system is covered under 14.2.7

16.0 FIRE RETARDANT PAINT / COATINGS

Fire retardant paint is a coating that is meant to curtail fire and diminish the flammability of fuels.
There are different types of fire retardants available including coating, dyes, gels, sprays,
extinguishers and others. It is used to provide additional time in a fire situation to exit a building and
extra time for firefighters to do their job before the fire spreads. Fire Resistive coatings provide
protection for structural steel so that buildings don't collapse in a fire. Applying fire retardant coating
on objects can help in reducing the intensity of fire destruction.

Fire retardant paint helps in reducing the overall intensity of fire but there are certain limitations to it.
Fire retardant coating cannot put an end to fire entirely. Coating your objects with fire retardant paint
does not mean that your workplace or house will not catch fire. However, once a fire has been set,
fire retardant coating will ensure that the intensity, by which it spreads, is reduced.

A wide range of intumescent epoxy coatings are available. These can be described as a mix of
thermally reactive chemicals in a specific epoxy matrix formulated for fireproofing applications. Under
fire conditions they react to emit gases, which cool the surface while a low density carbonaceous char
is formed. This char then serves as a thermal barrier.

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Advantages of intumescent epoxy coatings are:

• Properly applied, these coatings have excellent bonding and corrosion protection.
• They are typically lightweight and durable under no fire conditions.
• Product is available that is flexible and tolerates vibration.
• Certain materials have demonstrated exceptional durability in severe jet-fire tests. e. Because
they are based on an organic system, special characteristics can be designed into the coating.
• Coatings are available that provide an attractive finish appearance.

Disadvantages of intumescent epoxy coatings are:

• There is a possibility of damage to a char coating during a fire, if subjected to impingement by

fire hose streams.
• They require expertise in application, and may require multiple coats or special equipment
which can apply dual components simultaneously.
• Some manufacturers require factory-certified applier personnel.
• Some concerns have been raised regarding potential toxicity of gases generated during fire
conditions.

Fire retardant paints are manufactured by many companies under different brand names, few of them
are given below:

Company Brand name

Akzo Nobel Interchar & Chartek
Asian paints/ Albi Albi clad 800
PPG protective & marine coating PITT/CHAR

17.2 Ground Color

The system of color coding consists of a ground color and secondary color bands superimposed over
the ground color. The ground color identifies the basic nature of the service and secondary color band
over the ground color distinguishes the particular service. The ground color shall be applied over the
entire length of the un-insulated pipes. For insulated lines ground color shall be provided as per
specified length and interval to identify the basic nature of service and secondary color bands to be
painted on these specified lengths to identify the particular service. Above color code is applicable for
both unit and offsite pipelines.

The following ground color designation for identification of basic classification of various important
services shall be followed:

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Post office red Fire protection material

Off white/Aluminum Steam (all pressures)
Canary yellow Chemical & dangerous material
Dark admiralty grey Crude oil, lube oil
Orange Volatile petroleum product (motor spirit & lighter)
Oxide red Non volatile petroleum products (Kerosene and heavier, including
waxy distillates and diesel, gas oil)
Black asphalt, fuel oil Residual oils, still bottoms, slop oils & asphalt, fuel oil.
Sky blue Water (all purities & temperatures)
Sea green Air & its components and Freon

17.0 COLOR CODE FOR PIPING

17.1 For identification of pipelines, the following color coding scheme shall be followed. (Except
ATF).

As per latest DGCA guide line for ATF service color coding shall be Leaf Brown with two black
bands.

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17.3 Color band & Identification lettering (except for ATF service)

For ATF service, 2 color bands of 100 mm with 50 mm gap in between them shall be provided.

The following specifications of color bands shall be followed for identifying the piping contents, size
and location of bands & letters. The bandwidth and size of letters in legends will depend to some
extent upon the pipe diameter. Either white or black letters are selected to provide maximum contrast
to the band color. Bands are spaced 25 mm apart when two bands are employed.

Outside dia of pipe or covering in mm Width of color band in mm

19-32 200
38-51 200
64-150 300
200-250 600
Over 250 800
In addition, ground colour as per specified length should be provided on insulated piping for easy
identification of nature of fluid, on which the colour bands should be painted for identification of each

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service. The length of the ground colour should be 3 times the width of normal band or 2 meters,
whichever is suitable depending on the length of the pipe.

Size of letters stenciled/ written for equipment shall be as given below:

Column and vessel : 150 mm (Height)
Pump, compressor and other machinery : 50 mm (Height)

17.3.1 Color bands

In addition, the contents of the pipe and/or direction of flow may be further indicated by arrows and
legend. If a hazard is involved it must be identified clearly by legend.
The location and size of bands, as recommended, when used, shall be applied to the pipe.

• On both sides of the valves, tees and other fittings of importance.

• Where the pipe enters and emerges from walls and where it emerges from road & walkway
overpasses, unit battery limits.

• At uniform intervals along long sections of the pipe.

• Adjacent to tanks, vessels, and pumps.

17.3.2 Color band specification

The location and size of bands, as recommended, when used, shall be applied to the pipe.
• Unit Area: Bands at intervals of 6.0 meters.

• Offsite Area: Bands at intervals of 10.0 meters.

• Each pipe segment will have minimum one band indication, irrespective of length.

• The bands shall also be displayed near walkways, both sides of culverts, tanks dykes, tanks,
vessels, suction and discharge of pumps/ compressors, unit battery limit, near valves of line,
etc.

17.3.3 For piping, writing of name of service and direction of flow for all the lines shall be done
at following locations

• The letters will be in black on pipes painted with light shade colours and white on pipes
painted with dark shade colours to give good contrast.

• Only writing of service name shall be done on stainless steel lines. Precautions should be
taken while painting by using low chloride content painting to avoid any damage to the
stainless steel pipes. It is preferable to use adhesive plastic tapes to protect stainless steel
pipes.

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Size of Lettering and Direction Arrow shall be as follows:

Lettering

Pipe diameter Width x Height- spacing

2” to 6” inclusive 30 x 30mm - 10 mm min.
6” to 50” inclusive 80 x 80mm - 25 mm min.
Greater than 50” 100 x 100mm - 30 mm min.

Direction arrow

Pipe Diameter W1 (mm) W2 (mm) L1 (mm) L2 (mm)

2” to 6” inclusive 10 30 45 135
6”to50” inclusive 40 80 90 270
Greater than 50” 50 100 150 450

17.4 Special Camouflage Painting for Un-Insulated Crude and Product Storage Tanks

Note: - Camouflaging shall be removed in future paintings or would be done after obtaining
clearance from respective department as per painting recommendation, if unavoidable, then to
be done as per below mentioned details and recommendations. (Recommended for removal)

Two coats of selected finish paint as per defense requirement shall be applied in a particular pattern
as per given below and as per the instructions of the Engineer-in-Charge.
Method of camouflaging
Camouflage painting scheme for Defense requirement in irregular patches will be applied with 3
colours.

• Disruptive painting for camouflaging shall be done in three colours in the ratio of 5:3:2 (all matt
finish)

Dark Green Light Green Dark Medium Brown

5 3 2

• The patches should be asymmetrical and irregular.

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• The patches should be inclined at 300C to 600C to the horizontal.

• The patches should be continuous where two surfaces meet at an angle and the patches
should be coinciding with corners.

• Slits and holes shall be painted in dark shades.

• Width of patches should be 1 to 2 meters.

18.0 INSPECTION & TESTING

All painting materials including primers and thinners brought to site by contracting agency for
application shall be procured directly from manufacturers as per specifications from reputed
recommended brands and shall be accompanied by manufacturer’s test certificates. Paint
formulations without certificates are not acceptable. Site-in-charge at his discretion shall check for
tests for quality and composition of paint at random. Contracting agency shall arrange to carry out
such tests including batch wise tests of wet paints for physical and chemical analysis. All costs for it
shall be borne by the contracting agency.

The painting work shall be subject to inspection by site-in-charge at all times. In particular, following
stage wise inspection will be performed and contracting agency shall offer the work for inspection and
approval of every stage before proceeding with the next stage. The record of inspection shall be
maintained in registers. Stages of inspection are as follows

• Surface preparation

• Each coat of primer application

• Each coat of paint.

All defects noticed during various stages of inspection shall be rectified by the contracting agency to
the entire satisfaction of site-in-charge before proceeding further. Irrespective of the inspection, repair
and approval at intermediate stages of work, contractor shall be responsible for making good any
defects found during final inspection/guarantee period/defect liability period. DFT shall be checked
and recorded after application of each coat of paint and extra coat of paint shall be applied to make
up the DFT specified without any extra cost to owner. Final inspection shall include measurement of
Dry film thickness, check of finish and workmanship. The thickness should be measured at as many
points/locations as decided by the Site-in-charge and shall be within + 10% of the total DFT specified.

The shades of successive coats shall be different in color in order to ensure application of individual
coats, the thickness of each coat and complete coverage should be checked as per the provision of

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this specification. This should be approved by Engineer-in-charge before application of successive

coat.
The following coating inspections and tests shall be done during application:
Surface Contamination

Tests indicating the extent of substrate contamination as a result of iron, chlorides and dust are
specified in ISO 8502-1, ISO 8502-2 and ISO 8502-3, respectively.

Wet Film Thickness, WFT

To avoid rework it is preferable to take wet film thickness measurements during painting in order to
ascertain the adequacy and uniformity of thickness. Spot checks shall be carried out during the
course of the painting operation to ensure that film thickness is being maintained. These shall be
performed according to the procedure described in ISO 2808, Method No. 7B.

Dry Film Thickness, DFT

ISO 2808, Method No.6, describes the test techniques suitable for measurement of the dry film
coating thickness.

Holiday Testing

Holiday testing shall be conducted in accordance with ASTM D 5162 on equipment where the
continuity of the coating is important, for example internal tank linings which are subjected to
corrosive conditions.

Adhesion
The adhesion of the primer to the steel substrate and the intercoat adhesion of the subsequent
coat(s) after curing shall be determined by the application of either a crosscut test in accordance with
ISO 2409 or a pull-off test described in ISO 4624.

Following table gives the summary for Frequency of inspection and criteria for acceptance of painting
work as described above.
Test Standard Frequency Acceptance criteria
Surface ISO 8501-1 One per ten (10) As per surface preparation
cleanliness square meters method.
Surface Profile ISO 8503-2 One per ten (10) As per coating procedure /
square meters data sheet
Holiday Detection NACE RP0188 Random 10% of Zero defects
surface
Dry Film SSPC PA-2 As per Annexure – Shall not be less than 80 %
Thickness A and more than 120 % of
Specified dry film thickness
(DFT).
Wet Film ISO 2802 One per ten (10) Consistent with providing
Thickness square meters required DFT

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18.1 Coating Evaluation

The following tests are normally required to be carried out for a particular type of paint. It is essential
that the Paint supplier/ manufacturer furnish BORL with their QC test report for these tests. This can
be co-related in case of any doubt at any reputed laboratory/ Institute.

18.1.1 Volume volatile content test

The test is used to determine the volatile content of paints and is usually conducted according to
ASTM D-2369, “the Methods for Volatile Content of Coatings”. This test is a means to determine the
percentage of solvents (or other volatile matter) in a coating. The technique is simple and straight
forward and involves weighing small samples of wet paint, both before and after heating, in an oven
maintained at 110 C. Cure time and final film thickness are directly related to the volatile content.

18.1.2 Volume Non-volatile Content Test

The volume nonvolatile test usually referred to as solids by volume test, or volume solid test, as per
ASTM D-2697, “Test Method for Volume Nonvolatile Matter in clear OR pigmented coatings”.
Whereas the weight solids test is used to determine the percentage by weight of nonvolatile matter in
a coating, the volume solids test is used to determine the percentage by volume of nonvolatile
material. This test involves the coating and weighing of metal coupons, both in air and when
suspended in water.

18.1.3 Pigment test

Pigments are insoluble, finely divided materials that provide colour and determine many physical
properties of coatings. When it is necessary to know only the amount of pigment, the method most
commonly, used in ASTM D-2371, “The Method for Pigment Content of Solvent-Reducible Paints”.
This test involves weighing a sample of wet paint, thinning it with solvent, and centrifuging it to isolate
the pigment component. Then the solvent and resins are withdrawn, and the pigment is again
suspended in thinner and centrifuged. This technique is repeated to obtain pigment that is free of
vehicle, which is then thoroughly dried and weighed. When this test is used in conjunction with the
weight solids test, the pigment to-binder ratio can be determined.

18.1.4 Viscosity test

There are a number of ways to measure the viscosity of a coating ranging from measuring how long it
takes for a certain amount of coating to pass through an orifice of a specified dimension, to the use of
a viscometer equipped with a stroboscopic attachment. Viscosity, pigment-to-binder ratio, and
volumes solids are all interrelated and all affect performance and the ease of application of the
coating material.

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18.1.5 Spraybility test

The sprayability test measures the relative ease or difficulty with which a coating is spray-applied.
This is a much more subjective test than any of the above and should be performed under as nearly
identical conditions as possible, including the use of the same technician in evaluating one product as
another.

18.1.6 Hiding power test

There are numerous methods for determining a coating’s hiding power (opacity). Basically, a coating
may be said to “hide” when it has been applied to such thickness as to totally obliterate any traces of
the background to which it was applied. One of the most common methods involves the application
over a black and white checkerboard pattern. The coating is applied in various thicknesses until the
technician can no longer determine the outline of the pattern. The hiding power can also be
determined by measuring the contrast ratio of the black and white squares using laboratory
instruments.

18.2 Coating performance parameter

The common performance measures for coatings and methods of determining them are as follows:

18.2.1 Hardness

There are a number of ways to determine the hardness of a dried coating. One of the oldest methods
is the “pencil hardness” test, which can be performed in accordance with National Coil Coaters
Association (NCCA) Bulletin 11-12, “Specification for Determination of Relative Pencil Hardness”.
(Another is ASTM 3363, “Standard Test Method for Film Hardness by Pencil Test”). In these tests,
the hardness of a pencil needed to rupture a coating is recorded and termed the “pencil hardness”.
Hardness of thick film product can be tested using indentation testers.

18.2.2 Adhesion

A common test to determine adhesion is ASTM D-3359m, Method B, “Test Methods for Measuring
Adhesion by Tape Test”. This test involves scribing a crosshatch pattern of closely spaced parallel
lines in the sample, followed by the application of a special pressure sensitive tape. The tape is then
removed from the panel, in accordance with the provisions of the standards, and, the amount of
coating that is detached is determined in accordance with the method’s visual standards. This test is
also commonly performed on coatings prior to and after exposure to other testing environments, such
as water immersion or accelerated weathering.

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Another useful method is tensile adhesion. With this method, metal doilies are glued to a coated
panel and the force needed to disband them is measured. Though more time consuming than tape
adhesion testing, a more objective numerical result is obtained.

18.2.3 Chemical resistance

The testing of chemical resistance is a rather broad category and includes everything from tap water
immersion testing to sodium hydroxide spot testing. A coating can be tested for chemical resistance
by total or partial immersion in a chemical at ambient or elevated temperatures, or by the application
of a few drops of a chemical at random locations on the panel. The latter is referred to as a spot test,
and the spots are usually covered with a small watch glass to prevent evaporation.
Resistance to various solvents can also be tested in this manner, but an alternate method of testing;
NCCA Bulletin 11-18, “Specification for Evaluation of Solvent Resistance by Solvent Rub Test” is also
commonly used. This test involves applying a particular solvent to a section of cheesecloth and
determining the number of hands rubs necessary to remove some of the coating from the substrate.
Although more subjective than other methods, this method is fast and relatively consistent when
performed by the same technician.
A more severe chemical resistance test involves the use of special test cells consisting of glass
cylinders (commonly referred to as an atlas cell) to which coated. The chemicals of interest (typically
concentrated acids or bases) are then placed in the cell and held at -a given temperature by the use
of an immersion heater. This is a convenient way of obtaining coating performance data at elevated
temperatures and simultaneously tests a coating’s resistance in both the liquid and the vapor phase.
This test is helpful in determining a coating’s resistance to the stresses that occur when a
temperature differential exists across the coating film.

18.2.4 Abrasion resistance

An important property of a coating is its ability to resist abrasion, especially if the coating is designed
to be applied to floors or any structure where mechanical abrasion or natural erosion can be
expected. ASTM Method D968, “Test Method for Abrasion Resistance of Organic Coatings by Falling
Abrasive”, determines the volume of falling sand required to wear through a specified thickness of
coating. Less time consuming is the test in accordance with Method 6192 of Federal Test Method
No.141 A. “Abrasion Resistance (Trabeser Abraser). In this method, the sample is mounted on a
turntable that rotates under a pair of weighed abrasing wheels, and the weight of coating lost per
revolution is calculated.

18.2.5 Flexibility

All structures and/or substrates flex to some°ree. Wood undergoes rather severe dimensional
changes depending on temperature and moisture content and steel will expand or contract in
response to temperature changes. Because of this, it is desirable that coatings have some flexibility.
Test methods for determining flexibility include ASTM D1737, ‘Standard Test Method for Elongation

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of Attached Organic Coatings with Conical Mandrel Apparatus”, Flexibility (Percent Elongation)”. This
method involves the bending of a coated substrate over a mandrel and determining the amount of
bending that can take place before the coating cracks.

18.2.6 Impact resistance

The impact resistance of a coating is a measure of both its flexibility and adhesion. ASTM Method
D2794, “Test Method for Resistance of Organic Coatings to the Effects of Rapid Deformation
(Impact)”, is commonly used and involves dropping a weight on to the coated object from various
heights until the coating fractures or disbands.

18.2.7 Gloss

The gloss of a coating can be measured using a number of instruments, such as a gloss meter, that
will measure the specular gloss of a coating. Thirty and sixty°ree gloss is the most common readings
used. Like adhesion, gloss can also be measured to any of a number of tests as a further means of
characterizing the coating’s performance.

18.2.8 Freeze/Thaw stability

Although freeze/thaw stability is also employed as a test on wet paint, particularly water-based paints
(Methods ASTM D2243, “Test Method for Freeze-Thaw Resistance of Waterborne Paints” and D
2337, “Test Methods for Freeze/Thaw Stability of Multicolor Lacquers”), a freeze/thaw test can be
performed on coated specimens. By changing either the frequency of the freeze/thaw conditions or
the temperature differential between them. Often a tape adhesion test will be performed both before
and after testing in order to determine the effect of freeze/thaw on the coating’s adhesion.

18.2.9 Humidity

Depending on its intended use, a coating’s ability to perform well under conditions of high humidity
may be crucial. A usual means of determining this is to expose coated panels on a condensing
humidity cabinet: Basically, the test panels form a roof over a heated trough of water with the coating
face down. Not only does a high humidity condition exist, but since the back of the panels are
relatively cool, water condenses on the exposed face. The general method is found in ASTM D2247,
“Practice for Testing Water Resistance of Coatings in 100% Relative Humidity”

18.2.10 Salt spray resistance

The salt spray resistance test is used for coatings that are designed to provide corrosion resistance
over metallic substances. The most widely used method is ASTM Bill “Test Method of Salt Spray (fog)
Testing”. The panels are placed in a closed cabinet and exposed to a warm mist of neutral sodium
chloride/ water solution.

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18.2.11 Accelerated Weathering

During their Lifetime, exterior coatings are subjected to a variety of destructive elements, such as
rain, heat, and sunlight. In order to determine a coating’s general durability, numerous methods of
artificial or accelerated gathering have been devised. Although they differ in their actual method of
operation, the various apparatus all of them rely on a combination of moisture and radiation to°rade
the coating. Moisture may be introduced either by spraying or immersion of the specimens or
produced by condensation. Radiation may be introduced either by arcs or by fluorescent ultraviolet
tubes.
Regardless of the instrument used, it should always be kept in mind that this is strictly a comparison
test and that efforts to relate the number of hours of artificial weathering to a period of natural
weathering are difficult at best. Common tests for weathering are ASTM D822, “Practice for
Conducting Tests on Paint and Related Coatings and Materials Using Filtered Open Flame Carbon-
Arc Light and Water Exposure Apparatus” ASTM G53, “Recommended Practice for Operating Light
and Water- Exposure Apparatus (Fluorescent UV-Condensation Type) for Exposure of N Materials”
ultraviolet exposure cabinet or the KTA Envirotest.

18.2.12 Permeability

Most coatings function as a barrier by physically isolating the substrate from moisture. As such, the
permeability of a coating is an important factor in its performance. An applicable test method is ASTM
D 163,”Test Method for Water Vapor Permeability of Organic Coating Films”. A film of coating, either
free standing or with a porous backing such as paper or glass cloth is fastened over the mouth of a
cup containing water and placed in a dissector. The cup is weighed at various intervals, and weight
loss is determined.

19.0 PAINT PERFORMANCE EVALUATION

The paint performance evaluation has to be done by observing the defects that may arise on the films
and metal surface periodically. The defects that may arise include chalking, blistering, cracking,
fading, rusting etc.

19.1 Chalking

Chalking is deterioration of the hard paint film by the attack of UV radiation and other contamination
of the atmosphere, leading to the deformation of film former and also in some cases by the pigment
present. The formation of powdery mass over the surface is the indication, which could be identified
by silk cloth wrapped around the index finger with the medium pressure turning 180°C and observing
the powdery mass absorbed in the cloth. The standard marking of the chalking level could be judged
with ASTM 659.

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19.2 Checking

The formation of short, shallow cracks in an exposed glossy film is defined checking. Visual
observation of extent of checking could be compared as per standard ASTM 660.

19.3 Blistering

The up liftment of the film from the surface, due to pressure developed underneath because of
moisture permeating through film will lead to blister formation on prolonged duration which will leads
to rusting underneath as well. The visual observation on extent of blistering can be recorded as per
ASTM D714.

19.4 Rusting

The formation of rust spots on the painted surface due to penetration of moisture, ions and other
contaminants of the atmosphere is called rusting and the extension of such rust spots over the
surface is called spreading of rust. The extent of rusting can be assessed as per ASTM D 610-85.

19.5 Flaking/Cracking

The defects mainly associated with the coatings, which lift from the surface, or on the film underneath
in the form of plates or at times in the form of bulk layers are called flaking. The extent of flaking or
cracking could be visually compared with ASTM D 661/772.

19.6 Bleeding

‘Bleed Through’ is generally a full or partial redissolving of the previous coat. Bleeding can happen
when strong solvents are used in the top coats.

19.7 Chessiness

The main causes of chessiness are wrong mixing ratio for two pack paints, too low a drying/curing
temperature & excessive solvent reatined within coating.

19.8 Cissing

Surafce contamination by either moisture or foreign matter such as oil, grease silicone etc.

19.9 Cratering

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Trapped air bubbles which have burst to leave small craters as the coating dries. The coating has
insufficient time to flow into the uniform film. It may be avoided by improving spray technique to avoid
air entrainment; by adding thinners as recommended by paint supplier.

19.10 Delamination

Provided compatible paint materials have been used, delamination defects are generally related to
poor surface preparation and application defects, such as contamination between coats; excedding
overcoat times; application to glossy surface.

19.11 Orange Peel

Failure of paint film to flow out. Usually caused by poor application techniques or by incorrect solvent
blend.

19.12 Wrinkling

Usually due to the initial formation of a surface skin with solvent based paints. Also swelling of the
coating due to solvent attack.

20.0 GENERAL INSPECTION GUIDELINES

Check for -
The Paint Manufacturer Certification
Manufacturing date and Expiry date
General health of the packing
Correctness of specification

Surface Cleanliness of the subject surface

Surrounding area to ensure non-contamination during or just after application

Surface cleaning equipment and procedure with due consideration to safety

Proper surfaces after preparation free from all loose particles
Proper cleaning of nooks & corners and difficult to access location

Application Proper time lag from surface preparation to application

Proper mixing (for two pack system)
Correct application tools, procedure and skill
Uniformity of wet film thickness per coat
Proper inter-coat time interval
Adequate post drying hardness

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21.0 PACKAGING & LABELING

All coating materials shall be stored in their original container bearing the manufacturer's label and
instructions. At least the following information shall be shown on the label -
• Name of the coating material

• Name of the paint manufacturer

• Color of the coating material

• Batch number

• Date of manufacturer
• Expiry date

22.0 RECORDS & REPORTS

Prior to final acceptance of the paint work an inspection shall be made. The Contractor and the
Owner shall both be represented and they shall sign an agreed report.
These reports shall include:

General
• Names of the Contractor and the responsible personnel.

• Dates when work was carried out.

Materials preparation
• Equipment and techniques used.

• Materials receipt condition.

• Type and calibration of instruments used.

Environmental conditions
• Weather and ambient conditions.

• Painting periods

Surface preparation
• Condition of surface before preparation.

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• Tools and methods used to prepare surface.

• Condition after preparation.

Paints and painting

• Information on systems being applied.

• Mixing and testing prior to application.

• Paint application techniques.

Testing
• Type of quality control checks carried out, and results.

• Compliance or otherwise with specification.

23.0 ANNEXURE – A

Procedure for Measurement of Dry Film Coating Thickness

Definitions:

• DFT – Dry Film Thickness

• Gauge Reading – A single DFT reading at one point
• Spot – A circle of 4 cm diameter
• Spot Measurement - Average of acceptable three gauge readings within a spot (circle of 4 cm
diameter)

Spot Measurement Procedure:

Minimum of three (3) gauge readings shall be made for each spot measurement of either the
substrate or the coating. Repeated gauge readings, even at points close together, may differ due to
small surface irregularities of the coating and the substrate. For each new gauge reading move the
probe to a new location within 4 cm diameter circle defining the spot. Discard any unusually high or
low reading that cannot be repeated consistently. Take the average of the acceptable gauge readings
as the spot measurement.

Required Number of Measurements for Conformance to a thickness specification

Number of Measurements:

Make five (5) spot measurements spaced randomly over each 10 m2 (100 ft2) area to be measured.
No. of spot measurement beyond five for an area of 10 m2 can be increased as decided by BORL.
The five spot measurements shall be made for each 10 m2 (100 ft2) of area as follows :

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• For structures not exceeding 30 m2 (300 ft2) in area, each 10 sq m2 (100 ft2) area shall be
measured.

• For structures not exceeding 100 m2 (1000 ft2) in area, three 10 m2 (100 ft2) areas shall be
randomly selected and measured.

• For structures exceeding 100 m2 (1000 ft2) in area, the first 10 m2 (1000 ft2) shall be measured
as stated above and for increment thereof or each additional 100 m2 (1000 ft2) of area, one 10
m2 (1000 ft2) area shall be randomly selected and measured.

• If the dry film thickness for any 10 m2 (100 ft2) area as mentioned in (b) & ( c) above is not in
compliance with the requirements of (e) & (f) as mentioned below, then additional
measurements must be made to isolate the nonconforming area.

Specifying Thickness:

Both a maximum and a minimum DFT should be specified for the coating. If a maximum thickness
value is not explicitly specified, the specified thickness shall be minimum.

• Minimum thickness: The average of five spot measurements for each 10 m2 (100 ft2) area
shall not be less than the specified minimum DFT. The average of three gauge readings at
any single spot measurement in any 10 m2 (100 ft2) area s hall not be less than 80% of the
specified minimum DFT. If the average of five spot measurements for a given 10 m 2 (100 ft2)
area meets or exceeds the specified minimum DFT and any spot measurement does not meet
80% of the specified minimum DFT, additional spot measurements may be made to define the
non-conforming areas.

• Maximum thickness: The average of five spot measurements for each 10 m2 (100 ft2) area
shall not be more than the specified maximum DFT. No single spot measurement in any 10 m2
(100 ft2) area shall be more than 120% of the specified minimum DFT. If the average of the
five spot measurements of a given 10 m2 (100 ft2) area meets or falls below the specified
maximum DFT, but one or more spot measurements is more than 120% of the specified
minimum DFT, additional spot measurements may be made to define the non-conforming
area.

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24. EXTERNAL PAINTING OF TANKS

A) DURING M&I AND NEW CONSTRUCTION

Type of tanks
Location (Insulated/ Un-insulated) Tank Component

Un-insulated Full Tank including roof

Refinery Insulated Tanks
Full Tank including roof
COT Un-insulated Full Tank including roof

Note: - Painting of crude oil tank shall be done as per Annexure-A

B) IN SERVICE (INCLUDING CRUDE TANKS)

Type of tanks (Insulated/

Location Un-insulated) Tank Component

Refinery Un-insulated Full tank including roof

COT Un-insulated Full tank including roof

c) All carbon steel pontoons internal surfaces of external floating roof and internal floating roof
tanks shall be painted with respective painting system.
d) External floating roof tanks top shell internal painting shall extend up to 100 mm above top
of shunt of secondary seal marked at safe filling height during hydro test.
e) Before changing of tank service resistivity of the painting system to be verified.
f) In tank history details of paint manufactures with brand name to be mentioned. These
would facilitate defects observations and would also be basis for evaluation of the painting
contractor /paint system and manufacturer for future works.
g) For all internal lining / internal painting works including external painting, manufacturer’s
laboratory test statement / Laboratory Paint performance certificates to be submitted by
paint manufacturers & checked apart from material test certificates for specified services at
operating temperature and condition.
h) Material shall be procured from only those approved manufacturers who meet the required
criteria. For details of tanks internal and external painting, respective paint system shall be
followed.
i) Camouflaging shall be removed in future paintings or will be done after confirmation and
recommendations only for all tanks including Crude tanks.

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25. CRUDE OIL TANKS PAINTINGS

25.1 Scope

This standard exclusively covers the painting of crude oil storage tanks in BORL Refinery including
COT, Vadinar. This standard has been derived from existing SOP/09/11, Rev.-1 & AE-S-5430,
Rev. 2 (BPCL) and painting practices being followed at BPCL MR. Intent of this standard is to
have better protection of Crude tanks against adverse environments.

25.2 Tank operating conditions

Operating temperature: Not above 65 degree Celsius.

Operating pressure: Ambient.

25.3 Surface preparation

The purpose of surface preparation is to create a continuous highly adherent, homogeneous and
defect free paint film with an even thickness over the tank surfaces. For new painting, all the
internal & external surfaces shall be blasted to achieve the surface profile as given in
Annexure – A. Light shades and streaks are not allowed. When steel shot is used, it shall be
used together with steel grit. The purpose of surface preparation is to create a continuous highly
adherent, homogeneous and defect free paint film with an even thickness over the tank surface.
Compressed air used shall be free of moisture and oil. Adequate separators and traps shall be
provided, installed in the coolest part of the system. The presence of oil and water shall be
determined at least two (2) times per eight hours and following every compressor start-up. The
air discharge temperature shall not exceed 100 °C. The blasting nozzles should be venturi style
with tungsten carbide or boron carbide as the materials for liners. Blasting nozzles shall be
replaced when the specified minimum blast pressure, surface cleanliness and surface roughness
can no longer be achieved. Blasting equipment and the equipment being blasted shall be
properly earthed to prevent the occurrence of electrostatic discharges. If possible, vacuum
collector shall be installed for collecting the abrasives for recycling. Recycled shot shall be used
only after ensuring that it is clean enough to provide the minimum surface preparation mentioned
above.

When working in confined spaces, adequate ventilation and intrinsically safe lighting shall be
used. As a minimum, ventilation shall ensure sufficient air changes such that the threshold limit
value (TLV) of the various coating materials in use shall not be exceeded. Access for coating
work should be constructed so as to provide easy and sufficient access for surface preparation,
painting and inspection of all surfaces

25.4 Recommended environment conditions for Paint Application

For all cases, paint manufacturer guidelines shall be followed. Following restrictions are given as

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recommended practices:

25.4.1 Coating application shall not be permitted in the following conditions.

4.1.1 During fog, mist or rain.
4.1.2 When the relative humidity is 85 percent or above.
4.1.3 When the steel surface temperature and/or ambient temperature is below 10°C
(50°F).
4.1.4 When the steel surface temperature and/or ambient temperature is above 50°C
(120°F).
4.1.5 When the steel surface temperature is less than 3°C (5°F) above the dew point.

25.4.2 For all internal painting work, the dehumidification of the surrounding air dew point shall
be maintained 5 degree Celsius below the prevailing surface temperature. The relative
humidity shall be maintained not more than 45% from preparation to curing of coatings. It
is strongly recommended to use Dehumidifiers to maintain the better conditions for
painting and effective results.

25.4.3 The measurement of the following shall ensure prior to start of work and shall be done
every three hours for the entire duration of the painting work and shall extend till the paint
is dried and cured.

4.3.1 Relative Humidity (RH).

4.3.2 Ambient air temperature.
4.3.3 Surface temperature of the object being painted.
4.3.4 Air temperature at surrounding of the painting.
4.3.5 Air flow

25.4.4 There shall be no welding activity or radiography testing on the shell during and after
installation of coating system.

25.4.5 Humidity and dew point readings shall be taken with a sling Psychometric meter and
calculated using psychometric tables.

25.4.6 Coatings shall not be applied before the surface has been inspected and the preparatory
work approved.

25.4.7 All edges shall be ground to a minimum radius of 3.2 mm. Flame cut areas and weld
spatter shall have been ground flush. All rough welds shall be ground to remove sharp
edges and other such irregularities. The amount of grinding performed shall be judicious
and performed only to the extent necessary to prepare the weld surface and surrounding
metal surfaces in accordance with the specification. Over grinding, which would result in

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decreasing the wall thickness or the integrity of the weld beyond the limitations imposed
by good welding practices, applicable welding codes, or tank or vessel ratings, shall be
avoided. All weld spatter and arc strikes must be removed. (Refer NACE SP 0178).

25.4.8 Salt water spray areas shall require fresh water blasting or fresh water (Max. Chloride
content 50 ppm) mopping to remove the salts deposited on metal surface before
application of primer. Mopping can be repeated before application of other coats to
remove salts deposited on previous coats, if such deposits are suspected.

25.4.9 Blast cleaned steel surfaces shall not be touched by bare hand.

25.4.10 If the surface being cleaned is adjacent to a coated surface, the blast cleaning shall cut
in to 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.

25.4.11 To prevent dust and abrasive contamination, blast cleaning shall not be carried out
adjacent to painting operations or wet (painted) surfaces.

25.5 Mixing and Painting

25.5.1 Mixing & Thinning
All paint spraying equipment, including mixers, shall be thoroughly cleaned before
mixing of new materials. All coating materials shall be mixed and thoroughly stirred in
accordance with the instructions of the paint Manufacturer. Sufficient agitation to
maintain good mixing shall be applied until the product is used. If air is entrapped in the
product during mixing/stirring, sufficient time should be allowed for the air bubbles to
escape before application.

25.5.2 Application of paint/primer:

5.2.1 Blast cleaned surface shall be coated with one complete application of primer as
soon as practicable but in no case later than 4 hrs. the same day or as per the
time frame stipulated in the technical data sheet of the paint, whichever is
earlier.

5.2.2 To the maximum extent practicable, each coat of material shall be applied as a
continuous film uniform thickness free of porous. Any spots or areas missed in
application shall be recoated and permitted to dry before the next coat is
applied. Applied paint should have the desired wet film thickness.

5.2.3 No coat shall be applied until the preceding coat has dried and cured as

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recommended by Paint Manufacturer. Next coat shall be applied within the time
stipulated by the paint manufacturer. Before over coating, over-runs, drips and
smears shall be removed and any coating damage or imperfection shall be
repaired. The material shall be considered dry for re-coating when another coat
can be applied without the development of any film irregularities such as lifting or
loss of adhesion of undercoats. Drying time of the applied coat should not
exceed maximum specified for it as a first coat; if it exceeds the paint material
has possibly deteriorated or mixing is faulty.

5.2.4 No paint shall be force dried under conditions, which will cause cracking,
wrinkling, blistering formation of pores, or detrimentally affect the conditions of
the paint. No drier shall be added to paint on the job unless specifically called
for in the manufacturer's specification for the paint. Paint shall be protected
from rain, condensation and contamination until dry.

5.2.5 All paints and painting materials shall be stored only in rooms to be arranged by
contractor and approved by Engineer-in-charge for the purpose. All necessary
precautions shall be taken to prevent fire.

5.2.6 Surface preparation and paint application shall be done in presence of

Manufacturer’s representative. Manufacturer’s representative shall have
necessary certification from agency like NACE to supervise and ensure the
quality of paint applied.

5.2.7 All personnel shall be provided with personnel protection, e.g. protective
clothing, safety glasses, safety shoes, hard hats, goggles, respirators, earplugs,
fresh air-fed hood and any other necessary safety equipment. All safety
equipment shall be maintained in a good working condition. Warning signs shall
be prominently displayed at all access points to areas where abrasive blasting
and painting is in progress.

5.2.8 The Contractor shall protect all equipment, structures and any other areas from
mechanical damage, environmental damage, blockage or obstruction and
damage caused by over blasting, dripping paint, paint splashes and overspray.

5.2.9 To minimize the risk of damage, no lifting, transportation, erection or fabrication

operations shall be done before the paint has been fully dried and/or cured.

5.2.10 Abrasive blast cleaning and coating operations should be carried out during
daylight hours. However, grit blasting and coating may be carried out at night
providing the lighting and environmental conditions are acceptable. Minimum
lighting requirements for abrasive blasting, painting and inspection are 500 lux.

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5.2.11 For internal tank coatings and the external coatings of buried or immersed
equipment and structures, pinhole testing for electrically non-conductive coatings
shall be carried out in accordance with NACE SP0188. The high voltage
technique shall be used; nominally set at 5 V/µbased on DFT, or as agreed with
the paint Manufacturer but not exceeding 25 kV in total. For coating thickness <
500 µ DFT, the low voltage wet sponge technique shall be used.

25.5.3 Spray application

Spraying is the required method of application. The painting Contractor shall supply the
required range of spray tips, sizes and fan angles for the work being undertaken. The
spray pressure shall be uniform and the spray pattern smooth.

25.5.4 Brush application

Brush application may be done for Maintenance operations, in those cases where
spray application may affect other plant, equipment, property or personnel in or near the
work site. Where the coating product is specified as only being suitable for brush
application. Manufacturer shall confirm in writing that paint is suitable for brush
application and will able to meet the guarantee period. Brush application shall be done
only with concurrence of Engineer in charge. Coatings applied by brush shall be
smooth and even

25.5.5 Roller application

Roller application shall only be allowed for steel floors and for panels and equipment
inside climate-controlled areas. Rollers shall be of good quality to ensure uniformity of
the applied coating.

25.5.6 Stripe coat

Before spray application of each coat, irregular surfaces such as sharp edges, welds,
small brackets, interstices etc. shall be stripe-coated, usually by brush, to ensure the
specified film thickness is provided. Stripe coat shall be applicable in all the painting
systems.

25.5.7 Repair of coating defects

Damaged areas, defects in the coating system such as over-runs, drips and smears
that have to be removed or areas with inadequate dry film coating thickness shall be
re-cleaned. The re-cleaning shall carry over on to the sound coating for not less than
50 mm all round, the edges of which shall be feathered.

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After the surface cleaning, the specified coating system shall be re-applied. Any
additional coats shall blend in with the final coating at adjoining areas. Paint
Manufacturers shall be consulted if the existing coating requires abrading before over-
coating to obtain good bonding.

25.5.8 Only thinners specified by the paint Manufacturer shall be used

25.6 Paint Procurement

Painting Contractor shall procure paint material from BORL approved manufacturers only.

25.7 Inspection and testing

25.7.1 Refer section 18 or point no. 25.12 for testing of paint material

25.7.2 Minimum suggested stages of inspection shall be:

a. Surface Preparation
b. Primer application
c. Each coat of paint

25.7.3 All defects noticed during stages of inspection, shall be rectified free of cost by the
contractor. All records shall be kept by the contractor.

25.7.4 Wet film thickness measurements shall be made throughout the course of painting in
order to ascertain the adequacy and uniformity of thickness. The readings shall be
taken at least one every ten (10) square meters.

25.7.5 Dry film thickness shall be taken on each coat after drying and curing of the coat. Dry
film thickness (DFT) readings shall be taken using a non-destructive dry film
thickness instrument capable of storing the readings. Sufficient readings shall be
taken covering each coat prior to application of the following coat to ensure the
correct required DFT.

25.7.6 The DFT indicated against each system shall be obtained by applying one or more
coat of the paint based on paint properties. The Contractor is responsible to obtain
the indicated DFT as per painting system specification.

25.7.7 DFT meter used shall be calibrated before each inspection and shall be witnessed by
the Inspector. It is the duty of the Inspector to satisfy him/herself with the
performance of the DFT meter.

25.7.8 Criteria for acceptance of painting work shall be in accordance with table – 2.

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TABLE - 2
Test Standard Frequency Acceptance criteria
Surface ISO 8501-1 One per ten (10) Sa 2 ½
cleanliness square meters
Surface Profile ISO 8503-2 One per ten (10) As per coating procedure / data
square meters sheet
Total Soluble ISO 8502-9 One per twenty (20) <5 g/cm2
salt square meters or
contamination minimum 5 tests
whichever is more.

Dust ISO 8502-3 One per ten (10) Rating 2 or better

square meters
Adhesion ISO 4624 One pretest panel, 5 MPa
per shift
Holiday NACE SP0188 100% of surface Zero defects
Detection
Dry Film SSPC PA-2 As per Annexure - F Shall not be less than 80 % and
Thickness more than 120 % of the Specified
dry film thickness. (DFT).

Wet Film ISO 2802 One per ten (10) Consistent with providing
Thickness square meters required DFT

25.8 Painting Contractor’s Responsibility

25.8.1 Contractor shall mobilize the adequate capacity dehumidification unit at site for all
internal painting work, if required. The surrounding air dew point shall be maintained 5
degree Celsius below the prevailing surface temperature. The relative humidity shall be
maintained not more than 45% from preparation to curing of coatings.

25.8.2 The contractor shall ensure proper functioning of the dehumidification unit, measuring
RH and temperature, measuring air flows and maintained 24 hours till coating work is
completed in the tank.

25.8.3 All paints and consumables for a particular tank painting work shall be sourced from
one manufacturer only to have desired paint performance, guarantee and single point
responsibility.

25.8.4 Painting contractor shall deploy adequate number of NACE CIP Level 2 qualified

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coating Inspectors to supervise, monitor, inspect & control entire painting process
right from the surface preparation, storage, handling, mixing and application on
substrate of the painting/coating and to ensure the compliance of this specification.
These qualified painting inspectors will report to and shall get guided by BORL
Inspection Dept.

25.8.5 Each contractor shall possess relevant standards and deploy all inspection
tool/instrument to carry out the all above inspection and testing as per relevant
standard.

25.8.6 Organizing of testing all the painting parameters, supply of all the testing instruments,
consumables for testing each parameter as defined in clause 7.10 above, including
getting accepted by BORL, shall be the responsibility of painting contractor.

25.8.7 The Inspection test plan which will be mandatory part of the contract shall be
prepared by the above qualified coating inspector and get it approved by BORL
inspection department. The Contractor’s qualified coating inspector and BORL shall
sign an inspection report as per approved inspection test plan.

25.8.8 The report shall consist, as a minimum, of the following in addition to the inspection
parameters and acceptable criteria:

8.8.1 Names of the applicator and the responsible personnel.

8.8.2 Dates when work was carried out.
8.8.3 Paint testing parameters tested
8.8.4 Equipment and techniques used.
8.8.5 Type and calibration of instruments used.
8.8.6 Weather and ambient conditions.

25.9 Frequency and Guarantee of painting

25.9.1 Frequency of Crude oil tanks Painting system for both internal and external painting
shall be once in 10 years.

25.9.2 Painting Contractor shall furnish Guarantee for minimum 10 years for both internal
and external painting with shot blasting as per Annexure – B, C, D & E.

25.9.3 BORL reserves the right to invoke the guarantees in case contractor (paint applicator)
or contractor fail to repair the paint failed area within reasonable time.

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25.10 Painting system

25.10.1 The painting system shall be as mentioned in Annexure – A.

25.10.2 No painting is considered for roof legs for new tanks. Roof legs to be hot dip
galvanized. Schedule 80 pipes to be used for both roof legs and sleeves. The sufficient
clearance shall be ensured between sleeves and roof legs. However, painting shall be
as per directions & recommendations of inspection in case of Old roof legs with CS
pipes or as applicable.

25.11 SIGN WRITING

All painting work information shall be mentioned (sign writing) with date of completion on
Tank shell as per Engineer-in-charge instructions.

25.12 INSPECTION AND TESTING OF PAINTING MATERIAL

25.12.1 All the procured paint material along with batch/test certificates shall be offered for
BORL inspection for approval. Remaining Shelf life shall be at least 90% of the total
duration at the inspection above.

25.12.2 All paint materials shall be accompanied by Manufacturer Test Certificate.

Inspection Engineer at his discretion may test paint formulations, if required.

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ANNEXURE – A
THIS PAINTING SYSTEM SHALL BE APPLICABLE FOR CRUDE TANKS AT COT VADINAR FOR ALL EXTERNAL PAINTINGS
EXPOSED TO ENVIRONMENT AND FOR CRUDE TANKS AT BINA REFINERY FOR TOP SHELL COURSE PAINTING (FREE
BOARD) & EXPOSED PORTION OF FLOATING ROOF

SR. SURFACES SURFACE SURFACE PRIMER FINISH COAT TOTAL DFT,

NO. PREPARATION PROFILE MICRONS

1 Bottom plate under side Blast cleaning with Profile of 1 Coat of F-15@ 100 2 Coats of F-15@ 100 300
(soil side) grit and shot to Sa 40-70 DFT/Coat DFT/Coat 2x100 = 200
2.5 microns

2 Top shell internal 100 Blast cleaning with 40 Epoxy Coal Tar Epoxy Coal Tar Paint-1x100
mm above top of shunt of grit and shot to Sa microns Paint-1x100 Microns. microns 200
secondary seal marked 2.5
at safe filling height -----OR ---------- OR
during hydro test. 1) Two coat of epoxy high
OR
(Free Board area) One coat of solids MIO (minimum 50 %
inorganic zinc ethyl lamellar MIO on dry film and
silicate (VS 65%; vol solids - 80%). Mist coat &
85% zinc on dry film full coat 100 microns plus one 350
minimum) – 1X 70
coat 100 microns DFT.
Microns DFT
2) Two coats of aliphatic
acrylic polyurethane with
minimum 55% vol solids - 2 x
40 microns DFT.(in approved
colour only)

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SR. SURFACES SURFACE SURFACE PRIMER FINISH COAT TOTAL DFT,

NO. PREPARATION PROFILE MICRONS
---------- OR -----------
1) Two coats of modified
epoxy (vol solids -80%).
Mist coat & full coat 100
microns plus one coat 100
microns DFT.

2) Two coats of aliphatic

acrylic polyurethane with
minimum 55% vol solids - 2
x 40 microns DFT (in
approved colour only)
3 a) Shell external Blast cleaning with 40 One coat of 1) Two coat of epoxy high 400
surface. grit and shot to Sa microns inorganic zinc ethyl solids MIO (minimum 50 %
b) Vertical Gauging 2.5 silicate (VS 65%; lamellar MIO on dry film
band. 85% zinc on dry and vol solids - 80%).
film minimum) – Mist coat & full coat 125
1x70 microns DFT. microns plus one coat 125
microns DFT.
2) Two coats of aliphatic
acrylic polyurethane with
minimum 55% vol solids -
2 x 40 microns DFT. (in
approved color only)

------------OR ------------

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SR. SURFACES SURFACE SURFACE PRIMER FINISH COAT TOTAL DFT,

NO. PREPARATION PROFILE MICRONS

1) Two coats of modified

epoxy (vol solids -
80%).Mist coat & full coat
125 microns plus one
coat 125 microns DFT.
2) Two coats of aliphatic
acrylic polyurethane with
minimum 55% vol solids -
2 x 40 microns DFT. (in
approved color only)
4 Roof deck plates top Blast cleaning with 40 1) Two component Amine / 680
surface grit and shot to Sa microns Amine adduct cured
(Floating roof top surface) 2.5 high solid glass flake
epoxy coating (in
conformance to ISO
20340) – 2 X 300 micron
DFT
2) Aliphatic acrylic modified
high solids weather
resistant recoatable two
pack polyurethane
(finish coat) – 2 X 40
micron DFT
200
5 Pontoon inside surface SSPC – SP2/ST2 Not 1 Coat of F-8 @ 1 Coat of F- 8 @ 100μ
applicable 100μ DFT/Coat DFT/Coat

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SYSTEM FOR EXTERNAL PAINTING OF CRUDE TANKS AT BORL, BINA REFINERY (EXCEPT FREE BOARD INTERNAL AND
FLOATING ROOF TOP SURFACE WHICH SHALL BE AS PER ABOVE TABLE)

SR. SURFACES SURFACE SURFACE PRIMER FINISH COAT TOTAL DFT,

NO. PREPARATION PROFILE MICRONS, MIN
1 External surfaces of Blast cleaning with Profile of 1 Coat of F-15@ 100 2 Coats of F-15@ 100
bottom plate (soil side) grit and shot to SA 40-70 DFT/Coat DFT/Coat 2x100 = 200 300
for Crude tanks. 2.5 microns
2 External shell, wind Blast cleaning with Profile of 1 coat of F-9 @ 65- 2 coat of F-6A @ 100μ
girders, rolling and grit and shot to SA 40 75μ + 1coat of P6 @ DFT + 1 coat of F-2 @ 345
stationary ladders, spiral 2.5 microns 40 μ DFT / coat 40μ DFT
stairways, hand rails for
all environments for
crude oil

SYSTEM FOR INTERNAL PAINTING OF CRUDE TANKS AT BORL, BINA REFINERY (EXCEPT FREE BOARD) & AT COT, VADINAR
(FOR INTERNAL FREE BOARD SECTION OF CRUDE TANK AT BORL, BINA, REFER ABOVE TABLES)

SR. SURFACES SURFACE SURFACE PRIMER FINISH COAT TOTAL DFT,

NO. PREPARATION PROFILE MICRONS, MIN
1 Underside of floating Blast cleaning with Profile of 1 coat of Primer* @ 75 2 Coats of F-6C @ 300μ 675
roof, oil side surface of grit and shot to SA 40 microns μ DFT/ coat (Primer DFT/ Coat 2X300=600
pontoons, support 2.5 shall be compatible
structures and ladders with F-6C & F-6C
and other CS internals should be suitable for
etc, inside of bottom immersion service of
plate, internal surface of products given)
bare shell for 1.5 mtr
from bottom , for storing
Crude Oil and Crude +
Water Tank (52-TT-CR-
15).

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SR. SURFACES SURFACE SURFACE PRIMER FINISH COAT TOTAL DFT,

NO. PREPARATION PROFILE MICRONS, MIN
2 Internal surfaces of bare Blast cleaning with Profile of 1 Coat of F-15 @ 2 Coats of F-15 @
shell above 1.5 mtrs from grit and shot to SA 40 microns 100 μ DFT/Coat 100μ DFT/ Coat
bottom including 2.5 2X100=200 300
underside of cone roof
and supporting structures
for Crude + Water Tank
(52-TT-CR-15).
3 Inside surface of pontoon Blast cleaning with grit 1 Coat of F- 8 @ 100μ 200
1 Coat of F-8 @
of all floating roofs. and shot to SA 2.5 DFT/Coat
100μ DFT/Coat

Note 1) Stripe coat is must for weld area, edges and corners.
2) Over zinc silicate, intermediate coat to be applied in mist coat and full coat technique.
3) In PU paint of silver shade, total thickness to be built in two coats.
4) For PU paint QUVA 340 requirement of 80 % gloss retention after 3000 hrs.
5) All sharp edges to be grinded well before painting.
6) Pitted area having width greater than 2mm or depth greater than 5 mm to be filled with solvent less polyamine adduct cured
epoxy.
7) Camouflaging not to be done.

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ANNEXURE – B

PAINT PERFORMANCE GUARANTEE REQUIREMENTS

a) In order to ensure that BORL gets proper value for the amount invested in painting system, all
endeavor should be to entrust the painting job in totality to the paint manufacturers/ paint
applicators approved by paint manufacturer.

b) The contractor/ paint manufacturers shall guarantee that the chemical and physical properties
of paint materials used are in accordance with specifications contained herein.

c) Any defects that occur during the guaranteed life for the paint system either due to improper
paint materials used or due to faulty application shall be rectified by the paint
manufacturer/contractor at no extra cost to BORL.

d) For surfaces painted after shot and grit blasting - The bank guarantee for initial 2 years
from the date of completion of the job and 8 years Corporate guarantee in the required format
(enclosed) for the tank painting system shall be submitted by paint manufacturer & applicator
either prior to taking up the painting job or after the completion of painting job subject to
release of payment only after the submission of this guarantee.

e) The performance guarantee consists of 2 years bank guarantee for an equivalent value of
10% of the applicable job value (or as per contract terms) and balance 8 years against
corporate guarantee.

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ANNEXURE – C

1. All the guarantees should be submitted to BORL in the Standard format given in this
specification. The guarantee will be two components.

i. The performance guarantee shall be given by the painting contractor for the period
of two years. The retention period is for two years from the date of completion.
Hence, Bank guarantee for 2 years for an amount equal to 10 % of contract value of
painting work to be submitted to BORL.

ii. Corporate guarantee for balance 8 years shall be provided. The painting
contractor and paint manufacturer should have proper agreements and both should
sign the corporate guarantee.

2. During the guarantee period, the paint supplier will carry out joint inspection every six
months for first two years and every one year after this along with BORL engineers. All
repairs during the guarantee period will be done by paint manufacturers at their cost. The
extent of corrosion will be monitored during joint inspections by paint supplier and BORL
engineer.

3. High pressure water washing for tank internal to be carried out. The water shall be potable.

4. Dehumidification system shall be used for internal painting of tanks and is strongly
recommended for all type of internal painting works for better working conditions and
quality works. Paint Manufacturer / Concerned department shall decide on whether
dehumidifier is required there based on the atmospheric condition and painting works could
be permitted under favorable conditions only to have desired quality and performance.

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ANNEXURE – D

PROFORMA OF BANK GUARANTEE

(PERFORMANCE)

To,
M/s Bharat Oman Refineries Limited

Dear Sirs,

In consideration of the Bharat Oman Refineries Limited (hereinafter called ‘the Company’ which
expression shall include its successors and assigns) having awarded to M/s. (Name)
____________________________________________________ (Constitution)_______________
________________________________ (address) _____________________________________
herein after referred to as ‘ The Vendor’ which expression shall wherever the subject or context so
permits include its successors and assigns) a supply contract in terms inter alia, of the
Company's Letter no. _____________________dated ____________ and the General Purchase
Conditions of the Company and upon the conditions of Vendor’s furnishing security for the
performance of Vendor's obligations and / or discharge of the Vendor’s liability under and/or in
connection with the said supply contract up to a sum of (in figures) (in
words) __________________________________________________________________ only
amounting to 10% (Ten percent) of the total contract value or as per contract conditions.

We, (name) (constitution) ______

(hereinafter called ‘the Bank’ which expression shall
include its successors and assigns) hereby jointly and severally undertake and guarantee to pay to
the Company in (Currency) forthwith on demand in writing and without protest or demur of any and
all moneys anywise payable by the Supplier to the Company under, in respect of or in connection
with the said supply contract inclusive of all the Company’s losses and expenses and other moneys
anywise payable in respect of the above as specified in any notice of demand made by the Company
to the Bank with reference to this Guarantee upon an aggregate limit of Rs. (in
figures) (in words) only).

And the Bank hereby agrees with the Company that:

a) This Guarantee I Undertake shall be a continuing Guarantee and shall remain valid and
irrevocable for all claims 'of the Company and liabilities of the Vendor arising upto and until
midnight of _______________________________ .

b) The Guarantee / Undertaking shall be in addition to any other guarantee or security of

whatsoever that the Company may now or at any time otherwise have in relation to the
Vendor's obligations / liabilities under and / or in connection with the said supply contract, and
the Company shall have full authority to take recourse to or reinforce this security in preference

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to the other security(ies) at its sole discretion, and no failure on the part of the Company in
enforcing or requiring enforcement of any other security shall have the effect of releasing the
Bank from its full liability hereunder.

c) The Company shall be at liability without reference to the Bank and without effecting the full
liability of the Bank hereunder to take any other security in respect of the Vendor's obligations
and / or liabilities under or in connection with the said supply contract and to vary the terms vis-
a-vis the vendor of the said supply contract or to grant time and / or indulgence to the Vendor or
to reduce or to increase or otherwise vary the prices of the total contract value or to release or
to forbear from enforcement all or any of the obligations of the Vendor under the said supply
contract and / or the remedies of the Company under any other security (ies) now or hereafter
held by the Company and no such delaying(s), variation(s), reduction(s), increase(s) or other
indulgence/s or arrangement/s with the Vendor or release or forbearance whatsoever shall have
the effect of releasing the Bank from its full liability to the Company hereunder or of prejudicing
rights of the Company against the Bank.

d) This Guarantee / Undertaking shall not be determined by the liquidation or winding up,
dissolution or change of constitution of insolvency of the Vendor but shall in all respects and for
all purposes be binding and operative until payment of all moneys payable to the Company in
terms hereof.

e) The Bank hereby waives all rights at any time inconsistent with the terms of the Guarantee /
Undertaking and the. obligations or the Bank in terms hereof shall not be anywise affected or
suspended by reason of any dispute or disputes having been raised by the Vendor (whether or
not pending before any Arbitrator Officer, Tribunal or Court) or any denial of liability by the
Vendor or any other order of communication whatsoever by the Vendor stopping or preventing
or purporting to stop or prevent any payment by the Bank to the Company in terms hereof.

f) The amount stated in any notice of demand addressed by the Company to the Guarantor as
liable to be paid to the Company by the Vendor or as suffered or incurred by the Company on
account of any losses or damages or costs, charges and / or expenses shall as between the
Bank and the Company be conclusive of the amount so liable to be paid to the Company or
suffered or incurred by the Company, as the case may be, and payable by the Guarantor to
Company in terms hereof.

Signed for and on behalf of:

Name of Bank:

Address:

Seal of the bank:

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ANNEXURE - E

CORPORATE GUARANTEE IN THE FORM OF INDEMNITY BOND FOR 120 (ONE HUNDRED
TWENTY) MONTHS FOR PAINTING WORKS (To be executed in Rs.100/- stamp paper)

(To be executed by Paint manufacturer / applicator)

To,
M/s. Bharat Oman Refineries Limited

Sub: Agreement No.

The Indemnity Bond/ Undertaking/ Guarantee Bond executed at this ______________

day of the month of by M/S.___________________________
(Name of Paint Supplier/applicator) called the "Guarantor” (which expression shall mean and include, if
the context so admits, the partners or partner for time being of the firms & their or their prospective
heirs, executors, administrators, successors and assigns in law) in favor of:

M/s. BHARAT OMAN REFINERIES LIMITED, having its registered office at Administrative Building,
Refinery Complex, Post- BORL Residential Complex, Bina, District- Sagar, Madhya Pradesh –
470124, hereafter called the "OWNER"(which expression shall include its administrators, successors
and assigns in Law).

Whereas the "OWNER" desirous of having executed painting works specified in the Agreement No.
dated issued by the “OWNER" on the
successful tenderer who had participated in the tender No invited
by the "OWNER" and opened on has caused drawings
specifications and bill of quantities showing and describing the work to be done and the same have
been signed on behalf of the successful tenderer.

WHEREAS the successful tenderer have agreed with the "OWNER" to execute and perform the said
work specified in the work order upon terms and conditions provided in the Agreement executed.

‘AND WHEREAS the paint manufacturer has fully acquainted himself and understood all the terms
and conditions attaching to the agreement entered into between the ‘OWNER’ and successful
tenderer regarding execution and performance of the works specified in the Agreement
aforementioned".

IT IS, THEREFORE, THE INTENT OF THIS INDEMNITY BOND BY THE "GUARANTOR" jointly and
severally to indemnify and keep indemnified the "owner" as stated hereinafter:

1.0 Frame work and purpose of this contract

This contract defines what constitutes a defect in the coating system and what are the rights,
obligations and liabilities of the parties in case of defect.

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2.0 The Guarantee

a. The "GUARANTOR" hereby confirms having carefully examined the coating system supplied
by the "OWNER" in the tender document. Considering all technical aspects & climatic
conditions prevailing at the location, the "GUARANTOR" confirm that specified coating system
are fully suitable for the desired services on mild steel vertical oil storage tanks, steel
structures and steel pipelines etc. at the location.

b. The " Paint supplier/ Applicator” hereby confirms that they will ensure thorough surface
preparation as per specified Swedish Standards so as to have desired surface profile before
application of paint system on the steel surface.

c. The "GUARANTOR" hereby agrees to provide all latest codes, SSPC guidelines for painting,
providing surface profile comparators, wet & dry film thickness measuring gadgets and other
painting inspection kits for inspection by "OWNER" conforming to latest SSPC guidelines for
painting inspection.

d. The " Paint supplier/ Applicator hereby confirms to provide Dry Film Thickness (DFT) of paint
specified for every coat .If, actual DFT of a particular coat is beyond the permissible limits of
acceptance of variation in DFT, the "GUARANTOR" undertakes to blast the painted surface
again and apply paint system so as to achieve the specified DFT for every coat.

e. The "GUARANTOR" hereby confirms that the coating system will be free from the defects i.e.
chalking, cracking, alligatoring, flaking, peeling delamination, rusting, blistering, wrinkling,
edge failure and failure around welds etc. during the Guarantee period of the coating system.
The Guarantors guarantee the performance of the coating system during the Guarantee
period.

f. "Performance" means that there will be no defective areas of the coating system during the
Guarantee period.

g. The "GUARANTOR"(Paint supplier/ Applicator) hereby agree that guarantee period of coating
system will commence on the completion of work as detailed in the Agreement
No.____________ dated _______. This corporate guarantee shall commence on
completion of retention period of two years from the date of completion of work. (The Painting
Contractor shall provide Bank Guarantee for the first two years from the date of
completion). It expires 8 (Eight) Years after commencement of corporate guarantee period.
However, the "OWNER’ agrees that guarantee period shall not be extended by any repairs or
repainting made during this guarantee period.

h. "Defective Areas" mean an area or areas where spontaneous visible corrosion has broken the
paint film to a degree exceeding Rust grade No.6 (1% or more of the area painted) of SSPC
Visual Standard No.2 (Guide to Standard method of evaluating Degree of rusting on painted
steel surfaces), within the Guarantee period and or where softening of paint and or peeling of
paint is noticed. Irrespective of the paint in other respects, such as but not limited to staining,
loss of gloss on an area is not considered defective when corrosion activity is rust grade No.6
or less during the said Guarantee period.

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i. The " Paint supplier/ Applicator (GUARANTOR) hereby confirms that in case of premature
paint failure attributable to the quality of the paint, this Guarantee covers that the Guarantor will
supply paint free of cost and will repaint/rectify free of cost for those areas (defective) where
premature paint failure has been accepted and is attributable to the quality of paint and or
workmanship.

3.0 EXCLUSIONS/Force Majeure

The "GUARANTOR" shall have no liability under this contract for the following:

a) Deterioration and damage to the painting system not caused by wear and tear but by Welding
or other heating, Mechanical action, Fire, Explosion, unusual action of the elements or any
other occurrence outside the Guarantor control, and loss or damage which is a
consequence of the aforementioned excluded causes and occurrences.

b) Coating areas on which repair or other works have been performed by the "owner" after
commencement of painting.

c) Deterioration of coating system caused by physical abuse such as on walkways, handrails,

ladders etc.

d) The " Paint supplier and Applicator” obligations are automatically waived off and void if
coating system are affected as consequences of strike, war, invasion, acts of terrorism, or
foreign enemies, hostilities, civil war, rebellion, insurrection, military or usurped power,
confiscation or Nationalization or requisition or destruction of or damage to property by or
under the order of any Govt. or authority and to the extent that loss or damage is directly or
indirectly caused by such circumstances or natural catastrophe.

Authorized Signatory of the Paint Manufacturer/Applicator

Name of the Paint manufacturer/ Applicator: __________________________

Address of the Paint manufacturer/ Applicator: _______________________________________

_____________________________________________

Seal:

WITNESS

1.

2.

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ANNEXURE – H

EXTERNAL FLOATING ROOF INTERNAL FLOATING ROOF FIXED ROOF

1. Top Shell Course of External Floating Roof tank

2. Top Shell Course of Internal Floating Roof tank or Fixed Roof
3. Roof underside of External Floating Roof & Internal Floating Roof & Fixed Roof.
4. Trusses of Fixed roof and top side of Internal Floating Roof

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TANK SHELL PAINTING – INTERNAL

(Shall be carried out as per inspection recommendations and directions)

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26.0 SPECIFICATION FOR THERMALLY SPRAYED ALUMINUM (TSA) COATING

(These specifications shall be used for carrying out the TSA coating work as applicable as per
inspection recommendations only)

26.1 SCOPE:

The following sections outlines the requirement of supply, application and testing of thermally
sprayed aluminum, coatings (TSAC) for corrosion protection of insulated carbon steel piping
and equipment’s with design temperature not exceeding 5400C.

26.2 ITEMS TO BE THERMALLY SPRAYED:

Steel Structures/equipment’s to be protected by TSAC shall be as per standard 3C of this

standard specification. Structures, components thermally sprayed shall not have any uncoated
area or shall not be in mechanically connected by flanges etc. to any uncoated bare steel
work. Such adjacent areas to TSA coated areas, if not coated by TSA shall have suitable paint
coating system as per the standard specification.

26.3 TSAC REQUIREMENTS:

26.3.1 Surface Preparation:

All the parts to be sprayed shall be degreased according to SSPC-SP 1. The absence of oil and
grease after degreasing shall be tested by method given elsewhere in the specification (Refer
Sec.6.7). Thereafter the surface to be abrasive blasted to white metal finish as per NACE
1/SSPC-SP 5 for marine and immersion service. Using SSPC VIS 1, it is to be visually
assessed that the blast cleaned surface meets requirement of SSPC-SP 5. Thereafter clear
cellophane tape test as per ISO 8502-3 shall be used to confirm absence of dust on the blasted
surface. Finally blasted surface shall be tested for presence of soluble salts as per method ISO
8502-9. Maximum allowable salt content shall be considered 50mg/m2. (5 micrograms/cm2). In
case salt content exceeds specified limit. The contaminated surface shall be cleaned by method
as per Annex C of IS 12944-4 (Water Cleaning). After cleaning the surface shall be retested for
salt content after drying. Testing shall be carried out at least on each component, once per 200
m2 and a min of 3 times per shift during progress of work.

The blasting media shall be either chilled iron or angular steel grit as per SSPC-AB-3 of mesh
size G-16 to G-40. Copper, Nickel slag, Garnet or Aluminum Oxide as abrasives will also be
suitable having mesh size in the range of G16 to G24 (10-30 mesh), conforming to SSPC-AB-1.
Mesh size shall be required as appropriate to the anchor tooth depth profile requirement and
blasting equipment used. The blasted surface should be having angular profile depth not less
than 65 microns with sharp angular shape but shall not exceed 85 microns. The profile depth

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shall be measured according to NACE standard RP 0287 (Replica Tape) or ASTM D 4417
method B (Profile depth gauge).

For manual blasting one profile depth measurement shall be taken every 10 - 20m2 of blasted
surface.

Surface preparation shall be completed in one abrasive blasting cleaning operation wherever
possible.

If rust bloom (visual appearance of rust) appears on the blast cleaned surface before thermal
spraying, the affected area shall be re-blasted to achieve specified degree of cleanliness after
which only thermal spraying shall commence.

Air blasting pressure at nozzle shall be normally maintained at 100 psi. Air pressure and media
size should be reduced and adjusted to preclude damage/distortion to thin gauge materials.
Blasting time on work piece should be adjusted to only clean the surface and cut required
anchor tooth with minimum loss of metal. Blast angle should be as close to perpendicular as
possible but in no case greater than ± 30 0 from perpendicular to work surface. Blasting media
must be free of debris, excessive fines, and contaminants such as NaCl and sulfur salts (Ref.
SEC 6.0 of this Spec.). Blast cleaning shall not be performed when the surfaces to be blasted
are wet or less than 5 0 C above dew point temperature or when the relative humidity in the
vicinity of the work is greater than 90%.

a) Blasting Equipment:

The TSAC applicator shall use mechanical (centrifugal wheel) or pressure pot blast cleaning
equipment and procedures. Suction blasting equipment shall not be used. Sec. 6.6.2 shall be
used to validate clean and dry air.

b) Feed Stock:

The feed stock shall be in form of wire. The feed stock shall be 99.5% aluminum of commercial
purity grade, its composition shall be in accordance with requirement of BS 1475 or ASTM B833
or ISO 209-1 type A 1 (wrought aluminum and aluminum alloys, wire). Wire shall be supplied in
protective wrapping indicating batch number and other details.

c) Thickness Requirement:

The nominal thickness of finished TSAC shall be 250 microns having minimum value of 225
microns at low thickness area (valleys) and not more than 275 microns at peak areas.

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The finished thickness shall be measure using SSPC-PA 2 type 2 fixed probe gauge (Magnetic
Gauge).

d) Coating Bond Strength Requirement:

The TSAC coating shall have a minimum individual tensile-bond strength value of 1000 psi for
flame sprayed and 1500 psi for arc sprayed coating with an average of 2000 psi for arc sprayed
coatings. Minimum tensile bond strength should be achieved by proper anchor tooth profile of
blasted surface, laying down the TSA thickness in multiple passes and carrying out TSA
application under controlled environment.

e) Porosity:

All thermally sprayed metallic coatings will have porosity. For thermally sprayed aluminum
coatings porosity shall not exceed 15% of total surface area for flame sprayed coating and 8%
for arc spray coating.

26.4 THERMAL SPRAY APPLICATION PROCEDURE:

Items in the atmospheric zone to be coated by TSA shall be applied by either Flame spray or
Arc spray method only. For coating under insulation, application shall be by arc wire method.

26.4.1 Equipment Set Up:

a) Thermal spray equipment shall be set up calibrated, operated (1) according to

manufacturer instructions/technical manuals and also TSAC applicators refinement thereto
and (2) as validated by Procedure Qualification (See 7.0 of this application).

b) Spray Parameters:

Spray parameters (see table - 9 below) and thickness of each crossing pass shall be set
and shall be validated with bend test (See 6.5 of this Spec.).

c) Spray Parameters:
Spray Parameters Method of Application
Arc voltage Arc wire Spray Flame Wire Spray
27 V -

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Air pressure 80 psi 80 psi

Steel surface cleanliness NACE-1 white metal NACE-1 white metal/or
Near White metal
Steel surface profile 75 microns (minimum) 75 microns (min.)
Arc current 250 - 280A -
Coating thickness 225 microns (nominal) 225 microns (nominal)
Coating adhesion > 1500 psi (Total coating), see 3.1.4 >1000 psi
Coating porosity Less than 8% Less than 15%
Spray distance 6-8” 5-7”
(spray Gun work place)
Spray Pass width 40 mm 20 mm

The above parameters to be validated with a bend test by the contractor before start of work
(for details of bend test see Sec.6.5 of this Spec.).

26.4.2 Post Blasting Substrate Condition and Thermal Spraying Period.

a) The steel surface temperature shall be at least 50C above dew point of ambient air
temperature.

Steel substrate surface temperature shall be recorded by with a contract pyrometer.

Thermal spraying should commence within 15 minutes from the time of completion
of blasting.

b) Holding Period:

Time between the completion of final anchor tooth blasting and completion of
thermal spraying of blasted surface should be no more than four hours. If within this
period rust bloom appears Sec.4.4.1 of this specification will apply.

26.4.3 Pre-Heating:

For flame spraying, the initial starting area of 1 - 2 square feet to be preheated to
approx. 1200 C to prevent condensation of moisture in the flame on the substrate. For
arc spraying the preheating is not required.

26.4.4 Thermal Spraying:

Spraying should commence only after validation of equipment set up by procedure

qualification test and spray parameter validation tests described in Sec 7.0 and 6.5
respectively. Thermal spraying must commence within 15 minutes from the time of

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completion of blast cleaning.

The specified coating thickness shall be applied in several crossing passes. The
coating bond strength is greater when the spray passes are kept thin. Laying down an
excessively thick spray pass increases the internal stresses in TSAC and decreases
the bond strength of total TSAC. The suitable thickness for crossing passes shall be
determined by procedure qualification test described in Sec 7.0 of this specification.

For manual spraying, spraying to be done in perpendicular crossing passes to

minimize thin spots in coating. Approx. 75 - 100 microns of TSAC shall be laid down in
each pass.

The surface geometry of the item or area to be sprayed should be inspected before
application. The spraying pass and sequence shall be planned according to following.
0
- Maintain Gun as close to perpendicular as possible and within ± 30 from
perpendicular to the substrate.

- Maintain nominal standoff distance and spray pass width as given below:

Spray Method Standoff (Inches) Spray pass width (Inches)

Arc Wire 6-8 1 ½ (40 mm)
Flame wire 5-7 ¾ (20 mm)

a) Rust Bloom (Visual appearance of rust or Discoloration):

If Rust bloom appears on the blasted surface before thermal spraying, the affected
area shall be re-blasted to achieve the specified level of cleanliness.

If Rust bloom in form of discoloration, or any blistering or a degraded coating appears

at any time during application of TSAC, then spraying shall be stopped and acceptable
sprayed area shall be marked off. The unsatisfactory areas shall be repaired to the
required degree of surface cleanliness and profile.

Blast the edges of the TSAC to provide 2 – 3” feathered area overlap of the new work
into existing TSAC.

Then apply TSAC to the newly prepared surfaces and overlap the existing TSAC to
the extent of feathered edge so that overlap is a consistent thickness.

b) Masking:

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Masking all those parts and surfaces which are not required to be thermally sprayed
as instructed by purchaser should be inspected by applicator to ensure that they are
properly marked and covered by purchaser.

Complex geometries (flanges, valve manifolds, intersections) shall be masked by

applicator to minimize overspray i.e. TSAC applied outside spray parameters
(primarily gun to substrate distance and spray angle).

c) TSAC Finish:

The deposited TSAC shall be uniform without blisters, cracks, loose particles, or
exposed steel as examined with 10 X magnification.

26.5 SEALER:

Sealant shall be applied after satisfactory application of TSAC and completion of all testing and
measurements of the finished TSAC as per Sec 6.0 of this specification.

For shop work Sealer shall be applied immediately after thermal spraying and for field work
sealer shall be applied within 8 hours. The sealcoat shall be thin enough to penetrate into the
body of TSAC.

The sealant shall be Silicone Alkyd Aluminum paint having DFT not more than 35 – 40 micron.
Typically seal coast shall be applied at a spreading rate resulting in theoretical 38 microns
DFT. The seal coat shall be applied in accordance with SSPC-PA 1 and the paint
manufacturer instruction for sealing.

26.6 TESTING AND MEASUREMENT SCHEDULE:

26.6.1 Surface Finish:

That the blasted cleaned surface meets the required criteria (NACE 1/SSPC-SP 5) shall be
visually inspected using SSPC-VIS 1. The clear cellophane-tape test as per ISO 8502-3 shall
be used to confirm absence of dust or foreign debris on the cleaned surface. Checks shall be
done on each component at least once per 200 m2 of blasted surface and minimum of 3
checks per shift.

26.6.1 Blast Profile Measurement: (In-Process testing during actual production before
application of TSA coating)

The angular profile depth measurement shall be done by profile tape as per method NACE
Standard RP 0287 or ASTM D 4417 method B (Profile depth gauge micrometer). Spot

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measurement shall be carried out every 15 m2 of blasted surface. At each spot three
measurements shall be taken over an area of 10 cm2 and average of measurements to be
recorded and reported. If profile is <65 microns blasting shall continue till greater than 65
microns depth profile is achieved.

26.6.2 TSAC Thickness (In-Process Testing for finished coating during regular
production)

TSAC finished thickness shall be measured using SSPC-PA 2 type 2 fixed probe gauge.

a) For flat surfaces, measurements shall be taken along a straight measurement line, one
measurement line for every 15 m2 of applied TSAC shall be selected along which 5
measurements to be taken at 25 mm internal and average to be reported.

b) For curved surface or complex geometry, 5 measurements shall be taken at a spot

measuring 10 cm2 in area. One spot to be taken for every 15 m2 of applied TSAC area.

c) The TSAC thickness in surface changes or contour changes, welds and attachments shall
be also measured and reported.

d) If TSAC is less than specified minimum thickness, apply additional TSAC until specified
thickness range is achieved.

e) All locations and values of TSAC thickness measurements shall be recorded in Job Record
(JR).

26.6.3 Tensile Bond Testing (In-Process testing for finished coating during regular
production)

- Tensile Bond strength of the TSAC finish coat shall be determined according to ASTM D
4541 using a self-aligning adhesion tester.

- One measurement shall be made every 50 m2. If tensile bond at any individual spot is
less than 1000 psi for flame sprayed coating and 1500 psi for arc sprayed coating the
degraded TSAC shall completely remove and reapplied.

- The tensile bond portable test instrument to be calibrated according to ASTM C 633.

26.6.4 Bend Tests:

Bend test shall be carried out at beginning of each work shift. Bend tests shall also be
conducted on sample coupons before start of thermal spraying work to qualify the following
as mentioned earlier in this specification.

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- To qualify spray parameters and thickness of each crossing pass.

a) Test Procedure:

i) Five corrosion control steel coupons each of dimension 50 mm x 150 mm x 1.3

mm thk. to be prepared.

ii) Surface shall be prepared by dry abrasive blast cleaning as per this specification.

iii) TSAC shall be applied as per specified thickness range. TSAC should be
sprayed in crossing passes laying down approx. 75 – 100 microns in each pass.

iv) TSAC applied coupons shall be bent 1800 around a 13 mm diameter mandrel.

v) Bend test shall be considered passed if on bend radius there is

- No cracking or spalling or lifting by a knife blade from the substrate

- Only minor cracking that cannot be lifted from substrate with a knife blade.

vi) Bend test fails if coating cracks with lifting from substrate.

26.6.5 Tests for blasting media, blasting air

a) Blasting Media (For every fresh batch of media and one random test during blasting)
Blasting Media shall be visually inspected for absence of contamination and debris using
10 X magnification.

i) Inspection for the absence of oil contamination shall be conducted using following
procedure:

- Fill a small clean 200 ml bottle half full of abrasive.

- Fill the bottle with potable water, cap and shake the bottle.

- Inspect water for oil film/slick. If present, the blasting media is not to be used.

ii) Soluble salt contamination if suspected shall be verified by method ASTM D 4940. If
present, media to be replaced.

iii) Clean blasting equipment, especially pot and hoses, and then replace blasting media
and retest.

b) Test for Blasting Air (Once Daily before start of blasting and once at random during
blasting).
The air for blasting shall be free from moisture and oil. The compressor air shall be

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checked for oil and water contamination per ASTM D 4285.

26.6.6 Test for presence of oil/grease and contamination

The steel substrate after degreasing as per SSPC-SP 1 shall be tested as per following
procedure to validate absence of oil and grease contamination.

a) Visual inspection – Continue degreasing until all visible signs of contamination are
removed.

b) Conduct a solvent evaporation test by applying several drops or a small splash or

residue-free dichloromethane on the suspect area especially pitting, crevice corrosion
areas or depressed areas. An evaporation ring formation is indicative of oil and
grease contamination.

Continue degreasing and inspection till test is passed.

26.7 TSAC APPLICATOR QUALIFICATION:

Following tests to be carried out as part of procedure qualification test for the applicator.

- Thickness measurement

- Coating bond strength

- Porosity test

- Bend strength

TSAC applicator’s surface finishing and application process and equipment set up, calibration
and operation shall be qualified by application of TSA on a reference sample which shall be
used as a comparator to evaluate the suitability of application process. Only that applicator will
be permitted to carry out the work when test specimens coated by the applicator meets the
desired requirements as cited below.

The sample shall be made of a steel plate measuring approx. 18” x 18” x ¼” thick. If the actual
work is less than ¼” thick then the sample to be made from material of representative
thickness.

The surface preparation, TSAC application shall be made with actual field equipments and
process/spray parameters and procedures as per the specification. The depth profile of
blasted surface, TSAC coating thickness for each cross pass and total thickness range shall
be as per specification.

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The surface preparation and thermal spraying shall be carried out in representative
environmental conditions spraying with makeshift enclosure.

26.7.1 After application of coating, thickness and tensile bond measurements shall be made in
following manner.

- Divide the sample piece into four quadrants.

- Measure thickness along the diagonal line of each quadrant.

- For each quadrant five in-line thickness measurements at 1” interval shall be done using
SSPC-PA 2 type 2 fixed probe gauge. Thus a total of four “five in line” thickness
measurements to be done for the whole sample.

- One tensile bond measurement using ASTM D 4541 type III or IV portable self-aligning
test instrument to be done at center of each quadrant. Total of 4 measurements for the
sample.

- One porosity evaluation test by Metallographic examination shall be conducted to

demonstrate the achievement of porosity within the limits specified. Sample shall be
prepared for Metallographic examination as per ASTM E-3.

- The procedure shall be considered qualified if thickness and tensile-bond strength and
porosity values meet the specification requirement.

26.7.2 Bend Test: Bend test shall be carried out as detailed at Sec.6.5 of this specification.

Applicators thermal spray equipment set-up, operation and procedure of application including
in-process QC checkpoints adopted during procedure qualification as described above should
be always subsequently followed during entire duration of work.

26.8 DOCUMENTATION:

The following information shall be provided by TSAC applicator before award of work.

- TSAC application process consisting of equipment capabilities and their technical

parameters, feed stock material and source of procurement.

- Detailed application procedure and in-process quality control check points for (a) surface
preparation (b) thermal spraying (c) seal coats.

- Type and specification of instruments to be deployed for measurement of blast profile

depth, TSAC thickness and tensile bond.

- Paint manufacturer data sheet for the selected sealing coat to be applied.

26.9 RECORDS:

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- The TSAC applicator shall maintain job record to record production and QC information.
All the results of the tests and quality control checks shall be entered in the record for
each component/part thermally sprayed. All the result of tests (thickness, tensile bond,
bond tests) and other validation tests (e.g. procedure qualification test, test for surface
cleanliness after abrasive blasting, test for cleanliness of abrasives and air) shall also be
recorded and duly signed by owner.

- All the information mentioned in Sec 8.0 above should also form part of the job record.

- Any modification affected after procedure qualification in the procedure, QC, spray
parameter, equipment spec to the original information (submitted before award of the
work) must also form part of Job record.

26.10 WARRANTY:

The TSAC applicator shall warrant the quality of material used by providing the purchaser with a
certificate of materials used to include

- Spray feed stock: Alloy type/designation, Lot Number, wire diameter, chemical analysis,
name of supplier, manufacturer.

- Sealant: Name of manufacturer, application data sheet.

26.11 SAFETY:

The TSAC applicator shall follow all safety procedures required by the purchaser/owner. Owner
shall also give compliance requirement to be followed by applicator. The applicator shall follow
all appropriate regulatory requirements.

26.12 CODES AND STANDARDS:

This specification shall apply in case of conflict between specification and following applicable
standards:

AWS C.2.17 Recommended Practice for Electric arc Spray

Test Method for Adhesive/Cohesive Strength of Flame

ASTM C 633
Sprayed Coatings

ASTM D 4285 Method for indicating Oil or Water in Compressed Air

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Test Method for Field Measurement of Surface Profile of

ASTM D 4417
Blasted Steel

BS 2569 Specification for Sprayed Metal Coating

Field Measurement of Surface Profile of Abrasive Blast

NACE Standard RP 0287
Cleaned Steel Surfaces using a Replica Tape

Test method for Pull-Off Strength of Coating Using Portable

ASTM D 4541
Adhesion Testers

Guide for the Protection of Steel with Thermal Spray

ANSI/AWS C2.18
Coatings of Aluminum, Zinc and their Alloys and Composites

NACE No.12/AWS Specification for the application of thermal spray coatings

C2.23M/SSPC-CS (Metalizing) of aluminum, zinc, and their alloys and
23.00 composites for the corrosion protection of steel

The inspection of coating and linings: A Handbook of Basic

SSPC Publication
practice for Inspectors, Owners and Specifiers

SSPC-AB 1 Mineral and Slag Abrasives

SSPC-AB 3 Ferrous Metallic Abrasives

SSPC-PA 1 Shop, Field and Maintenance Painting of Steel

SSPC-PA 2 Measurement of Dry Coating Thickness with Magnetic Gages

NACE No.1/SSPC-SP 5 White Metal Blast Cleaning

NACE No.2/SSPC-SP 10 Near – White Metal Blast Cleaning

Guide and Reference Photographs for Steel Surfaces

SSPC-VIS 1
prepared by Dry Abrasive Blast Cleaning

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27.0 BUILDING AND RCC STRUCTURE PAINTING

All the Buildings, RCC structures, pumps and Equipment Foundation shall be coated with protection
coatings to enhance their life, prevent deterioration by time and improve overall aesthetic with
vibrant colours. Also, underground surface shall be coated with protective layer to prevent
deterioration by time and corrosion.

Type of paint shall be as per the painting manual with approved colours.

27.1 BUILDING PAINTS

This section covers various building paints and also concrete and rebar coating.

27.2 UNDERGROUND SURFACE

All under-ground surfaces shall be coated with 2 coats of coal tar epoxy for All RCC structures,
Foundations etc,

27.3 PLANT CONCRETE SURFACE:

Note: After scrap cleaning fill the cracks cavities with suitable polymer mortar like Poly fill AR /
Polyalk EP.

Painting of Plant Concrete Surfaces (Pipe racks, tracks, pump foundations & others)
Sr. Anti- Manufacturing Application
No. Carbonation Primer Company
Fresh / New
Paint Name Old Surfaces
Surfaces
1 Sikagard-670 W Sikagard-670 W M/s Sika 1 Coat Primer + 3 1 Coat Primer + 2
Elasto Color Elasto Color with Coats Anti - Coats Anti -
5% water Carbonation Paint Carbonation Paint
OR

2 Uniguard-815 Uniguard-815 M/s Dr. Fixit 1 Coat Primer + 3 1 Coat Primer + 2

with 20% water Coats Anti - Coats Anti -
Carbonation Paint Carbonation Paint
OR
3 Sunext-8 with Sunext-8 with M/s Sunanda 1 Coat Primer + 3 1 Coat Primer + 2
10% water 50% water Coats Anti - Coats Anti -
Carbonation Paint Carbonation Paint
Note:- Painting shall be done in given pattern in desired colours preferably bright in shades.
Colour Shall be Azure Blue for RCC foundations of pumps & Equipments and Ivory for Piperacks. and
track. (Or same shall be approved & finalized by concerned department or EIC if required).
Frequency – 4 yrs or as per requirement

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27.4 BUILDINGS & SHEDS

TABLE – A:

Important Buildings such

TYPE Sheds Other buildings (SS, as admin. bldg., control
SRR , etc) rooms, main gate house
etc.
Building Weather proof Exterior Weather proof Exterior Antifungal, anti-algae
external Emulsion paint in 2 or Emulsion paint in 2 or acrylic copolymer paint
more coats over a coat of more coats over a coat of
suitable primer. suitable primer.
Building Premium Emulsion paint Premium Emulsion paint Premium Acrylic emulsion/
internal in 2 or more coats over a in 2 or more coats over a plastic emulsion –2 or more
coat of primer with coat of primer with coats over a coat of solvent
surface preparation and surface preparation and thinnable primer including
application of putty as per application of putty as per application of putty as per
requirement requirement requirement
Building Oil Bound Distemper OR Oil Bound Distemper OR Premium Acrylic emulsion/
ceiling Premium Emulsion paint Premium Emulsion paint plastic emulsion –2 or more
in 2 or more coats over a in 2 or more coats over a coats over a coat of solvent
coat of primer with coat of primer with thinnable primer including
surface preparation and surface preparation and application of putty as per
application of putty as per application of putty as per requirement
requirement requirement
Metal surface Synthetic Enamel paint in Synthetic Enamel paint in Anodizing / powder coating
2 or more coats over a 2 or more coats over a or Synthetic Enamel paint
coat of red oxide primer coat of red oxide primer in 2 or more coats over a
after proper surface after proper surface coat of red oxide primer
preparation preparation after proper surface
preparation

Wooden Synthetic enamel in 2 French polish –min.2 French polish –min. 2 coats
surface coats or more coats over coats or Synthetic or Synthetic enamel in 2
a coat of wooden primer enamel in 2 coats or coats or more coats over a
after proper surface more coats over a coat of coat of wooden primer after
preparation wooden primer after proper surface preparation
proper surface
preparation

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Important Buildings such

TYPE Sheds Other buildings (SS, as admin. bldg., control
SRR , etc) rooms, main gate house
etc.
AC sheets Antifungal, anti-algae As Applicable As Applicable
(Vertical acrylic copolymer paint or
Cladding and Weather proof Exterior
slopes from Emulsion paint in 2 or
inside and / or more coats over a coat of
outside) suitable primer.
Cooling water Coal tar epoxy-2 coats as NA NA
Sump /basin per recommendations
Note:-
a) Paints shall be from the approved manufacturers only as per EIC like Asian, Nerolac etc.
b) Colour & quality shall be finalized by EIC. Painting shall be done in given pattern in desired
colours preferably bright in shades or as approved.
c) Application of samples shall be done by contractor as per advise for finalization of colours.

27.5 FREQUENCY FOR BUILDINGS AND RCC STRUCTURE PAINTING

Sr. No. Description Frequency in yrs Paint Application

1 Buildings – Internal & External (including 5 yrs Selection of Paint

pump houses) would be as per
above tables and
2 RCC Pipe racks & Equipment Foundations 4 yrs
recommendations
etc in units and offsite areas

• Frequency may be increased or decreased as per site requirement and priority.

• All Pipe rakes of units including Equipment foundations shall be painted in every shutdown /
Turn Around once in every 4 years or as per schedule.

• For Pipe rakes in offsite area, Painting shall be done as per the finalized frequency or as per
site requirement.

• Proper records shall be maintained and kept for future reference by concerned department.

*********** *********** ***********

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 FOLLOWING ARE THE KEY MODIFICATION / AMMENDMENTS IN PAINTING MANUAL
SOP/09/11, R-2 DATED 20.11.2020 WHICH SHALL BE CONSIDERED FOR PAINTING
WORKS AT BINA REFINERY

List of Paint Manufacturers

Painting Contractor shall procure material from approved manufacturers as mentioned

below:
a) Akzo Nobel paints
b) Asian Paints PPG Pvt. Ltd
c) Berger paints Ltd
d) CDC Carboline Ltd
e) Goodlass Nerolac Paints Ltd / Kansai Nerolac Paints Ltd
f) Growel India (old - Bombay Paints) / Grauer & Weil (India) Ltd
g) Hempel paints
h) Jotun coatings
i) Kirloskar Corrocoat Private Limited
j) PPG Ind USA ( Sigma Coatings & Amercoat)
k) Shalimar paints Ltd.

Additional manufacturers may be approved / advised by BPCL Inspection, subjecting to

technical evaluation. Procurement of paint shall be made preferably from the paint
manufacture only. However, for requirement of small quantities for the maintenance jobs
or other jobs, if the manufacturer denies to supply directly, then supply of same shall be
done through the authorised dealer / distributor only with valid authorisation letter from
manufacturer for dealership / distributorship.

All the procured paint material along with batch/test certificates shall be offered for BPCL
inspection for approval. “Remaining Shelf life shall be at least 50% of the total
duration at the time of above application of procured material by contractor / owner.
However, it is preferred to have the materials from the fresh stock for better
performance of coatings.”

It is recommended to submit data sheets for review and take prior approval from
BPCL inspection team for paint material before ordering / procurement. Further
inspection of the material shall be offered once the material is received at site well before
utilisation of the same. Only inspected & satisfactory paint material is permitted to use
while carrying out the painting job and as per the manufacturer’s recommended
application procedure only or as advised.

Base / Ground Colour Coding of Pipeline for Water, Air & Nitrogen
(As per IS Code-2379:1990)
Following ground colour coding shall be followed for pipelines of :

Page 1 of 4

Page 884 of 1510 : B933-011-CC-MR-6101-2-RFQ : Rev. A

 1) Water - Sea Green (RAL 6018) – All water lines-
2) Air - Sky Blue (RAL 5015) - All types of Air lines
3) Nitrogen – Canary Yellow (RAL 1012)

Coating system for Carbon steel plant piping (underground) for CBD, underground /
under soil (buried) pipelines / vessels from 51 to 400 ° C for CS and 600 ° C for SS
surfaces etc

Total
Sr. Design Surface DFT in
Paint System Remarks
No. Temp in °C Preparation Microns
(min.)
F-16 coating- Inorganic,
Inert multi-polymeric matrix
coating Suitable for under
3x125µ
insulation coating of CS
=
1 51 to 400°C SA-2.5 and SS surface for high
Total
temperature service and 375µ
suitable for cyclic
conditions especially for
CBD

Internal Coating system in Tanks / vessels in RODM/ ETP / RCT/ CPP

Applicable at locations where existing coating is SA 2 ½ Surface preparation + 1 coat of
F-9 @ 65-75μ + 1coat of P6 @ 40 μ DFT / coat + 2 Coat of F-6A @ 100μ DFT/Coat = Total
DFT 315µ.
Same shall be replaced with SA 2 ½ surface preparation followed by 3 X 100µ F-15 coating
(Phenolic epoxy coating) = 300µ DFT

Dehumidification shall be ensured while carrying out internal blasting and painting
works.
(Technical Specification as follows)

Page 2 of 4

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 Technical Specification for Dehumidification During Internal Blasting and Painting
of Tanks, Vessels & Pipelines

This specification outlines the essential requirements for dehumidification during

internal blasting and painting of tanks, vessels, and pipelines. It ensures optimal
conditions by controlling humidity, dew point, and temperature, preventing moisture-
related issues like condensation and flash rust. Adhering to these guidelines enhances
coating adhesion, promotes faster curing, and ensures long-term protection against
corrosion.
An adequately designed dehumidification system shall be employed during internal
blasting and coating operations in tanks, vessels, and pipelines. The system must meet
the following criteria to ensure optimal surface preparation and coating performance:
1. Relative Humidity Control:
The relative humidity (RH) inside the tank, vessel, or pipeline shall be maintained
at less than 55% throughout the entire blasting and painting process, including
during nighttime hours.
2. Dew Point and Surface Temperature:
To prevent condensation and flash rusting, the air dew point must be maintained
at least 3°C below the surface temperature of the material surface being blasted
and painted.
3. Moisture Removal Rate:
The minimum grain drop (moisture removal rate) across the dehumidifier shall be
determined based on the volume of the area being dehumidified. Calculations
shall be performed using a psychometric chart to ensure proper dehumidification
capacity.

4. Partitioning of Large Tanks:

For larger diameter tanks, the dehumidification process shall be applied to
approximately ¼ of the tank at a time. For other tanks, up to ½ of the tank may be
dehumidified at once, with the area divided using suitable partitions such as
scaffolding, tarpaulin sheets, or GI sheets.
5. Air Change Rate:

Page 3 of 4

Page 886 of 1510 : B933-011-CC-MR-6101-2-RFQ : Rev. A

 The required dehumidified air quantity shall be calculated based on the tank
capacity, with the following air change rates applied:
o Up to 2000 KL: 3 air changes per hour
o 2000 - 10,000 KL: 2 air changes per hour
o 10,000 - 35,000 KL: 1 air change per hour
o Above 35,000 KL: 0.75 air changes per hour
6. Temperature Control:
The internal temperature of the tank shall be maintained between 25°C to 35°C
during blasting and painting. A condensing unit may be used in conjunction with
the dehumidifiers and blowers to achieve this temperature range.
7. Continuous Dehumidification:
Dehumidification shall be maintained round-the-clock during the entire surface
preparation and painting process to accelerate paint curing. The dehumidifier
must not be stopped until the priming of the blasted surface is fully completed to
the satisfaction of the Engineer in Charge (EIC) or Inspection team.
8. Equipment Breakdown:
In the event of a dehumidifier failure, the contractor must replace the equipment
at their own risk and cost. Any unfinished work due to the failure must be repeated
as necessary.
9. Performance Compliance:
The EIC or inspection team reserves the right to disallow the use of any
dehumidifier if its performance does not meet the specified requirements. The
contractor shall, at no additional cost to the owner, replace the equipment to
ensure compliance with the specified standards.
10. Data Logging:
The contractor is required to maintain detailed dehumidification data on a two-
hourly basis using a standardized format approved by the EIC or inspection team.
Sr Date & Time Dry Bulb Wet Bulb Relative Sign of Sign of BPCL
No. (In Hrs) Temperature Temperature Humidity Contractor Rep.
Contractor Sign Rep.

*******************

Page 4 of 4

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 ADDITIONAL REQUIREMENTS TO JOB SPECIFICATION NO.
BPCL PAINTING MANUAL B933-000-06-42-PLS-08
BPREP PAGE 1 OF 3

ADDITIONAL REQUIREMENTS TO BPCL

PAINTING MANUAL SOP/09/11

Project : Bina petrochemical & refinery

expansion project

Owner : BPCL

MPMC : ENGINEERS INDIA LTD.

0 29-10-2024 Issued along with panting manual JATIN SAHIL SRIDHAR

Rev.
Date Purpose Prepared by Checked by Approved by
No

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

Page 888 of 1510 : B933-011-CC-MR-6101-2-RFQ : Rev. A

 ADDITIONAL REQUIREMENTS TO JOB SPECIFICATION NO.
BPCL PAINTING MANUAL B933-000-06-42-PLS-08
BPREP
PAGE 2 OF 3

Revisions History:

Sno. Revision Date Description Reference

number
1 0 29-10-2024 Colour coding for external BPCL mail dated 25-10-
surfaces of Crude tank. 2024 regarding crude tank
at COT - Vadinar

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

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 ADDITIONAL REQUIREMENTS TO JOB SPECIFICATION NO.
BPCL PAINTING MANUAL B933-000-06-42-PLS-08
BPREP
PAGE 3 OF 3

1.0 INTRODUCTION

Bharat Petroleum Corporation Limited (BPCL) is operating a 7.5 MMTPA (on 8000 hrs
per year basis) Bina Refinery (BR) at Sagar, Madhya Pradesh. The existing refinery is
producing MS and HSD conforming to BS VI specifications by processing of high sulphur
crudes besides other petroleum products like LPG, Naphtha, Kerosene, ATF, Pet coke
and Sulphur. In order to remain competitive and improve refinery profitability further, Bina
Refinery (BR) has embarked on Petrochemical Diversification Plan and as a part of
further expansion of Petrochemical portfolio, it is intended to set up world scale Ethylene
Cracker & Associated Units and Ethylene and Propylene based Petrochemical units for
its diversification to Petrochemicals along with expansion of its refinery capacity to about
11 MMTPA.

BPCL has awarded the role of MPMC to EIL for Bina petrochemical and refinery expansion project
(BPREP). Along with MPMC, EIL is also EPCM-1, EPCM-2 and PMC -1 of BPREP.

2.0 SCOPE

Protective coating requirements of the BPREP are governed by the BPCL painting manual
SOP/09/11. Initially, second revision of the manual is received by EIL for issue to various tenders
and MRs.

The purpose of this document is to address specific requirements of the BPREP, which are not
covered in BPCL painting manual. This document lists various protective coating related technical
inputs received or developed during course of the BPREP. Therefore, this document shall always
read in conjunction with BPCL painting manual SOP/09/11 latest revision.

If any conflict or superimposition of the provisions or any issue generated between painting manual
and this document, the same shall be resolved in consultation with MPMC(EIL) and BPCL.

3.0 Additions modifications or deviations to painting manual.

3.1 Colour coding for external surfaces of Crude tank

External Colour of tanks (All other tanks Category in manual) shall be Pure white (RAL – 9010 –
F2) with intermediate coat with colour Signal white (RAL 9003) or Traffic White (RAL – 9016) to
have light but little changed intermediate colour under finish paint”.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

Page 890 of 1510 : B933-011-CC-MR-6101-2-RFQ : Rev. A

 BHARAT PETROLEUM CORP. LTD. osLky fMtkbu MkVk
BINA PETROCHEMICAL &
REFINERY EXPANSION
PROJECT (BPREP) ISSUED AS JOB SKETCH
MONKEY LADDER eksUdh ySMj

Page 891 of 1510 : B933-011-CC-MR-6101-2-RFQ : Rev. A

 DOCUMENT No.
PROCEDURE FOR SMART INTEGRATED
ENGG., DIGITAL HANDOVER OF B957-999-69-41-SP-0001
DRAWING/DOCUMENT/ Rev. A
3D MODEL AND DIGITAL INTERVENTION Page 1 of 11
BY BIDDER

PROCEDURE FOR SMART INTEGRATED ENGG.,

DIGITAL HANDOVER OF DRAWING/DOCUMENT/
3D MODEL AND DIGITAL INTERVENTION BY BIDDER

PROJECT : BINA PETROCHEMICAL & REFINERY EXPANSION

PROJECT, BPREP

OWNER : M/s BHARAT PETROLEUM COOPERATION LIMITED.

CONSULTANT : M/s ENGINEERS INDIA LTD.

JOB NO. : B957

A 28/10/2024 ISSUED FOR ENGINEERING MS MK SV

Rev. Prepared Checked Approved
Date Purpose
No by by by

Template No. 5-0000-0001-T1 Rev. 1 Copyright EIL – All rights reserved

Page 892 of 1510 : B933-011-CC-MR-6101-2-RFQ : Rev. A

 DOCUMENT No.
PROCEDURE FOR SMART INTEGRATED
ENGG., DIGITAL HANDOVER OF B957-999-69-41-SP-0001
DRAWING/DOCUMENT/ Rev. A
3D MODEL AND DIGITAL INTERVENTION Page 2 of 11
BY BIDDER

1. GENERAL

This chapter details the requirements pertaining to various drawings, documents and 3D model
to be generated at various stages during the course of execution of the project by the
Bidder(contractor/vendor/supplier) for activities associated with Smart Integrated
engineering and digital handover. These stipulations are supplementary to following
specifications (enclosed elsewhere in the contract):

S. No. Spec. No. Specification detail

1. 6-78-0001 Specification for quality management system requirements from bidders
2. 6-78-0002 Specification for documentation requirements from contractors
3. 6-78-0003 Specification for documentation requirements from suppliers

The Bidder shall recognize that efficient handling of drawings and documents to be prepared by
him under the contract is the key to the timely completion of the plant.

The Bidder shall ensure that all drawings and documents to be submitted by him to the
OWNER/CONSULTANT shall be of professional quality and conforming to the contractual
requirements.

The Bidder shall submit the drawings through the defined document management system for the
project for review by OWNER /CONSULTANT, and shall maintain a record of drawings submitted
till date at all times. Access to document management system shall be provided by
client/consultant to the successful bidder which shall be utilized by the bidder for their smart
engineering activities without any deviation.

Compliance of this chapter on drawings and documents is mandatory and is non-

negotiable.

A pre-defined document numbering philosophy will be provided to successful bidder which shall be
adopted and implemented by bidder for documents generated for this project.

Computer aided design and drafting shall only be used. Standard, approved and well-established
PC based computer programs/software packages, available in market shall only be used by the
Bidder and its sub-vendors etc.

All documents, before forwarding to OWNER /CONSULTANT shall be vetted in detail by Bidder.
Documents received without vetting will be returned without review. Also, any in
accuracies/mistakes found will not only be rectified by the BIDDER but the BIDDER shall remain
liable for bearing charges towards efforts spent by OWNER/CONSULTANT for discussing the
same. Delay owing to these shall be to the account of BIDDER.

Review of the drawings/documents by OWNER/CONSULTANT would be only limited to the review

of compatibility with basic designs and concepts. The review by the OWNER/CONSULTANT shall
not be construed by the BIDDER as limiting any of his responsibilities and liabilities for mistakes
and deviations from the requirements, specified under these specifications and drawings.

All drawings, datasheets, specification & model etc. shall be generated by the use of
authoring tools specified elsewhere in the contract document. The digital handover shall
be in soft native files along with associated database.

BIDDER shall furnish 3D modeling (with complete details with respect to equipment,
Piping, Civil, Structure, Electrical & Instrumentation in line with scope of work for 3D
Template No. 5-0000-0001-T1 Rev. 1 Copyright EIL – All rights reserved

Page 893 of 1510 : B933-011-CC-MR-6101-2-RFQ : Rev. A

 DOCUMENT No.
PROCEDURE FOR SMART INTEGRATED
ENGG., DIGITAL HANDOVER OF B957-999-69-41-SP-0001
DRAWING/DOCUMENT/ Rev. A
3D MODEL AND DIGITAL INTERVENTION Page 3 of 11
BY BIDDER

modeling) of plant with dynamic walk-through facility to check any interference,

requirement of safety, operation and maintenance for getting approval from
OWNER/CONSULTANT with input data. Associated data base files along with library shall also
be furnished at 30%, 60% and 90% model reviews.

Each drawing submitted by the BIDDER shall be clearly marked with the name of the Owner, the
unit designation, the specifications, title, the specification number and the name of the Project with
revision No. and date. If standard catalogue pages are submitted the applicable items shall be
indicated there in. All titles, notings, markings and writings on the drawings shall be in English. The
template shall be approved by the consultant/client. All documents shall be prepared on the approved
template.

All the Engineering design and specifications shall be normally prepared in MKS system excepting
for Civil/Structural wherein, the SI system is in vogue based on applicable design codes. Upon
receiving comments on Drawings/Documents, the BIDDER shall provide compliance
report/comment resolution sheet, separately on each of the comments, document-wise, along with
the subsequent submission. Comments given by OWNER/CONSULTANT shall be discussed, if
required, and finalized within the agreed schedule.

The schedule of submission of Drawings/Documents shall be in accordance with project plans only.
The detailed list under different category, document-wise, shall be prepared by BIDDER for
review/records of OWNER/CONSULTANT.

The BIDDER shall maintain up-to-date record of drawings & document status and make regular
issue of drawing/documents index discipline wise, on monthly basis, with copies to
OWNER /CONSULTANT Site &, H.O. indicating schedule date of submission, submission date of
various revisions and date of review with code of review/ approval.

2. Category of Documents and Cycle Time

The handling of documents by OWNER/CONSULTANT /BIDDER shall be as follows:

2.1 OWNER /CONSULTANT’s Review/Records

A detailed document list clearly identifying review/records category against each document shall be
developed. Following may please be noted for all the documents engineered by the BIDDER:

a) Review
BIDDER can proceed if OWNER/CONSULTANT’s comments are not received within 10 working
days of its receipt by OWNER /CONSULTANT. However, if major deviation to contract specification
for any design deficiency is detected in the course of review after stipulated period, it shall be the
responsibility of the Bidder to see that such deviations and deficiencies are corrected to ensure
compliance to contract without any cost and time implication to Owner.

b) Records

BIDDER shall submit documents for OWNER/CONSULTANT’s information and proceed with the
work. OWNER/CONSULTANT comments, If any, which relates any cost and/or time implication to
the owner due to inadequacies/inaccuracies may be brought to the attention of BIDDER at any
stage for incorporation without any cost or time impact to owner.

The documents falling under review category shall in general, except for drawings requiring multi-

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 DOCUMENT No.
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3D MODEL AND DIGITAL INTERVENTION Page 4 of 11
BY BIDDER

disciplinary review, be returned with comments within 10 working days.

Documents submitted without meeting pre-requisite requirements will be returned without review.

However, documents like equipment layout etc. where multi-disciplinary activity is involved, the
BIDDER, after submission for OWNER/CONSULTANT’s review, shall visit OWNER/CONSULTANT
for discussion for expeditious review of documents.

In absence of visit of BIDDER’S engineering team at OWNER/CONSULTANT office, review time

shall be 15 working days. The information category document will be retained for records only. It is
BIDDER’S responsibility to correct the deviation, if any, to the stipulation in the bid document,
without any cost or time implication to Owner.

2.2 BIDDER’S Review

BIDDER shall furnish compliance statement to OWNER /CONSULTANT’s comments while

submitting the next revision within 10 days from the date of release of drawings and documents by
OWNER/CONSULTANT.

2.3 Control and Monitoring of documents review and submission

Drawing schedule shall indicate the following:

 Schedule/Actual submission date to owner
 Category of submission
 Receipt of comments from Owner
 Category of return status from Owner
 Issue date for Construction

This updated schedule shall be issued on fortnightly/monthly basis, as agreed, and compared with
Owner’s log.

Detailed listing of documents (discipline wise) which are scheduled to be submitted or re- submitted
incorporating OWNER/CONSULTANT’s comments shall be provided by BIDDER in the weekly
meetings. Bidder shall ensure that drawings /documents are submitted as per the agreed schedule
only. Bunching of documents/out of sequence submissions and consequential delay of documents
and its review thereof shall be exclusively attributable to BIDDER.

2.4 Pre-Requisites from Bidder

2.4.1 At the kick-off meeting, the BIDDER must submit discipline wise list of documents and drawings
index.

2.4.2 The Drawing Index (discipline wise) shall include description of drawings/ documents, category
of drawings, scheduled date of submission, actual date of submission, review code received with
dates. This shall be updated fortnightly/monthly, as agreed by BIDDER and copies issued to
OWNER /CONSULTANT site and H.O. as well as Owner. Drawings submitted before finalization
of drawing index shall be rejected.

2.4.3 BIDDER shall separately submit list of drawings/documents involving multi- disciplinary reviews,
considering the OWNER /CONSULTANT departmental activities (furnished in the contract)
during the kick off meeting itself. They are also highlighted in the discipline- wise document list.

2.4.4 Critical and typical drawings/documents having impact on schedule and quality should only be
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3D MODEL AND DIGITAL INTERVENTION Page 5 of 11
BY BIDDER

identified for such timely reviews in Document Control Index. This shall be adopted after receipt
of drawings/documents indexes from the BIDDER at the kick-off meeting with mutual
understanding of the BIDDER/concerned specialist/Owner.

2.4.5 Any deviation on Record category drawings/documents and on review category drawings
observed later or in execution at site during site visit/technical review by OWNER/CONSULTANT
shall be taken seriously. Bidder shall rectify the same at his own cost and time.

2.4.6 BIDDER shall plan submission progressively so that no bunching takes place in any discipline.

2.4.7 Review period shall be reckoned from the “Date of Receipt” of documents/drawings at OWNER
/CONSULTANT to the “Date of Receiving” the reviewed documents by the BIDDER from
OWNER /CONSULTANT office. BIDDER shall monitor submission and receipt.

2.4.8 Documents/drawings r e c e i v e d prior to holiday/week end shall be accounted as received on

the following working day and the review period committed shall include only working days.

2.4.9 Quality of drawings/documents is the essence for a timely review. If major comments/deviations
to the contract document are noticed, the drawing shall be returned in Code-3.

2.4.10 Sequence of submission of drawings is essential for proper review of documents and timely
completion of the project and the same is to be adhered to. In case sequence is not maintained,
the documents submitted shall not be reviewed by OWNER/CONSULTANT and the responsibility
of timely execution of the plant shall remain with BIDDER.

2.4.11 Piping/Instrument & other engineering drawings/documents shall be issued only after the
corresponding P&IDs& Process documents coming under review category are first reviewed
by the concerned department in code-2 as a minimum.

2.4.12 In principle. BIDDER is not expected to revise drawings/documents already reviewed in Code-1.

a) If it is of utmost necessity to revise or add some minor details in Code-1 drawings, BIDDER shall
highlight such revisions by marking “CLOUD” and providing appropriate revision nos. to such
additions/alterations. BIDDER is also needed to provide a “BLOCK” in the drawing indicating
reasons of such changes and to insert another “Review Block”. OWNER /CONSULTANT shall
put relevant code for such revisions only. Code marking given by OWNER /CONSULTANT on
such revisions shall not change the category of drawing.

b) Any major change in Code-1 drawing shall call for preparation of new drawing.

2.4.13 Based on the confidence gained on BIDDER’S quality of drawings/documents already

submitted, “Review Category” drawings could be retained as Information/Records and vice versa
at the discretion of OWNER/CONSULTANT. This however, does not change the category of
drawings.

2.4.14 Once a document is already reviewed in Code-2, subsequent submission due to non-
incorporation of comments shall not be accounted for any contractual commitment of review period
from OWNER /CONSULTANT. BIDDER is expected to comply with OWNER /CONSULTANT’s
comments in the next revision after Code-2 and is required to submit a compliance report
accordingly

2.4.15 Deviation permit, submitted for seeking deviation in vendor document management system,
shall be separately identified and shall not be considered as a document for timely approval/review.

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BY BIDDER

2.4.16 When OWNER/CONSULTANT deploys engineers at the BIDDER’S work center following shall be
satisfied:
- Review is limited to identified long delivery/schedule critical items only.
- Readiness of documents/drawings shall be ensured by the BIDDER.
- Presence of lead engineers of all disciplines of the BIDDER.

2.4.17 If OWNER/CONSULTANT highlights any necessary rectifications required in the construction at

the time of Technical Review/Audit, construction executed based on record category
drawings not complying with Bid requirement, BIDDER shall rectify without any impact of time
and cost to Owner.

2.4.18 BIDDER shall submit designs drawings for review only after the corresponding GA/Equipment
datasheets etc. have been coordinated in his office and reviewed by OWNER/CONSULTANT
engineers at least in Code-2. Such OWNER/CONSULTANT reviewed drawings shall be furnished
along with drawings/designs for timely review.

2.4.19 BIDDER shall open an engineering office in India for speedy document submission and to help
faster review of the drawings & documents.

2.5 Approved for Construction Drawings

Drawings reviewed under Code1 & Code2 required for execution at site shall be decided by
BIDDER and copies need to be sent to OWNER /CONSULTANT (RCM), BIDDER’S RCM and PLL
(site).

- “Approved for Construction” stamped/sticker drawings shall be issued by BIDDER for

execution.

- “Approved for Construction” stamped/sticker shall be done separately on the reviewed print
and not on the Title block.

- Without c h a n g i n g R e v i s i o n N u m b e r , B I D D E R t o a r r a n g e adequate number of

prints of documents and drawings to BIDDER’S RCM, OWNER/CONSULTANT RCM and BPREP
(site) with transmittal.

- Copies of only reviewed or final documents like design calculations, design basis etc. shall be
sent to OWNER /CONSULTANT site for records.

- Copy of such transmittal shall be sent to OWNER /CONSULTANT (HO) & B P R E P (HO) for
records.

2.6 Critical Drawing/documents shall be reviewed by Licensor during the course of Project execution,
list of Licensor mandatory review document is enclosed elsewhere in the contract.

2.7 Mandatory compliance to the smart engineering activities at Bidder’s end

2.7.1 Plant Breakdown Structure (PBS) supplied by EIL to be adhered to. The SEED file and Plant
Breakdown Structure (PBS) shall be provided by consultant to the successful bidder which
shall be utilized by the bidder for their smart integrated engineering activities without any
deviation.
For any deviation in this regard prior approval need to be taken by Bidder from EIL.
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BY BIDDER

2.7.2 For residual engineering (process), work share to be followed. In case any new symbol is
required, same shall be obtained from/ authorized by EIL.

2.7.3 All P&IDs need to be smartly developed. All the constituents of P&ID need to be intelligently
mapped with database/database driven. There shall not be any graphics/symbols/texts in the
smart P&IDs. There shall not be any dummy graphics/symbols/texts in main body of the P&ID.

2.7.4 3D Modeling for Piping, Equipment, Instruments & Electrical need to be database driven. Dummy
graphics need to be avoided. Quality check & data connectivity shall be ensured at Bidder’s end
before submitting the data files/documents/3D Model to the Consultant.

2.7.5 All the applicable deliverables shall be extracted from 3D model without any manual rework done
thereafter. This is to maintain the consistency between 3D model and extracted deliverables.

2.7.6 Deliverables from 3D model shall be extracted only on conforming the alignment of interfaces
with client model and clash free design.

2.8 Digital handover of Engineering Information

Smart Integrated engineering shall be utilized to carry out engineering activities. Intelligent
Systems shall be used for the management of P&ID, Equipment layout, 3D Model, Piping,
Electrical and Instrumentation design & deliverables including P&IDs, Reports, MTO, procurement
etc.

The data in each such intelligent system, including the 3D Model and Intelligent P&ID’s to be
submitted by the B i d d e r in a predefined S o f t w a r e v e r s i o n / format, as t a b u l a t e d below.
The same shall be submitted by the respective LSTK vendor/equipment suppliers strictly without
any deviation.

Software versions/Format Requirements

The definition is in general terms containing (native (N), image (I), portable document format (D))
the formats in which Bidder shall provide electronic versions of Documents. Acceptable applications
for each format type are listed in the table below.

Data/Document Types Authoring Software* Version

2D CAD S3D, AutoCAD */2018

Intelligent P&IDs SPID *

Instt. Index, Datasheet etc. SI *

Electrical load list/Single SEL *

line diagram/Interconnection
details/Cable Schedule

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3D MODEL AND DIGITAL INTERVENTION Page 8 of 11
BY BIDDER

3D Model S3D *

2D Documents from the S3D *

3D model
Text Documents/Reports MS Word 2013 or as agreed with Company *

Datasheets/Lists MS Excel 2013 or Adobe Acrobat as agreed *

with Company

Email Rich Text Format

Schedules Primavera *
Organization Visio 2013, Microsoft power point or as
Charts/diagrams agreed with Company

Portable Document PDF files shall always be directly generated to

Format Files PDF from the authoring application.
Scanned documents/Images which are
converted to Adobe Acrobat format do not
qualify as Portable Document Format files
and shall be treated as image files for the
purpose of format compliance.

*Version shall be finalized during KOM.

In case documentation submitted is of authoring software mentioned below, the data has to be
submitted comprehensively including native files, databases, catalogs etc., as detailed here.
Project DBs in oracle/sql** (version shall be compatible with
SMART 3D latest version of SMART 3D) along with Reference project for
Catalogues, Standards, customization develop for the job etc.
INTERGRAPH SMART SPID Project Backup along with deliverables extracted from
P&ID SPID (P&ID, PDS, Line list) and database in oracle/sql** (version
shall be compatible with latest version of SMART PID)
AUTOCAD DWG/DXF files
SMART Instrumentation SPI Project Backup (DWG + Datasheets + Tags & Attributes in excel
format) and database in oracle/sql** (version shall be compatible
with latest version of SMART Instrumentation)
SE Project Backup (DWG + Tags & Attributes in excel format)
SMART Electrical and database in oracle/sql** (version shall be compatible with
latest version of SMART Electrical)
*Database (oracle/sql) and Version shall be finalized during KOM.

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 DOCUMENT No.
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ENGG., DIGITAL HANDOVER OF B957-999-69-41-SP-0001
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3D MODEL AND DIGITAL INTERVENTION Page 9 of 11
BY BIDDER

2.9 Real Time Tracking of Major Shipments for BPREP Project and Data Sharing
for Use on BPREP Control Tower

2.9.1 General Requirements

The Bidder (Vendor/ Contractor) (directly and/or through their transport agency) shall
provide real-
time tracking information for all consignments as per the following:

1. Tracking information of all shipments through all modes of transport vs. Air, Land and
Sea
2. GPS tracking for all shipments exceeding INR 10 lakhs in value
3. Electronic sharing of GPS tracking data (as applicable) and consignment tracking
data (through Transport Agency’s Transport Management System) via REST API and
on web portal of bidder or transport agency, including depiction of location of
consignments on map where GPS tracking is applicable
4. Tracking details for both international and domestic shipments.
For International Shipments mandatory vessel tracking through AIS (Automatic Identification
System)

2.9.2 Mandatory Tracking Information

The Bidder must provide the following information for each consignment:

1. Unique consignment identifier

2. Real-time GPS coordinates for in-transit shipments
3. Scheduled, Estimated and actual departure times from point of origin
4. Scheduled, Estimated and actual arrival times at destination
5. Current location and status updates on a daily basis (GPS Status updates shall be
live)
6. Total Distance, Cumulative Actual Distance Travelled, Daily Distance Travelled to be
updated on Daily basis.
7. Any deviation from planned route or schedule
8. Detailed consignment route details with GPS coordinates for key touchpoints like
ports, terminals and warehouses.

2.9.3 Data Sharing Protocol

The Bidder shall:
1. Provide access credentials for their tracking platform as applicable
2. Share tracking data in real-time for GPS tracking and daily basis
3. Provide notification of any tracking system failures/ downtime or data gaps

2.9.4 Security and Confidentiality

1. All tracking data shall be treated as confidential information

2. Data transmission must use secure protocols
3. Bidder shall comply with relevant data protection regulations

3.0 Project Monitoring and Reporting for BPREP Project and Data Sharing for Use on
BPREP Control Tower

3.0.1 Client is deploying a Project Monitoring System and Control Tower for the project. The
bidder shall have the following obligations wrt Project Planning, Scheduling and Monitoring.
This will be read in conjunction with project management clauses specified elsewhere in
the Tender/MR.
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 DOCUMENT No.
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ENGG., DIGITAL HANDOVER OF B957-999-69-41-SP-0001
DRAWING/DOCUMENT/ Rev. A
3D MODEL AND DIGITAL INTERVENTION Page 10 of 11
BY BIDDER

3.0.2 The bidder shall submit a comprehensive monthly progress report via the PMIS, which will
include the following:

1. Executive Summary: A high-level overview of the reporting period’s progress,

summarizing key accomplishments and major issues encountered.

2. Progress Monitoring: Progress Monitoring/ Earned Value Management (Planned vs

Actual) at project and Functional Level based on underling Deliverable List/DCI, Sub-
ordering/ Material Control Index (MCI), Manufacturing Milestones and actual progress
against planned schedules.

3. Project Schedule: Bidder shall submit the Critical Path Method Schedule (CPM)
Project Scheule in Primavera P6 or MS Project Format on a monthly basis.

4. Areas of Concern: A detailed description of any issues or risks impacting project

timelines, Engineering, Manufacturing, or Sub-ordering activities. The bidder must
identify bottlenecks, supply chain delays, and potential risks that may affect overall
project progress.
5. Engineering Status: Detailed progress reports on engineering tasks, including design,
technical drawings, and any engineering-related milestones, document approval
status, pending approvals, revisions, or rejections etc. Any delays or issues affecting
these deliverables must be clearly reported. EIL VDMS data shall may be available to
bidder for reference.
6. Sub-ordering Status (MCI): A summary of all sub-ordering activities, including key
milestones, supplier performance, and delivery timelines. Any delays or issues
affecting suborders must be clearly outlined.

7. Manufacturing Status: A detailed update on the manufacturing process, including the

production schedule, quality checks, and any deviations from planned timelines.

8. Dispatch Status: Detailed status of items dispatched, Packing Lists, LR Details,

Transporter Details, Tracking Details etc.

3.0.3 Data Integration: The bidder shall ensure that all required data, including schedules,
deliverables, and KPI inputs, are entered (manual entry, predefined templates) accurately
into the PMIS system. Bidder will be provided access to the PMIS System. The bidder is
responsible for ensuring data integrity and timely submission.

3.0.4 Compliance with Workflows: The bidder must adhere to the defined workflows in the PMIS
system for report submission, review, and approval. The bidder’s reports will undergo review
at multiple levels and the bidder shall address any feedback or corrections promptly.

3.0.5 Earned Value Management (EVM): The bidder is responsible for providing inputs that align
with the Earned Value Management methodology, including schedule and cost data,
weighted WBS, and progress updates, which contribute to the generation of project S-
curves and EVM reports.

3.0.6 The reports will be submitted in PMIS predefined templates, reviewed through the PMIS
workflows, and updated in the system on a monthly basis. The bidder shall ensure all data is
accurate and up to date to allow for timely review and integration into the overall project
progress monitoring system.

3.0.7 Failure to provide data/ info on timely basis may be considered a breach of contract.
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 DOCUMENT No.
PROCEDURE FOR SMART INTEGRATED
ENGG., DIGITAL HANDOVER OF B957-999-69-41-SP-0001
DRAWING/DOCUMENT/ Rev. A
3D MODEL AND DIGITAL INTERVENTION Page 11 of 11
BY BIDDER

3.0.8 Contractor shall comply with cybersecurity guidelines/advisories/acceptable use policy

issued by BPCL/EIL.

3.0.9 In case, any of the systems are not deployed, or are stopped during the course of the
contract; executing, reporting and monitoring of the work will continue through traditional
methods, other platforms as directed by the Engineer-in-Charge.

3.0.10 Non availability of platforms will not be a reason for seeking time extension, change orders
pertaining to time and/ or cost.

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 STANDARD SPECIFICATION No.
ENGINEERS GENERAL SPECIFICATION
Oal egw
.treR riezb-tF 3OasNt
INDIA LIMITED FOR 6-12-0001 Rev. 7
IA Go, of India UnaertaAngl
PRESSURE VESSELS Page 1 of 14

Ovr{ *Trm-prz
- r fdPaqr

GENERAL SPECIFICATION
FOR
PRESSURE VESSELS

7 12.03.2024 REVISED AND REISSUED AS STD. SPEC. PS Kh KA/NK MN

6 28.08.2018 REVISED AND REISSUED AS STD. SPEC. SK TK KJH RKT

5 30.06.2010 REVISED AND REISSUED AS STD. SPEC. KA RKT AKM/DM N.DUARI

4 20.11.2009 REVISED & REISSUED AS STD. SPEC. VB RKG AKM N.DUARI

3 15.05.2000 REVISED AND REISSUED AS STD. SPECN. RKT AKM CRMN MI

2 15.12.1994 REVISED AND REISSUED AS STD. SPECN. DD AKM VC AS

Standards Standards
Rev. Committee Bureau
Date Purpose Prepared by Checked by Convenor Chairman
No
Approved by

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 GENERAL SPECIFICATION STANDARD SPECIFICATION No.
ENGINEERS
Oge-11 fei154eg
r.rmrm,.Juami
artzn
INDIA LIMITED FOR
6-12-0001 Rev. 7
IA Govt of India Undettaiongt
PRESSURE VESSELS
Page 2 of 14

Abbreviations:

AI Authorized Inspector
ASME : American Society of Mechanical Engineers
DNV Det Norske Veritas
IBR Indian Boiler Regulations
ISO International Organisation for Standardisation
NB Nominal Bore
PESO : Petroleum & Explosives Safety Organisation
PWHT : Post Weld Heat Treatment

Static Equipment Standards Committee

Convenor: Mr. Nalin Kumar

Members: Mr. K. Anjaneyulu (Co-Convener)

Mr. Tarun Kumar (Emp. No. A328)
Mr. Tarun Khurana (Coordinator)
Mr. P V S Satyanarayana
Mr. Anish Trehan
Mr. P Barik
Mr. Saikat Chakraborty
Mr. Piyush Suryavanshi
Mr. Mittal Kumar Patel
Mr. Srikanth Karanam
Mr. Aasheesh Handa (Projects)
Mr. Prabhakar Choudhary (SMMS)
Mr. Avdhesh Agarwal (SCM-Inspection)

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

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 STANDARD SPECIFICATION No.
ENGINEERS GENERAL SPECIFICATION
$fgar 0154-egw
s INDIA LIMITED
[3111,, FT,151, c151,1,135T1
FOR 6-12-0001 Rev. 7
A GO 1 Min cha UndertakIngy
PRESSURE VESSELS
Page 3 of 14

CONTENTS

1.0 SCOPE 4

2.0 REFERENCES 4

3.0 DESIGN 5

4.0 FABRICATION 6

5.0 INSPECTION & TESTING 10

6.0 SUPPLY 12

7.0 GUARANTEE 13

8.0 SITE FABRICATION AND ERECTION 13

9.0 DATA FOLDER 14

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 STANDARD SPECIFICATION No.
ENGINEERS GENERAL SPECIFICATION
Og-ar idWeg INDI A LIMITED FOR
6-12-0001 Rev. 7
laiRn Te 2 I e111.1q05.11 CA Govt of India Undedaking)
PRESSURE VESSELS
Page 4 of 14

1.0 SCOPE

1.1 This specification covers the general requirements for design, fabrication, workmanship, erection,
inspection, testing and supply of unfired pressure vessels and is intended to supplement the minimum
requirements of the applicable codes.

1.2 Supplementary specification indicating special or additional requirements shall form addenda to this
specification and shall govern. Supplementary specification, when made addenda to this specification shall
be referred to in the Material Requisition and / or Purchase Order. Following are the supplementary
specifications:

a) 6-12-0002 Supplementary specification for carbon steel vessels.

b) 6-12-0003 Supplementary specification for low alloy steel vessels.
c) 6-12-0006 Supplementary specification for austenitic stainless steel vessels.
d) 6-12-0007 Supplementary specification for stainless steel clad vessels.
e) 6-12-0008 Supplementary specification for 31/2 %Ni steel pressure vessels.

1.3 In case of conflict, the order of precedence shall be as follows:

a) Statutory Requirement
b) Engineering drawing
c) Specifications and standards
d) Codes

In general, the most stringent requirement out of the above shall govern. However, in such a case, vendor
shall promptly refer the conflicts to client / EIL in writing to obtain client / EIL instruction before
proceeding with manufacture. Decision of client / EIL shall be binding without any time and cost
implication.

2.0 REFERENCES

2.1 Design Codes

The following codes in the edition and addenda referred to in the datasheet shall form the basis for design,
fabrication, inspection, testing and acceptance of equipment:

(a) ASME Boiler and Pressure Vessel Code Section VIII Div. 1

(b) ASME Boiler and Pressure Vessel Code Section IX and Sec V.

(c) Indian Boiler Regulations- IBR (whenever applicable).

(d) The Static and Mobile Pressure Vessels (Unfired) Rules 2016 (whenever applicable).

2.2 Material Codes

Material to be used shall conform to:

(a) ASME Boiler and Pressure Vessel Code Sec. II.

(b) Indian Standard specification.

Other specifications of equivalent grade can be used only after written approval from EIL.

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 GENERAL SPECIFICATION STANDARD SPECIFICATION No.
^0 ENGINEERS
Ogal fa5reg '_Wj
U INDIA LIMITED FOR
IA Gov, o1 India Underlakmg) 6-12-0001 Rev. 7
PRESSURE VESSELS
Page 5 of 14

2.3 Regulations

National laws and regulations together with any local by-laws for the country or state wherever the vessels
are to be used must be complied with by the fabricator.

3.0 DESIGN

3.1 Design Pressure

3.1.1 Design pressure specified shall be at the top of vertical vessel or at the highest point of horizontal vessel.

3.1.2 The design pressure at any lower point shall be determined by adding the maximum operating liquid head
and any pressure gradient within the vessel.

3.2 Corrosion Allowance

3.2.1 Corrosion allowance shall be added to both sides of tray support rings and other fixed internal non-pressure
parts.

3.2.2 Removable internal parts (with the exception of trays) which are bolted or clamped in place, shall be provided
with extra thickness equal to half the specified corrosion allowance on each surface exposed to vessel
contents.

3.2.3 Full corrosion allowance shall be added to the throat thickness necessary for strength or sealing in case of
fillet and seal welds on internal attachments.

3.3 During fabrication or shop/site hydro-test conditions in horizontal position, the supports for shell shall be
so provided that combined stresses in any shell component (based on corroded thickness for site test) do
not exceed the following:

(a) Tensile : 90% of ambient yield

(b)Compressive: Code allowable stress

3.4 All conical reducers shall be designed as tori conical type with knuckle radius at each end as minimum 10%
of the adjoining diameter, unless otherwise specified in requisition. 100% radiography shall be carried out
for all weld seams of tori cone.

3.5 Statutory Approvals

3.5.1 For vessels coming under the purview of Indian Boiler Regulations, it shall be vendor's responsibility to
get approval from IBR authorities pertaining to design, drawings, material of construction, fabrication,
inspection and testing etc.

3.5.2 For vessels coming under the purview of Static and Mobile Pressure Vessel rules, it shall be vendor's
responsibility to get approval from Petroleum & Explosives Safety Organization (PESO) pertaining to
design, drawings, material of construction, fabrication, inspection and testing etc.

3.6 Internals

3.6.1 For support beams, allowable deflection shall be limited to L/325 where L is the length of the beam.

3.6.2 For plates, allowable deflection shall be limited to T/2 where T is the corroded thickness of plate.

3.6.3 Allowable stress at design temperature shall be as per applicable Code.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL —All rights reserved

Page 907 of 1510 : B933-011-CC-MR-6101-2-RFQ : Rev. A

 GENERAL SPECIFICATION STANDARD SPECIFICATION No.
ENGINEERS
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INDIA LIMITED FOR
6-12-0001 Rev. 7
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PRESSURE VESSELS
Page 6 of 14

4.0 FABRICATION

4.1 Head/Dished Ends

4.1.1 Dished ends shall preferably be of seamless construction. However, dished ends with one chordal weld
seam are acceptable. In such cases, the width of chordal plate shall not be less than one third of the blank
diameter and chordal seam shall clear nozzle opening. Intermediate heat treatment, if considered necessary,
shall be carried out by the fabricator.

4.1.2 Whenever a dished end is made of more than two plates, it must have a seamless crown plate. Whenever a
nozzle or a manhole is positioned at the center of the dished end, the crown plate should be larger than the
nozzle /manhole reinforcing pad.

4.1.3 Wherever hot forming and subsequent heat treatment is involved, adopted procedure shall not impair the
mechanical properties of the material beyond the limits specified in respective material specification.

4.2 Nozzles, Manholes, Handholes and Attachments

4.2.1 Manhole cover shall be provided with a davit or hinge as per EIL standard and Handhole cover shall be
provided with suitable lifting handles.

4.2.2 Inside edges of Manholes/Handholes shall be rounded off smooth with a minimum radius of 3mm.

4.2.3 All nozzles shall be set-in type, unless otherwise specified in requisition. Set on type nozzle for size 50 NB
and below can be used with prior approval.

4.2.4 Reinforcing pads whenever required as per drawings or Code shall be of the same material or equivalent as
the vessel component to which it is welded. All reinforcing pads shall be provided with two 1/8" (3 mm)
NPT tapped holes located 180 apart for air soap solution test with a pressure of 1.25 kg/cm2 (g). This test
shall also be required to be carried out for slip on flanges. Higher test pressures are not recommended
because of accompanying risks and also because the soap bubbles have a chance to blow off. Tell-tale holes
in the reinforcing pads shall be plugged with hard grease unless otherwise indicated after the hydro test of
the vessel.

4.2.5 Wrapper plates, reinforcing pads, saddle plates or stiffeners of higher thickness than specified can be used
provided there is no change in basic dimensions and with the approval from Inspection Agency. No separate
deviation permit is required for the same.

4.3 Flanges

4.3.1 When tongue and groove or male and female faced flanges are used, groove or female face shall be in
nozzle flange. However, when the nozzle is located in the bottom, the groove or female face shall be in the
cover.

4.3.2 Dimensions of flanges shall be as per ASME B16.5 for sizes up to 600 mm NB (24" NB) and as per ASME
B 16.47 series '13' for sizes greater than 600 mm NB (24" NB).

4.4 Fasteners and Gaskets

4.4.1 All bolts/studs shall have ISO threading unless otherwise specified. Studs shall extend beyond nuts at least
by 2 threads & studs shall be threaded to full length. Bolts/studs (to be tightened by hydraulic bolt tensioner)
shall be longer than normal length by minimum 1 nut diameter.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL —All rights reserved

Page 908 of 1510 : B933-011-CC-MR-6101-2-RFQ : Rev. A