Code: CL-PPS/SV-CONS-005
Revision: 0 (*)
Total pages: 19
OUTBOARD SURFACE PREPARATION
AND PAINTING PROCEDURE
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TABLE OF CONTENTS
1 SCOPE................................................................................5
2 DEFINITIONS AND ABBREVIATIONS.......................................5
3 CODE STANDARDS AND REFERENCES...................................5
3.1
CODES AND STANDARDS...............................................................5
3.2
DOCUMENT OF PROJECT:...............................................................5
4 SURFACE PREPARATION.......................................................6
4.1
SOLVENT CLEANING.......................................................................6
4.2
HAND / POWER TOOL CLEANING...................................................6
4.3
WET ABRASIVE BLASTING CLEANING.............................................6
4.4
UHP WATER JETTING CLEANING.....................................................7
4.5
EQUIPMENT PROTECTION..............................................................7
5 ACCESSION METHOD...........................................................7
6 APPLICATION PROCEDURE...................................................8
6.1
MATERIAL COATING SYSTEMS........................................................8
6.1.1 MATERIAL SUPPLIER.......................................................................9
6.1.2 COATING SYSTEM...........................................................................9
6.1.3 PACKING AND STORAGE.................................................................9
6.1.4 VISUAL CHECKING..........................................................................9
6.1.5 MIXING...........................................................................................9
6.1.6 THINNING.......................................................................................9
6.1.7 POT LIFE.......................................................................................10
6.2
GENERAL APPLICATION................................................................10
6.2.1 APPLICATION................................................................................10
6.2.2 DUST............................................................................................10
6.2.3 PRIMER COATING..........................................................................10
6.2.4 DRYNESS......................................................................................11
6.2.5 RE-COATING.................................................................................11
6.2.6 MASKING......................................................................................11
6.2.7 STRIPE COATING TO ALL SHARP EDGES, CORNERS, WELDS,
INTERSTICES ETC....................................................................................12
6.3
SPRAY APPLICATION.....................................................................12
6.3.1 OPERATORS..................................................................................12
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6.3.2 APPLICATION................................................................................12
6.3.3 EQUIPMENT CLEANING.................................................................12
6.3.4 COMPRESSED AIR.........................................................................12
6.3.5 BRUSH AND ROLLER APPLICATION...............................................12
6.3.6 REPAIR / TOUCH UP OF DAMAGE..................................................13
7 INSPECTION / QUALITY CONTROL.......................................13
7.1
INSPECTION.................................................................................13
7.2
VISUAL INSPECTION.....................................................................13
7.3
FILM THICKNESS..........................................................................13
7.3.1 MEASUREMENT............................................................................14
7.3.2 DRY FILM THICKNESS (DFT) VALUE...............................................14
7.3.3 TEMPERATURE AND RELATIVE HUMIDITY.....................................14
8 SAFETY.............................................................................14
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1 SCOPE
This procedure covers the requirements of surface preparation and
coating for all of location where is outboard of FPSO, WHP-CS
2 DEFINITIONS AND ABBREVIATIONS
CUU LONG JOC
:Cuu Long Joint Operator Company
PPS
Company
:PTSC
CPP
:Central Processing Platform
TBVN
: FPSO Thai Binh VN
WHP-A
:Wellhead Platform A
WHP-B
:Wellhead Platform B
DFT
: Dry Film Thickness
WFT
: Wet Film Thickness
Production
Services
Joint
Stock
3 CODE STANDARDS AND REFERENCES
3.1 CODES AND STANDARDS
SSPC : Steel Structure Painting Council
NACE National Association of Corrosion Engineers
NACE
SSPC : Steel Structure Painting Council
SP-1
SP-2
SP-3
SP-12
:Solvent Cleaning
:Hand Tool Cleaning
: Power Tool Cleaning
: Ultra High Pressure Water Jetting
ISO 8501-1-1998 Surface preparation before application of
painting :
Sa 2.5
St-3
: Near White Blasting Cleaning
:Power Tool Cleaning
ISO 8501-4-2006 Preparation of steel substrates before
application of paints and related products
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Wa 2.0
Wa 2.5
3.2 DOCUMENT OF PROJECT:
SOW and Technical Requirement for paint maintenance
contract
TBVN-INSPECTION REPORT-Sep- 2013
CPP-INSPECTION REPORT-Sep- 2013
WHP-A INSPECTION REPORT-Sep- 2013
WHP-B INSPECTION REPORT-Sep- 2013
4 SURFACE PREPARATION
4.1 SOLVENT CLEANING
The surface preparation for each system shall comply with the
requirements detailed in coating system.
Prior to cleaning by wet blasting or surface preparation by power
tools, any oil and grease contamination shall be removed by solvent
cleaning.
4.2 HAND / POWER TOOL CLEANING
The surfaces for which UHP water jetting cleaning and Abrasive
blasting are specified but cannot be so treated because of their
location shall be power tool cleaned only after obtaining Company
approval. Surface preparation shall be in accordance with SSPC SP-2,
SP-3 and/or ISO St-3.
Non-sparking power tools such as copper wire brush cup, copper
chipping, abrasive disks shall be used in surface configuration.
Power
adjacent
surfaces
intended
tool cleaning shall overlap a minimum of 25mm onto
coated surfaces. No acid washes shall be used on metal
after they are blasted. This includes inhibitive washes
to prevent rusting.
Welded areas shall be ground and/or water cleaned by HP water
cleaning to remove rust, residual flux and weld spatters, sharp edge
and flame cut areas shall be ground flush.
Most of the areas on CLJOC offshore installations are hazardous
(equivalent to zone 2) with an explosive atmosphere. Therefore the
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non-sparking power tools such as copper chipping, copper wire discs
or abrasive discs shall be applied. Power tool for cleaning will be air
driven.
4.3 WET ABRASIVE BLASTING CLEANING
Abrasive blasting should be applied for the location which at hight
temperature (up to 600C) such as Flare Boom, Exhaust Stacks
locations.
Blasting abrasive shall be dry, clean. The size and type of abrasive
grits shall give the angular profile and standard cleanliness specified
in the applicable specification.
In order to avoiding environmental damage and damage to
existing equipment on CLJOC offshore installations, Garnet mix shall
be used for blasting of carbon steel surfaces only Abrasive shall
contain no more than 50ppm total soluble salts by weight, the type
and graded size adequate to give uniform, angular surface profile
(anchor pattern) of 35-65 microns average, with blast rough peak not
exceeding 100 micron unless otherwise noted in coating systems.
Prior to wet abrasive blasting, all parts of control valves, flanges,
tag names, machinery, electrical fixtures etc. that may be exposed
to either the blast or the abrasive material, shall be properly
protected from the blasting medium.
Prior to blast-cleaning, any oil and grease contamination shall be
removed by solvent cleaning.
Acceptable flash-rust degree before application: maximum M
(atmospheric exposure) / M, preferably L (immersion). Refer to ISO
8501-4.
After blasting, all blasting residues and spent grits shall be blown
down with compressed air for visual inspection. Any unsatisfactory
areas shall be re-blasted.
4.4 UHP WATER JETTING CLEANING
UHP water jetting should be applied for the most of location on
TBVN FPSO, SUTUVANG CPP, SUTUDEN WHP-A, SUTUDEN WHP-B.
Surface preparation shall be in accordance with SSPC SP-12 and/or
ISO 8501-4-2006 Wa2.0, Wa2.5.
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Prior to blast-cleaning, any oil and grease contamination shall be
removed by solvent cleaning. The wet basting cleaning using the
Ultra-high pressure water blasting (UHP unit) 35.000 psi to remove
salts, rust,damaged paints and other contaminants to achieve
minimum Wa 2 - Wa 2 (atmospheric exposure) or minimum Wa 2
(immersion) (ISO 8501-4:2006).
Acceptable flash-rust degree before application: maximum M
(atmospheric exposure) / M, preferably L (immersion). Refer to ISO
8501-4
After preparation by UHP water jetting, the surfacesshall be wet.
So that need to dry surface up before applied coating system.
4.5 EQUIPMENT PROTECTION
Before preparation surface by HP/UHP water blasting all necessary
equipment on CLJOC offshore installations such as all parts of control
valves, flanges, tag names, machinery, electrical fixtures etc. should
be protected by canvas in order to avoid damage from blasting
nozzle.
5 ACCESSION METHOD
All of outboard locations should be accessed by erection
scaffolding, gondola, abseiling such as Hull Topside external of
bulwarks & turret, Hull Bottom external under bulwarks & turret,
Helideck underside, TBVN - Flare boom piping & structure, WHP-SubCellar deck and under cellar deck, WHP Top of Jacket and Boat
landingetc
a) Erection scaffolding
Erection scaffolding should be conducted on CCP, WHP location
such as WHP-Sub-Cellar deck and under cellar deck, WHP Top of
Jacket and Boat landing, etc
Scaffolding team must have at least two years of experiences of
working offshore c/w the valid scaffolding certificate.
Scaffolding team leader or scaffolding supervisor must have at
least two years of experiences of working offshore c/w the valid
scaffolding certificate Level 3 or advance
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Scaffolder must have at least two years of experiences of working
offshore c/w the valid scaffolding certificate level 1 or level 2.
Scaffolding materials must have quality certificates (certificate of
analysis, mill test certificate)
b) Gondola equipment
Gondola equipment should be conducted on TBVN outboard
location such as Hull Topside external of bulwarks & turret, Hull
Bottom external under bulwarks & turret. Where could not accessed
by erection scaffolding
Gondola equipment must have load test certificate c/w the valid
certificates of their accessories such as slings, shackles, lifting
devices.
When accessing by gondola equipment or abseiling, only HP water
blasting method should be conducted to prepare surface.
c) Abseiling/Rope access
In case of could not access by erection scaffolding or gondola
equipment, abseiling should be conducted to access outboard
locations
Abseiling team must have at least two years of experiences of
working offshore c/w the valid rope access certificate.
When accessing by gondola equipment or abseiling, only HP water
blasting method should be conducted to prepare surface.
6 APPLICATION PROCEDURE
6.1 MATERIAL COATING SYSTEMS
1.1.1 MATERIAL SUPPLIER
1.1.2 COATING SYSTEM
The paint materials for project will be provided by Cuu Long JOC.
The coating systems and the required surface preparation
standard and anchor profile shall be in accordance with the Company
Specification, or Technical Data Sheet or AFC Drawing.
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The vendor coated items shall be assessed of its suitability for
exposure against offshore or marine environment. Where vendor
applied coating needs upgrading, the Company shall be notified for
disposition of the suitable coating products/coating system to be
applied on vendor applied coatings.
Damages to vendor coated items shall be repaired in compliance
with the Companysrequirements.
1.1.3 PACKING AND STORAGE
All paint and coating materials shall be furnished in the
manufacturer's unopened containers, which shall be identifiable and
protected.
Batch number and date of manufacture shall be clearly marked on
the containers.
The recommended shelf life and the "use by date" shall be clearly
identified.
All materials shall be stored out of direct sunlight in well ventilated
areas and away from heat sources, In addition manufacturer's
recommendation guideline in storage of coating materials shall be
attached to.
1.1.4 VISUAL CHECKING
Prior to paint work, the paint shall be visually checked confirming
that the paint is in suitable condition for application.
1.1.5 MIXING
All components shall be thoroughly mixed by mechanical means.
This mixing shall be done in clean containers, free from traces of
grease, other paint or contaminants.
Multi-component coatings, such as inorganic zinc, epoxy and
polyurethane shall have the components accurately measured under
the manufacturer direction.
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1.1.6 THINNING
Thinning ratio of the materials will conform to the limits
recommended by the manufacturer. Only manufacturer's specified
thinner shall be used.
1.1.7 POT LIFE
The coating manufacturer's recommended pot life shall not be
exceeded. When this limit is reached, the spray pot shall be emptied
and cleaned, and new material shall be mixed.
6.2 GENERAL APPLICATION
1.1.8 APPLICATION
Painting shall be carried out by airless spray and/or conventional
air spray according to the manufacturer recommendation.
Environmental Conditions Coatings shall not be applied when any
of the following conditions exist:
o Wet surfaces, damp, moisture surfaces
o Relative humidity exceeds the manufacturer's recommendations
or 85%
o Steel surface temperature is less than 3C above the dew point
o Ambient or surface temperature is above or below the
manufacturer's recommended temperature for application or is
greater than 40 C.
o The high temperature location where is not allowed to shut down
for long time for blasting and re-coating. Therefore, the blasting
and painting job shall be implemented online. If this is the case,
the normal marine paint could not be used. So, CLJOC shall
choose the suitable coating such as BELZONA-5851 for
application on line.
1.1.9 DUST
Every possible precaution shall be taken to eliminate dust before
and during painting process.
Cleaning down immediately before apply coating is recommended
by manufacturer following long periods between coats and following
inclement weather.
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Cleaning down may be done by chloride free fresh water spraying,
sanding paper or by other approved methods.
1.1.10
PRIMER COATING
Blast cleaned surfaces shall be coated with one complete
application of primer as soon as is practically possible, but in no case
later than 4 hours after blasting provide the surface condition is
SSPC-SP10 at the time of coating application.
UHP water jetted surfaces shall be coated with one complete
application of primer after dry surfaces up. Acceptable flash-rust
degree before application: maximum M (atmospheric exposure) / M,
preferably L (immersion). Please refer to ISO 8501-4.
1.1.11
DRYNESS
In a proper state of cure prior to the application of
successivecoats, materials shall be considered dry for next coating
when manufacturer's technical representative has accepted the coat
and the additional coat can be applied without the development of
any detrimental film irregularities, such as lifting or loss of adhesion
of the undercoat. The drying times as specified in the manufacturer's
data sheets, will be observed at all times.
1.1.12
RE-COATING
The maximum and minimum re-coating interval specified in the
manufacturer's data sheets, will be observed before successive coats
are applied.
The only exception to this may be after the application of a mist
coat where the recommended re-coat interval may be reduced in
accordance with the coating manufacturer's recommendations.
Any thin spots or area missed in the application shall be recoated
and permitted to dry before the next coat is applied.
All areas such as external corners and edges, welds, bolts, nut and
interstices (excluding galvanized surface) shall receive a "stripe"
coat prior to application of the specified coat (excluding the
inorganic zinc silicate primer) to ensure these areas have at least the
minimum specified film thickness as to ensure continuity of the
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coating. The "stripe" coat shall be allowed to become touch dry prior
to coating with the specified coat.
When successive coats of the same product have been specified,
alternate color shall be applied to ensure contrast for complete
coating coverage and control of thickness during application. Tinting
may be permitted when allowed by the Paint Manufacturer provided
the tinting materials are not detrimental to the service performance
of the coating or when the tinting of the final coat is not acceptable.
1.1.13
MASKING
All nameplates, manufacturer's identification tags, machined
surface, finish flange faces, control valves, electric fixtures etc, shall
be masked to prevent coating contamination.
Special consideration shall be given to protect high alloy stainless
steel such as 316L, 825 and duplex stainless steel surfaces so that
overspray from coating does not contaminate the surfaces.
1.1.14
STRIPE COATING TO ALL SHARP EDGES, CORNERS, WELDS,
INTERSTICES ETC...
All difficult to reach areas edges, corners, welding seam,
interstices areas, etc.(excluding galvanized surface) shall be stripe
coated prior to spray coating application of the specified coat
(excluding the inorganic zinc silicate primer) to ensure these are
have at least the minimum specified thickness as to ensure
continuity of the coating. The stripe coat shall be allowed to become
touch dry prior to coating with specified coat.
6.3 SPRAY APPLICATION
1.1.15
OPERATORS
Operators shall be skilled in the proper application technique for
each coating.
1.1.16
APPLICATION
Paint shall be applied in a uniform layer, with the gun held
perpendicular to the surface being painted and with 50% overlap on
the previous pass.
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EQUIPMENT CLEANING
Spray guns including spray tips, air caps, fluid tips, hoses and
pressure pots shall be cleaned with suitable equipment cleaner
recommended by the Paint Manufacturer before adding in new
coating material.
1.1.18
COMPRESSED AIR
Operation pressure shall comply with the recommendation of the
coating manufacturer.
Separate regulators shall be used to adjust the pressure and each
regulator shall be provided with a pressure gauge operating properly
at all times.
Adequate moisture traps shall be on the air supply line of the
compressor and other location as deemed necessary.
Compressed air supply used for blasting cleaning shall be free
from water and oil. A test in accordance with ASTM D 4285 shall be
conducted to determine the presence of oil or water in compressed
air used.
1.1.19
BRUSH AND ROLLER APPLICATION
Coating shall be applied with a brush only at corners weld seam
(Used only one type) after obtaining Cuu Long JOC approval.
Brushes, maximum 150mm wide, shall be of the type, style and
quality that will enable proper application of coating materials.
Paint shall be worked into all crevices and corners, and runs shall
be brushed out in order to eliminate air pockets, solvent bubbles or
voids.
1.1.20
REPAIR / TOUCH UP OF DAMAGE
Coatings damaged by fit up, cutting, heating, welding and
mechanical works shall be cleaned and prepared by spot abrasive
blasting to the specified SSPC-SP12or Wa2.5 near white metal blast
cleaning and required anchor profile.
Power tool cleaning must be achieved minimum Rz = 25microns
and shall only be carried out with prior company approval.
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All damaged areas, before and after erection, shall be repaired
using the original full paint system.
Where paint has been damaged or is loosely adhering, the paint
shall be re-blasted and applied the original full paint system.
The surface to be repaired shall be feathered back progressively
by fine sand paper, revealing each coat applied and will show
sufficient of each coat to permitting satisfactory keying in of each
repair coating applied.
If repair to the coating of vendor supplied equipment is necessary
it shall be carried out in accordance with the vendor's
recommendations and after Company approval.
All galvanizing damaged in fabrication, erection, assembly,
handling welding and by other or other operations shall be repaired
by spot blast cleaning and apply Company approved zinc primer.
Where the repaired damaged galvanizing is part of full-coated
galvanized item, the repaired area shall receive full coats of the
same coating system applied to that galvanized item.
7 INSPECTION / QUALITY CONTROL
1
INSPECTION
To ensure the quality control and painting inspection requirements
are maintained during painting operations, inspection will be carried
out by the paint manufacturer's representative in accordance with
the requirements of this procedure.
VISUAL INSPECTION
Individual coats and completed coating shall be visually inspected
for appearance. Coating shall be free from excessive sagging, dry
spray, pinholes, blisters and other types of coating application
defects and shall be free of any coating damages.
FILM THICKNESS
1.1.21
MEASUREMENT
During coating application, the wet film thickness shall be spotchecked using a clean wet film gauge. The dry film thickness of each
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coat shall be measured using a coating thickness gauge such as
Elcometer E-456 or equivalent.
1.1.22
DRY FILM THICKNESS (DFT) VALUE.
Five separate spot measurements, average of three readings,
spaced evenly over each 10 square meter area to be measured for
each coat. The average of five spot measurements for each such 10
square meters area shall not be less than the specified thickness.
The minimum acceptable thickness at any single reading shall be
not be less than 80% of the specified thickness. The averaged of the
three (3) readings shall constitute one spot measurement where the
thickness shall be equivalent or above the specified DFT.
The thickness of each coat shall be determined prior to the
application of subsequent coats in accordance with SSPC PA-2.
The acceptable range of DFT shall refer to painting system as
required in company specification.
Thickness measurement of coatings on curved surfaces such as
pipes, valve bodies shall be done using curve probe to the DFT
Gauge and calibrated using certified foils/shims on the same curve
surface to be checked. Pipe supports with usual geometry shall be
inspected for the coating integrity and coating thickness measured
with extended length and/or angle probe.
Controls DFT with Inorganic Zinc silicate for prevent mud cracking.
1.1.23
TEMPERATURE AND RELATIVE HUMIDITY
Temperature and relative humidity shall be measured by means of
a temperature gauge and a hygrometer using a humidity gauge such
as Elcometer E-319, 116C, 114
Readings shall be taken prior to the commencement of blasting
and/or painting and at regular intervals, if changes in climatic
conditions occur.
All gauges and recorders shall be calibrated and certified prior to
testing. Gauges, which are of doubtful accuracy, shall not be used.
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8 SAFETY
Hydroblast cleaning uses high pressures. Extreme caution should
be exercised with the equipment.
Instruction and training of operators about correct use and
equipment operation is essential.
Surfaces, other than metal, can be damaged with high pressure
water and should be protected from effects of the high pressure
water blast.
Blasting operator shall be equipped with rain suit, suitable longsleeved protective clothing preferably coverall, safety boots, air-fed
full face blasting helmet/hood, dust respirator, leather gloves and
safety goggles.
Blast nozzle shall be fitted with DEAD MAN CONTROL" and
checked it is functioning prior to blast leaning.
Everyone within 50 feet of the work area should be warned of
hazards associated with hydroblast cleaning.
No electrical power should be in the work area
MSDS of coating materials shall be posted in blast cleaning and
coating area.
When surface preparation and coating application are to be
carried-out inside a confined space such as the interior of the vessel,
a JSA shall be held first to identify all hazards associated with
internal blast cleaning and coatings.
For in internal blast cleaning and coatings application, a suitable
dust extraction machine shall be fitted to a vessel nozzle to ensure
that the dust level inside the vessel does not posed risk to the
basting operator and provide visibility for the blasting operators.
All of locations above 1,5m height from main deck should be
accessed by scaffold erection.
A body harness must be worn by the blasting operator or coating
applicator working at height or oversideso that in the event of an
incident, personnel can be easily retrieved through a life hook/line.
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A watcher must be always on watch while blast cleaning and
coatings application are being carried - out.
A supply boat standing at all timeis required when working
overside.
