TATA
TATA PROJECTS LIMITED
Quality Management
for
SURFACE PREPARATION AND
| Standard Procedure
PAINTING
| Doc No: TPL/QMD/ MECH/SPROC/004
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Rev| Date | Purporeofisue | Prepared by | Reviewed By | Reviewed By | _ Approved By
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STANDARD PROCEDURE FOR SURFACE PREPARATION AND PAINTING
Proc No.: TPL /AMD/MECHISPROC / 004
Rev No, & Date: 0 & 19.02.2014
1.0 SCOPE
This Procedure covers the application and testing requirements of Surface Preparation
and Painting on Storage Tanks, Piping and Structural Stee! Works.
2.0 STANDARD AND SPECIFICATIONS
All works covered by this Procedure shall be carried out in accordance with the relevant
sections of the following documents.
-1S0 8501-1
-1S0 129445
- Paint Product Data Sheets
- Approved FOP & Drawings
- Customer Specifications
e 2.0 ENVIRONMENTAL CONDITIONS
Unless otherwise specified by the Customer / Painting Manufacturer, no surface
preparation or application of top coating shall take place under the following conditions.
> Air temperature is below 102C
Surface temperature is below 52C
Surface temperature is 3°C or less than the Dew Point
Relative humidity is 85% or above
Wet or Damp atmosphere
Wet Surfaces
Rain, mist or fog is present
Wind speed above 25 kmph
‘Atmosphere contaminated by dirt, dust, oil, product or any pollutant
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3.0 PROCEDURE
3.1 SURFACE CLEANING
e 3.1.1 Mill scale, rust, rust scale and foreign matter shall be removed fully to ensure that a
clean and dry surface is obtained. Unless otherwise specified, surface preparation shall
be done as per Customer Specification / Approved Drawing.
3.1.2 The minimum acceptable standard in case of manual or hand tool cleaning shall be St. 2
or equivalent, in case of mechanical or power tool cleaning it shall be St. 3 or equivalent
and in case of blast cleaning it shall be Sa 2-1/2 as per Swedish Standard ISO 8501-01.
3.1.3 All other contaminates, oil, grease ete. shall be removed by use of an aromatic solvent,
prior to surface cleaning.
3.1.4 Blast cleaning shall not be performed where dust can contaminate surface undergoing
such cleaning or during humid weather conditions having humidity exceed 85%.In case
of internal coating or storage tanks. De-humidifiers shall be used to control the humidity
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STANDARD PROCEDURE FOR SURFACE PREPARATION AND PAINTING
Proc No.: TPL /QMD/MECHISPROC / 004
Rev No. & Date: 0 & 19.02.2014
levels during rainy season. If painting is to be carried out during the rainy days in case of
exigency of projects schedule, it shall be carried out with prior permission of Customer.
3.1.5 Irrespective of the method of surface preparation, the first coat of primer must be
applied by airless spray / as recommended by the paint manufacturer on dry surface.
This should be done immediately and in any case within 4 hours of cleaning of surface.
However, at times of unfavourable weather conditions, the Customer shall have the
liberty to control the time period, at his sole discretion and/or to insist on re-cleaning, as
may be required, before primer application is taken up. In general, during unfavourable
weather conditions, blasting and painting shall be avoided as far as practicable.
3.1.6 Surface preparation by Air Blast Cleaning with abrasives.
3.1.7 The surfaces shall be blast cleaned using one of the abrasives like copper slag, Al20
particles at pressure of 7Kg/cm2 at a appropriate distance and angle depending of
nozzles size maintaining constant velocity and pressure. The Quality of abrasives shall be
free from contaminants and impurities and shall meet the requirements of SSPC AB1
(Abrasive Specification No.1 "Mineral and Slag Abrasives”). Compressed air shall be free
from moisture and oil. Nozzles orifice may vary from 3/16” to %". 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.
3.1.8 Surface Preparation by Mechanical or Power Tool Cleaning
3.1.9 Power tool cleaning shall be done by mechanical striking tools, chipping hammers,
rinding wheels or rotating steel wire brushes. On completion of cleaning, the detached
rust mill scale etc. Shall be removed by clean rags and thoroughly dried with
compressed air jet before application of paint.
3.2 Coating Procedure and Application
3.2.1 The Paint Containers will be rolled to and fro on a level ground for a couple of times prior
to opening. if on opening any sedimentation is observed, the contents will be rejected of
further investigation to establish the quality. All paints will be stirred up thoroughly using
agitator prior to and during the application.
3.2.2 Primer or first coat of paint will be applied within 4 hours of surface preparation and as per
Manufacturer's recommendation.
3.2.3 Irrespective of the method of surface preparation, the first coat of primer / paint will be
applied by using the method as specified in Customer specification on dry surface.
3.2.4 Application of paint using air gun will not be carried out under the following conditions.
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STANDARD PROCEDURE FOR SURFACE PREPARATION AND PAINTING
Proc No.: TPL /QMD/MECHISPROC / 004
Rev No. & Date: 0 & 19.02.2014
a) When the ambient temperature is below 5° C.
b) When the ambient temperature is above 40°C.
c) During adverse weather condition of rain, fog, dust, storm and when humidity exceeds
85%
3.2.5 Primer / paint will be applied in uniform thickness.
3.2.6 Painting works will be done on daytime only.
3.2.7 The remaining paint in the open container will not be used if signs of polarization are
noticed
3.2.8 DFT will be checked using calibrated Elcometer after each coat of primer / paint as per
Customer Spec.
3.2.9 Each Coat must be dried for the time recommended by the Paint Manufacturer for
application succeeding Coat.
3.3. Drying of coated surfaces
3.3.1 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 po:
ly deteriorated or mixing is faulty.
3.3.2 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.
3.3.3 Paint shall be protected from rain, condensation, contamination, snow and freezing
until dry to the fullest extent practicable.
3.4 Repair of damaged paint surface
3.4.1 Where paint has been damaged in handling and in transportation, the repair of
damaged coating of pre-erection / fabrication and shop primer shall be done as given in
Customer Specification
4.0 Inspection, Tes
\g and Acceptance
4.1 _ FQE shall check the surface preparation as per Customer Specification / approved Drawing
/ FOP by using Testex Tape (or) Roughness Comparator (or) Surface Profile Gauge before
applying the Primer.
4.2 _Allthe prepared surfaces shall be inspected and cleared by FQE as per approved FOP
before applying the Primer.
4.3 During the painting works, the surface temperature, relative air humidity, air temperature
shall be measured and recovered at least 3 times a day.
4.4 Each coat shall be examined for signs of runs, roughness, patches, sags, pinholes etc and if
such short comings occur, the coats shalll be repaired and permitted to dry before the next
coat is applied.
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Page 3 of 4«
TATA
STANDARD PROCEDURE FOR SURFACE PREPARATION AND PAINTING
Proc No.: TPL /QMD/MECHISPROC / 004
Rev No. & Date: 0 & 19.02.2014
4.5 Field Quality Engineer shall inspect each coat for defects and check Dry Film Thickness
(DFT) to ensure compliance to the specified requirements, before taking up application of
subsequent coat.
45.1 Individual DFT measured value shall be more than 80% of the nominal dry film thickness.
4.5.2 The individual DFT measured values between 80 to 100% of the nominal DFT, are
acceptable, provided the overall average (mean) is equal to or greater than the nominal
DFT.
5.0 SAFETY
5.1 Proper masks will be used during grit blasting and painting to prevent inhaling of sand
particles and injurious chemicals. The paint recommended for spraying by the
manufacturer only will be used for spray painting.
5.2 During grit blasting all hose connections will be checked for adequacy of the clamps and
for proper tightness.
5.3. Use of thinners will be avoided unless it is necessary for proper application.
5.4 Coated pipes will be handled with bett slings only.
6.0 Documentation
Surface Preparation & Painting reports shalll be made by FQE and signature of Customer
shall be obtained.
prepare aEVIEWeD By revsh ov, approve By
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s.sh8inalddeina Constructo Services GVRRN Acharya
Sr.Engheer-QMD Quality Assurance - QMD Head - MD
Page 4 of 4TATA PROJECTS LIMITED
‘SURFACE PI
Job Code No. customer Project
Rev. Note No. Report No:
Ret. Doe vate
Test Conta Elcometo No.
‘S.No. ‘Activity ‘As per drg/ ‘As observed Signature.
: Customer Speen Te | customer tA.
{Lo SURFACE PREPARATION AND COATING
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TPL-FaE customer LA
Form No. FQ/032_ Rev No. 2
A. ~ Inspection AuthorityTATA PROJECTS LTD
TATA
DAILY REPORT OF SURFACE PREPARATION AND PAINTING
lcustomer ‘TPL Job Code No.
JProject Report No,
|customer’s Job No. Date:
[unit e, aint MIR No.
Biast Cleaning Clearance or Paint Thickness / Visual
sno} tem Desetoton Spec | Baten No Customer
Brand Ft |1PL| inspection
‘agency
Subcontractor Customer inspection Agency
Form No. FQ/081 Rev.2e ravarmosecrs umn
TATA
REPORT FOR PAINTING OF STRUCTURAL WORKS / EQUIPMENTS
eestor IREPORT NO, DATE:
pRosect: Tet J08 Gove No.
[GONSUCTANT TRI SUBCONTRACTOR:
SITE NAME:
tie |AREA / LOCATION:
Surtace Preparation | primer) Pant Thickness
Ambient Clearance rimer | Paine Visual Inspection by
/S.No.| tom Description |M2"*| time ‘Temp. Hntermediate |! spec. | Batch No. DFT Remarks
No (Deg. C) TPL PIA [Finish & C084 Brand TPLFOE| eA
‘Customer No. 7 (Customer |
Tike Third Party Inspection Agency
SUBCONTACTOR TrL-Foe TPIA oustomerae TATA PROJECTS LTD
TATA
SURFACE PREPARATION AND PAINTING INSPECTION REPORT FOR DUCT WORKS
Icustomer ‘TPL Job Code No.:
Project Report No.
Icustomer’s Job No. Date:
[Subcontractor Paint IMIR No.
Blast Cleaning Clearance | Primer? | paint Painting Painting Clearance
ltem Deseriation Ambient Intermediate /| ai
NO] SpootNo & Sze | OF |T™*lremperatue] rp. | customer ca ord |) visuat | ort | ter | customer | "met
Subcontractor TPLFOE Customer
Form No.: FQ/ 417 Reva,