For Public Comment: Draft Malaysian Standard

DRAFT MALAYSIAN STANDARD
10H003R0
STAGE : PUBLIC COMMENT (40.20) DATE : 01/03/2013-30/04/2013
ICS: 25.220
Descriptors: oil, gas production facilities, protective, coatings, linings, specification
Copyright 2013 DEPARTMENT OF STANDARDS MALAYSIA
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Oil and gas production facilities Protective coatings and linings Specification
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Contents
Page
Committee representation...........................................................................................................ii Foreword ..................................................................................................................... iii Introduction..iv 1 2 3 4 5 6 7 8 9 10 11 Scope..1 Normative references ....................................................................................................... 2
Surface preparation .......................................................................................................... 4 Application ...................................................................................................................... 12 Quality assurance (QA) .................................................................................................. 16 Painting and coating systems ......................................................................................... 17 Resource requirements .................................................................................................. 19 Health, safety and environment (HSE) protection .......................................................... 23 Colour scheme ................................................................................................................ 24 Development of specification new work ......................................................................... 29 Normative references ..................................................................................................... 34 Guide for determining the anchor pattern .............................................................. 33 A typical inspection and test plan for painting application on steel structures34 Hazard identification, risk assessment and risk control (HIRARC) form ................ 39 Proposed paint system ....................................................................................................42
Annex A Annex B Annex C Annex D Annex E
STANDARDS MALAYSIA 2013 - All rights reserved
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Definitions ......................................................................................................................... 2
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Committee representation
The Industry Standards Committee on Petroleum and Gas (ISC H) under whose authority this Malaysian Standard was developed, comprises representatives from the following organisations: Association of Malaysian Oil and Gas Engineering Consultants Department of Occupational Safety and Health Malaysia Department of Standards Malaysia Federation of Malaysian Manufacturers - Malaysian Industrial Gases Manufacturers Group Jabatan Bomba dan Penyelamat Malaysia Jabatan Pengangkutan Jalan Malaysia Kastam Diraja Malaysia Malaysian Gas Association Malaysian Palm Oil Board Malaysian Plastics Manufacturers Association Ministry of Domestic Trade, Co-operatives and Consumerism Ministry of International Trade and Industry Petroliam Nasional Berhad PETRON Malaysia Refining & Marketing Bhd PETRONAS Technical Services Sdn Bhd Shell Malaysia Trading Sdn Bhd SIRIM Berhad (Secretariat) Suruhanjaya Tenaga The Institution of Engineers, Malaysia Universiti Teknologi Malaysia Universiti Teknologi PETRONAS
Bredero Shaw (M) Sdn Bhd Chugoku Paints (M) Sdn Bhd Department of Environment
Department of Occupational Safety and Health Malaysia International Paints Sdn Bhd Jotun (M) Sdn Bhd
PETRONAS Carigali Sdn Bhd PETRONAS Gas Berhad
PETRONAS Technical Services Sdn Bhd PETRONAS Penapisan (Melaka) Sdn Bhd PETRONAS Penapisan (Terengganu) Sdn Bhd PETRONAS Research Sdn Bhd Shell Refining Company (FOM) Berhad SIRIM Berhad (Secretariat) SIRIM QAS International Sdn Bhd (Chemical and Consumer Testing Section)
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The Working Group on Protective Coatings and Linings for Oil and Gas Facilities which developed this Malaysian Standard consists of representatives from the following organisations:
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Foreword
This Malaysian Standard was developed by the Working Group on Protective Coatings and Linings for Oil and Gas Facilities under the authority of the Industry Standards Committee on Petroleum and Gas. Compliance with a Malaysian Standard does not of itself confer immunity from legal obligations.
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Introduction
Unprotected steel in the atmosphere, in water and in soil is subject to corrosion that may lead to damage. Therefore, to avoid corrosion damage, steel structures are normally protected to withstand the corrosion stresses during the service life required of the structure. There are different ways of protecting external and internal of both onshore and offshore facilities in the oil and gas industries from corrosion. This standard deals with protection by paint systems and covers, in the various parts, all features that are important in achieving adequate corrosion protection. Additional or other measures are possible but require particular agreement between the interested parties. In order to ensure effective corrosion protection of steel structures, it is necessary for the owners of such structures, planners, consultants, companies carrying out corrosion protection work, inspectors of protective coatings and manufacturers of coating materials to have at their disposal state-of the-art information in concise form on corrosion protection by paint systems. Such information has to be as complete as possible, unambiguous and easily understandable to avoid difficulties and misunderstandings between the parties concerned with the practical implementation of protection work.
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Although this standard does not deal with financial and contractual questions, attention is drawn to the fact that, because of the considerable implications of inadequate corrosion protection, non-compliance with requirements and recommendations given in this standard may result in serious financial consequences.
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This standard is intended to give this information in the form of a series of instructions. It is written for those who have some technical knowledge. It is also assumed that the user of this standard is familiar with other relevant International Standards or equivalent, in particular those dealing with surface preparation, as well as relevant national regulations.
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Oil and gas production facilities - Protective coatings and linings Specification 1 Scope
This Malaysian Standard provides minimum requirement for both external and internal coatings of both onshore and offshore facilities in the oil and gas industries. It also includes initial painting and maintenance painting. This standard is not applicable for onshore buried and submerge structures below the splash zones. Specialised equipment supplied by vendors such as valves, pumps, compressors, etc. will be coated in compliance with the users respective functional specification and as such, they are not covered in this standard.
a) b) c) d) e) f)
the type of facilities; the type of surface and surface preparation; the type of environment; the type of protective paint system; the type of work; and
the durability of the protective paint system.
The various aspects of the field of application are described in more detail in 1.3.1 to 1.3.6. 1.1.1 Type of structure
This standard concerns facilities made of carbon steel, low-alloy steel, stainless steel and galvanized steel, which are designed using an approved strength calculation. This standard does not cover concrete structures reinforced with steel. 1.1.2 Type of surface and surface preparation
This standard deals with the following types of surface consisting of carbon or low-alloy steel, and their preparation: a) b) c) d) uncoated surfaces; surfaces thermally sprayed with zinc, aluminium or their alloys; hot-dip-galvanized surfaces; zinc-electroplated surfaces; 1
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Although this standard does not cover all types of facilities, surface and surface preparation, it may, by agreement, also be applied to those cases which are not covered by the standard.
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1.1
The field of application is characterised by:
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e) f) g) 1.1.3
sherardized surfaces; surfaces painted with prefabrication primer; and other painted surfaces. Type of environment
This standard deals with atmospheric-corrosivity categories C4, C5-I and C5-M in accordance to Clause 5 of ISO 12944-2:1998. 1.1.4 Type of protective paint system
This standard covers a range of paint products which dry or cure at ambient conditions. This standard does not cover: a) b) c) d) 1.1.5 powder coating materials; stoving enamels; heat-cured paints; and
coatings of more than 2 mm dry-film thickness. Type of work
1.3.6
Durability of the protective paint system
This standard considers three different durability ranges (low, medium and high) (see 3.6). The durability range is not a guarantee time.
Normative references
The following normative references are indispensable for the application of this standard. For dated references, only the edition cited applies. For undated references, the latest edition of the normative references (including any amendments) applies. See Annex A.
Definitions
For the purposes of this standard, the following definitions apply. 3.1 coat
A continuous layer of metal material or a continuous film of paint (3.11), resulting from a single application. 2
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This standard covers both new work and maintenance.
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3.2
contractor
A firm that performs paint removal, surface preparation and coatings application in the industrial market. 3.3 corrosion
Physicochemical interaction between a metal and its environment which results in changes in the properties of the metal and which may often lead to impairment of the function of the metal, the environment or the technical system of which these form a part. [ISO 8044] 3.4 corrosion damage
Corrosion effect which is considered detrimental to the function of the metal, the environment or the technical system of which these form a part. [ISO 8044]
The environmental factors which promote corrosion. [see ISO 12944-1:1998] 3.6 durability
The expected life of a protective paint system to the first major maintenance painting [see also 7.1.1 f)].
3.8
lining
A protective coating on the inner surface of equipment. 3.9 maintenance painting
Periodic painting (repair/touch up of corroded areas or deteriorated paintwork) after initial painting. 3.10 owner
Operators of the facilities. 3.11 paint
A pigmented coating material, in liquid or in paste or powder form, which, when applied to a substrate, forms an opaque film having protective, decorative or other specific properties [EN 971-1]. This includes primers, enamels, varnishes, emulsions, catalysed coatings, bituminous coatings, and other organic coatings. 3.12 protective coating systems
A term which refers to the applied and cured multilayer film or to the components of a system based on non-paint type coating.
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Painting of new construction projects or complete recoating of existing facilities during major maintenance.
3.7
initial painting
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3.5
corrosion stresses
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3.13
protective paint systems
A term intended to include, with equal emphasis, not only the well accepted components of a system such as surface preparation and paint materials, but also the application, inspection, and safety functions. 3.14 substrate
The surface to which the coating material is applied or is to be applied. [EN 971-1] 3.15 work
A term which refers to all activities associated with the selection of the painting and coating systems, surface preparation, paint application, and inspection.
4.1
General
Cleaning of surfaces shall, as a general rule, be done by dry blast cleaning (hereafter referred to as blast cleaning) as outlined in ISO 8504-2. The surface profile and the anchor pattern shall be in accordance with the requirements in this standard. Fabrication should be completed before surface preparation begins. However, surface preparation and application of the base layers of the specified coating system before assembly is allowed. Prefabrication primers are allowed. However, after assembly these primers shall be removed by blasting and the surface shall be blasted to the initial specified surface cleanliness unless otherwise agreed with the owner. Alternative surface preparation for low accessibility area, hazardous area, etc. is only acceptable after written approval of the owner. Carbon steel cleaning tools shall not be used on stainless steel surfaces. Surface preparation shall be subjected to inspection before the prime coat is applied to ensure all traces of dust and foreign matter have been removed by brushing, blowing with dry clean compressed air or vacuum cleaning. Other surface preparation method can be used subject to the owner approval and paint manufacture acceptance. 4
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If the surface has been exposed to a pollutant e.g. salt-laden atmosphere, it shall be tested for presence of contaminants with procedures described in ISO 8502-6 and NACE 6G186 and removed in accordance with appropriate procedures such as that described in NACE 6G186, Health, Safety and Environment (HSE) or any recognised standard prior to blasting or power tool cleaning.
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For optimum paint coating performance surfaces to be painted or coated shall be completely dry and free from burrs, weld spatter, flux, rust, loose scale, dirt, grease, oil and other foreign matter before paint is applied.
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Surface preparation
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4.2
Pre-cleaning
Prior to the blast cleaning and/or prior to any painting operation, the surface shall be free of any contamination and any excessive rust scale shall be removed by impact cleaning tools or high pressure water jetting. All edges shall be ground to a minimum radius of 2 mm; flame cut areas and weld spatter shall be ground flush. In any deviation, the owner shall be informed and corrective action shall be taken prior to the final surface preparation. All bolt holes shall be solvent cleaned prior to the commencement of blast cleaning. Solvent cleaning shall be carried out in accordance with SSPC-SP1. When detergent, degreasers or chemical solutions is used, it shall be followed by adequate rinsing using fresh and clean potable water or pressure water/steam wash. The effluent discharge from the cleaning process shall comply with Environmental Quality (Industrial Effluent) Regulations 2009. Maintenance coating for offshore facilities should start with a steam/detergent cleaning to remove dirt, grease and/or salt deposits. In the specific case of uncoated stainless steel components, water/steam cleaning shall be using water with a temperature of < 50 C and low chloride content [the maximum Chloride content (i.e. 30 ppm)]. All welded areas and appurtenances shall be given special attention for removal of welding flux in crevices. Welding spatter, slivers, laminations and underlying mill scale not removed during fabrication and exposed before and during blast cleaning operations shall be removed by the best mechanical means and the edges smoothed or rendered flush. Before abrasive blast cleaning all equipment which could be damaged by blast, dust or particulate matter shall be suitably protected by masking, wrapping, taping or other means to prevent damage. Where required the degree of contamination shall be assessed in accordance with procedures described in ISO 8502-3. This equipment shall include but not necessarily limited to the following: a) b) c) d) e) f) g) h) i) j) bearings; control panels; control valves; conduit; instrument dials; expansion joint bellows; machined surfaces; shafts; push buttons; tags;
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screws; and exposed moving parts.
Proper and adequate blocking or enclosure of the work area by canvas or tarpaulin or suitable material shall be constructed and accepted by the owner in order to avoid damage to other areas or equipment. This enclosure shall be constructed such as to contain any waste produced from surface preparation activity from spreading and maintained in acceptable and satisfactory manner. Any necessary equipment i.e. exhaust fan, air cooler, lighting for night work and other related HSE requirement shall be installed within this enclosure. For the treatment of stainless steels attention shall be to the level of free halides in materials to be used. Particular care shall be taken to dry areas, which are not self-draining, so that water collected is removed and not allowed to evaporate leaving salt deposits on the surface. Detergents with a pH > 9 shall not be used on aluminium substrates. 4.3 4.3.1 Surface preparation by blast cleaning General
Blast cleaning shall not be done close to painting works or wet coated surfaces to prevent dust and abrasive contamination. Environmental restrictions shall be observed. Rough grit blasting will be allowed during the night providing that the surface is subsequently blasted under light conditions more than 500 lux. Blast cleaned steel surfaces shall not be touched by bare hands to avoid surface contamination. If the surface being cleaned lies adjacent to a coated surface, which is not to be repaired, the blast cleaning shall overlap 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. The surface profile and the anchor pattern for carbon steel and low alloy steels to be coated with liquid organic coatings shall be in accordance with the product specification from the paint manufacturer. If stainless steel, galvanised or non-ferrous metal surfaces are to be painted with liquid (organic) coating materials; blast cleaning of these surfaces shall be carried out by smooth sweep blasting, using a small size non-iron containing abrasive (e.g. aluminium oxide). On galvanised surfaces, the zinc layer shall not be damaged and no defects such as break through or crisping of the zinc layer shall be allowed. A smooth uniform surface roughness shall be in accordance with the agreement with the paint manufacturer. 6
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The blast cleaning of stainless steel shall be carried out by sweep blasting using a fine abrasive not containing iron (e.g. garnet, aluminium oxide, and aluminium silicates), glass pearls or stainless steel shots. To reduce the risk of unacceptably damaging the substrate while sweep blasting stainless steel or hot-dipped galvanised surfaces, it is recommended that a reduced nozzle pressure be used in combination with a small size abrasive.
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Blast cleaning and required visual standard shall be carried out in accordance to ISO 8504-2 and ISO 8501-1 or equivalent. The minimum requirement for successful coating application shall be Sa 2 at the time of coating, unless specified by paint manufacturer.
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Abrading with sandpaper or light grinding with a suitable (flexible) disc may be used for surface preparation if sweep blasting is not practical. Blast cleaning shall not be carried out when the temperature of the surfaces to be blasted is less than 3 C above dew point and when the relative humidity of the air is greater than 85 %. For dew point determination refer to procedure described in ASTM E337. Maximum speed and most effective cleaning are obtained by systematic even blasting. Work 2 should be blocked out in 30 cm and each square blasted evenly until complete. Any blast cleaned steelworks on which rust develops shall be re-blasted. At rough and pitted areas, pressure water/steam wash with fresh water shall be performed after the initial abrasive blasting to remove the residual salts. Should instant rust-back or black-spotting occur, the pressure wash shall be repeated.
For carbon steel, low alloy steels and stainless steels to be coated with thermally sprayed aluminium (TSA), the surface profile shall be as per recommended by vendor or manufacturer. For quality assurance and control requirements refer to ISO 12944-7. 4.3.1.1 New construction and modifications
The surfaces of carbon and low alloy steelwork for new construction and modifications to existing installations shall be blast-cleaned to the visual standard of Sa 2 in accordance with ISO 8501-1 at the time of coating. In addition to the requirements of this standard, blastedcleaned carbon steel surfaces shall be free of mill scale. Particular attention shall be given to shop blasted steel work (i.e. blast cleaning using wheel blast machines). The surface preparation for touch-up painting of welds (including field welds); corroded, chemical polluted or damaged areas shall be by blast cleaning (e.g. vacuum blasting). Abrading is acceptable for repair of damaged coating or areas other than described above. 4.3.1.2 Maintenance
Maintenance painting should be organised and carried out in accordance with the guidelines in this standard. Surface preparation requirements for maintenance painting are specified in Clause 7. To carry out proper maintenance, all parts of a facility should be made accessible for maintenance painting operations in consultation with the owner. This should include the removal of insulation, U-bolts, and the lifting of piping from supports. 4.3.2 Blast cleaning equipment
The compressed air supply used for blast cleaning shall be free from water and oil. A test in accordance with ASTM D4285 shall be conducted to determine the presence of oil and/or water in compressed air used.
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For painting of aluminium or galvanised components, white zinc or aluminium corrosion products and/or rust present shall be removed.
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No acid washes, cleaning solvents or other chemical treatments shall be used on metal surfaces after they have been (dry) blast cleaned. This restriction includes inhibitive washes intended to prevent rusting.
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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/or oil. Accumulation of oil and moisture shall be removed from the air receiver by regular purging. Air compressor shall not be allowed to deliver air at a temperature above 110 C. 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 mans handle at the blasting nozzle. Where air-operated equipment is used, the operators hood or head gear shall be ventilated by clean, cool air served through a regulator filter, to prevent blast cleaning residues from being inhaled. 4.3.3 4.3.3.1 Blasting abrasives International standards and characteristics of abrasives
Blasting abrasives for use in blast cleaning carbon steels and low alloy steels are specified in ISO 8504-2. Recommended blasting abrasives are as follows but not limited to: a) b) c) d) chilled iron grit or shot; steel and malleable iron grit or shot; natural mineral abrasives; and non-metallic abrasives.
Sand or other materials producing silica dust shall not be used due to HSE hazards. All metallic blast cleaning abrasives shall meet the requirements of ISO 11124 (series) and be tested in accordance with test methods specified in ISO 11125 (series). All non-metallic blast cleaning abrasives shall meet the requirements of ISO 11126 (series) and be tested in accordance with test methods specified in ISO 11127 (series). Metallic abrasives shall be sealed in hermetic packaging. Any product delivered in defective packaging shall be rejected. Products shall be handled and stored as per manufacturers recommendation. The blast profile and angular anchor pattern shall be that recommended by the paint manufacturer and agreed by the owner. Roughness or anchor pattern measurement shall be carried out in accordance with procedures approved by the owner. Where anchor patterns are not specified in the paint manufacturers technical data sheet, Table B.1 of Annex B will be used as a guide for determining the anchor pattern. Abrasives for use in blast cleaning steels shall be in accordance with Tables 1 and 2. 8
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Where used abrasives which are specified as scheduled wastes are generated, the wastes shall be collected and disposed of at prescribed premises as per the requirement of the Environmental Quality (Scheduled Wastes) Regulations 2005.
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Table 1. Commonly used non-metallic (N) blast-cleaning abrasives for steel substrate preparation
Type Natural Silica sand (SI) Olivine sand (OL) Staurolite (ST) Abbreviation N/SI N/OL N/ST Initial particle shape Grit - angular, irregular Short - round/ grit - angular, irregular Grit - angular, irregular Comparator
a
Grit - angular, irregular Short - round Grit - angular, irregular
Garnet (GA) Synthetic Iron furnace slag (FE) Copper refinery slag (CU) Nickel refinery slag (NI) Coal furnace slag (CS) (Calcium silicate slags) (Ferrous silicate slags)
N/GA N/FE N/CU N/NI (Aluminium silicate slags) N/CS N/FA
Note. Staurolite is designated S/G in this table as its particle shape is between S and G and is sub-angular, i.e. the edges and corners of the particles are rounded but the irregular grain shape is maintained. Comparator to be used when assessing the resultant surface profile. The method for evaluating surface profile by comparator is described in ISO 8503-2 (see introduction).
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Table 2. Commonly used metallic (M) blast-cleaning abrasives for steel substrate preparation
Type Metallic (M) blastcleaning abrasives Abbreviation M/CI Initial particle shape Grit - angular, irregular Short - round/ grit - angular, irregular Short - round Cylindrical sharp-edged Comparator Grit - angular, irregular Short - round
b a
Cast iron (CI)
Chilled
Cast steel
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High-carbon (HCS)
Low-carbon (LCS) Cut steel wire (CW)

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M/HCS M/LCS M/CW
Fused aluminium oxide (FA)
Grit - angular, irregular
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Short - round Short - round

b
Comparator to be used when assessing the resultant surface profile. The method for evaluating surface profile by comparator is described in ISO 8503-2 (see introduction).
b Certain types of abrasive rapidly change their shape when used. As soon as this happens the appearance of the profile changes and becomes more similar to that of the shot comparator.
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The abrasives shall be free from oil, grease, moisture, etc. Re-used abrasive shall be clean, sharp and free from contaminants and re-qualified to SSPC-AB1 requirements. 4.3.3.2 Selection of abrasives
There is a wide variation in performance between the products within a given generic class of abrasives. Surface anchor profile is directly proportional to the abrasive particle size (the larger the abrasive particle size, the deeper the profile). Cleaning rate is inversely proportional to the abrasive particle size (the larger the abrasive particle size, the slower the cleaning rate). A balanced mixture of particle sizes will produce the optimum level of cleanliness, cleaning rate and surface profile. Pre-qualification of the blast cleaning abrasives shall be conducted subject to acceptance and approval by the owner prior to their use. The pre-qualification test shall be carried out in accordance with a set of procedure covering field trials and laboratory testing to determine their physical and chemical properties, efficiency and effectiveness that can support the economics for their usage. The abrasives shall be free from oil, grease, moisture, chloride contamination etc. Each batch of abrasive should be tested to validate that it meets the requirements as specified in the ISO 11127 (series).
4.3.4
Grades of surface finish
The recognised surface finish grades are summarised in Table 3. Table 3. Surface finish grades
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1. Abrasive blast cleaning White metal blast cleaning Near white metal cleaning
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ISO 8501-1 ISO 8501-2 Sa 3 Sa 2 Sa 2 Sa 1 ISO 8501-1 ISO 8501-2 St 3 St 2 ISO -
The conductivity of abrasives to be used on carbon steels shall be less than 150 S/cm. The 2 salt contamination of abrasives shall be less than 30 mg/m .
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NACE No. 1 No. 2 No. 3 No. 4 NACE NACE -
Remarks
Commercial blast cleaning Brush-off blast cleaning
2. Tool cleaning
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Power-tool cleaning (to bare metal) Power-tool cleaning Hand-tool cleaning
3. Solvent cleaning Solvent cleaning
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SP10 SP6 SP7 SSPC SP11 SP3 SP2 SSPC SP1
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Table 3. Surface finish grades (continued)

4. High and ultrahigh pressure water jetting Water jet cleaning Wet abrasive blasting SSPC SP12 TR2 ISO 8501-4 NACE No. 5 6G198 WJ1-WJ4
4.3.5 4.3.5.1
Alternative methods of surface cleaning General
Alternative surface cleaning shall be conducted upon written approval of the owner. Alternative methods of surface cleaning may require alternative primers such as surface tolerant primers and in accordance with paint manufacturers recommendations. Alternative primers need the approval of the owner. 4.3.5.2 Wet abrasive blasting
4.3.5.3
Water jetting
Where black spots occur in pits or other surface defects, the surface shall be cleaned again at higher pressure to remove the residual salts. Only after written approval of the owner, a suitable corrosion inhibitor such as mass fraction 0.3 % sodium nitrite with mass fraction 1.2 % ammonium phosphate may be used to prevent flash rusting. Chromate inhibitors shall not be used. However, the paint manufacturer shall approve the use of an inhibitor or the removal of residues of the inhibitor before painting. The cleaned surface shall be thoroughly dry at the time of painting. Particular care shall be taken to dry areas, which are not self-draining, so that water collected is removed. All chemical use shall comply with the relevant regulations.
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High-pressure and ultrahigh-pressure water jetting may be used, if the abrasive blasting is not permitted for certain areas where dusting and over -blasting may damage process equipment. It is normally used for maintenance painting. Water jetting is a hazardous operation and requires the use of well-trained, experienced operators.
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The cleaned surface shall be dry at the time of painting. Particular care shall be taken to dry areas, which are not self-draining, so that water collected is removed.
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Wet abrasive blast cleaning techniques might be used to avoid dust or in cases where fire and/or explosion risks are present. The cleaned surface should be washed off immediately after blast cleaning using fresh water. Corrosion inhibitors should only be used after written approval of the owner. In general, corrosion inhibitors that contain chromate, nitrates or nitrites should not be used. The use of a corrosion inhibitor in the water may require that special waste disposal procedures have to be taken to comply with local environmental regulations. Disposal of corrosion inhibitor into the sea should not be allowed. The usage of the corrosion inhibitors shall be agreed among the contractors, paint manufacturers and owner.
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4.3.5.5
Centrifugal abrasive blasting
A portable blasting machine may be used to prepare steel decks and tank floors using recyclable steel abrasives. 4.3.5.6 Vacuum blasting
Vacuum blasting may be used in the areas where open abrasive blasting is not permitted or desirable for spot repair of damaged or corroded areas. 4.3.5.7 Power-tool cleaning
Power-tool cleaning should be confined to minor areas and preferable to bare metal. Unless otherwise specified it shall be done as outlined in ISO 8504-3. When power-tool cleaning to bare metal is not feasible, the surface cleanliness shall at minimum meet the visual standard in accordance with ISO 8501-2 at the time of coating. Care shall be taken to ensure that the steel surface does not become polished after power-tool cleaning. Hand-tool cleaning is permitted prior to power-tool cleaning. If the surface being prepared lies adjacent to a coated surface, the power-tool cleaning shall overlap the coated surface by at least 25 mm and the coated surface shall be feathered.
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5.1
Application
Pre-application procedures Materials storage and Handling
All related safety aspects to the use of paints and associated thinners shall comply with manufacturers requirement namely material safety data sheet (MSDS). The manufacturers recommended pot-life and induction time (if any) requirements shall be followed. Mixing of different brands for a system shall not be permitted unless respective manufacturer and owner consent is sought. Paint shall be applied to dry, clean, prepared surface under conditions recommended in the manufacturers product data sheet.
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Hazardous chemicals shall be classified, packaged and labelled appropriately in compliance with the Occupational Safety and Health (Classification, Packaging and Labelling of Hazardous Chemicals) Regulations 1997.
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Storing, thinning, mixing and handling of paint materials shall be in accordance with the manufacturers recommendation. All paint materials and solvents shall be stored in the closed original container bearing the manufacturers label until required for use. Each container must have full identification, information including manufacturers name, product identification, batch number and colour.
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5.1.2
Material Mixing and Thinning
All materials shall be mixed by solvent proof and spark free mechanical agitator for a sufficient time in order for proper stirring/mixing of paint to ensure uniformity. Tools other than mechanical agitator shall not be used whatsoever to avoid incomplete mixing and contamination. Continuous agitation type spray pots shall be used when applying heavily metal-pigmented paint such as zinc or aluminium loaded paint to avoid sedimentation. Thinner shall not be added to primer or paints unless necessary for proper application according to manufacturers recommendation. The type of thinner used must comply with the manufacturers recommendation. 5.2 Application conditions
c)
the relative humidity is more than 85 %, except for inorganic zinc ethyl silicate up to 90 %; the metal surface temperature is higher than that recommended by paint manufacturer for application;
d)
e)
f)
poor weather conditions for painting exist or are expected within two hours of application such as blowing sand or rain; where the lighting is less than 500 lux. Application methods
g) 5.3 5.3.1
General requirements
Coatings shall be uniformly applied without runs, sags, solvent blisters, dry spray or other blemishes. All blemishes and other irregularities shall be repaired or completely removed and recoated. Special attention shall be paid to crevices, corners, edges, weld lines, bolt heads, nuts and small brackets and apply the specified minimum dry film thickness by brush application if spray is inaccessible to cover all areas. Edges of existing coating shall be feathered towards the substrate prior to over-coating to ensure good adhesion. Surface which is inaccessible after assembly, including the surface of lap joint flanges, nozzle necks, lap joint stub ends, lap rings, bolt holds and some welded joints, shall receive the complete painting system before being assembled. Contact surface of bolted connections at minimum are to be primed.
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surface preparation has not been completed or oil, grease and dust are present on the substrate to be painted;
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b)
the surface temperature is below 5 C as it could adversely affect the curing of paints;
a)
the surface temperature is less than 3 C above dew point;
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Unless otherwise recommended by manufacturer and accepted by the owner, paints shall not be applied when:
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Primers should not be overcoated with the second coat paint until the specified minimum over-coating time is achieved. Surface preparation is required if the over-coating time is exceeded. Contact the paint manufacturer for the type and surface preparation required. Intercoat contamination shall be minimised by maintaining proper cleanliness and by applying the intermediate and finish coats within the over-coating time recommended by the manufacturer. If contaminants are present, they shall be removed before applying subsequent coats. Contrasting colour shall be used for each coat of paint so as to ensure different coats are applied to meet the required dry film thickness. Each coat shall be applied with acceptance limits of dry film thickness (dft) as specified. It must be ensured that solvent retention in any of the coats, caused by the application of excessive coating thickness is avoided. On structural steel areas subject to be assembled by high tension bolts, contact surface shall be primed only with inorganic zinc ethyl silicate. Intermediate and final coat shall not be applied.
Cover is to be kept on opened container of paints when not in used. 5.3.3 Brush Application
Application with brush is acceptable under the following conditions subject to the owner approval: a) b) c) when areas cannot be properly coated by spray for any reasons; when spray application is difficult due to accessibility; above ground level when it is considered that loss of paint under prevailing conditions is excessive e.g. windy and progress of work has to be maintained and personnel in or near the work site or requirement property, may be affected by spray particles; for touch-up or repair of localised damaged paint or areas of incorrectly applied paint; for painting of stripe coat e.g. when applying the initial coat of paint to corners, edges, crevices, holes, welds or other irregular surface prior to spray application;
d) e)
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In order to achieve a uniform application when applying large surface areas, application shall be made in two directions so that the passes are at right angles to each other i.e. cross spray at 50 % over lapping. Pressures and spray fan shall be adjusted so that the optimum spray pattern is obtained for the surface being coated.
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Hose and containers shall be thoroughly cleaned before addition of new materials. The spray gun shall be held no closer than 300 mm or more than 600 mm from the surface to be coated. During application the spray gun shall always be held at a right angle to the substrate (90 to the substrate). Each pass shall overlap the previous one by 50 %.
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Paints shall be applied by air spray or airless spray.
5.3.2
Spray application
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f) g)
when the substrate material to be applied are suitable for brush application; and the number of coats shall be adjusted to the wet and dry film thickness to match.
Paint brushes used shall be of a style and quality that will permit appropriate application of the material being applied. Material applied by brush shall be reasonably uniform in thickness, without any apparent surface defect such as brush marks, runs, sags, or curtains. 5.3.4 Roller Application
Roller application shall only be used with approval from the owner. Roller application may be used only when:
b)
5.4.1
General requirements
Inorganic zinc primer shall not overlap adjacent intermediate and finish coats. Areas with inadequate coating thickness shall be thoroughly cleaned and if necessary, abraded, and additional compatible coats applied until they meet the specification. These additional coats shall blend in with the final coating on adjoining areas. 5.4.2 Damaged coating not exposing substrate surface
Surface to be overcoated which has been contaminated or damaged shall be cleaned by solvent cleaning/degreasing and/or lightly brush blasted to ensure that the surface is free from contaminants. Contaminants shall be removed by dry compressed air and wipe by hand with clean, dry rags. The coating around the damaged area shall be chamfered by sanding to ensure continuity of the patch coating. The full coating system shall then be reapplied strictly in accordance with this specification.
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If the surface being prepared lies adjacent to a sound coated surface which is not to be repaired, the surface preparation shall overlap the coated surface by at least 25 mm. The remainder of existing coated surface shall be properly protected with shields or screens to prevent any possible damage to the coating.
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Before application of any subsequence coat of material, all damages from previous coats shall be repaired in accordance with manufacturers recommendation. All loose paint shall be removed to a firm edge. All surface irregularities and contaminations shall be removed. Hard, glossy surface may require abrading to obtain a suitable surface for painting.
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Procedure for repair and/or touch up of painting of each generic coating system shall be submitted by contractor to the owner for approval.
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5.4
Repairs and touch up painting
paint application by roller method is acceptable to paint manufacturer and is in accordance with the application data.
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a)
spraying is not feasible; and
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5.4.3
Damaged coating exposing substrate surface
The damaged area shall be cleaned to the original or maintenance painting system specified for that item and the full coating system reapplied in accordance with the application data. The cleaning shall carry over onto tightly adhering surrounding coating for not less than 25 mm all around and the edges shall be chamfered by sanding to ensure continuity of the patch coating. 5.4.4 Repair of zinc ethyl silicate primer
Damaged surface of zinc primer shall be cleaned to remove all loose materials and blast cleaned with a portable vacuum blast cleaning unit. The surface shall be coated with one coat of the primer which is the same as the damaged primer. If blast cleaning is not practical, power tool cleaning may be used subject to the owner and contractor agreement. In such cases, subject to operating temperature limitations, one or two packs recoatable zinc primer may be used in lieu of zinc silicate primer.
5.4.6
Inadequate coating thickness
Areas with inadequate coating thickness shall be thoroughly cleaned and if necessary abraded and additional coats applied shall blend in with the final coating on adjoining areas. 5.4.7 Handling and shipping of coated items
Coated items shall be carefully handled to avoid damage to coated surface. No handling shall be performed before the coating system is cured to an acceptable level. Packing, handling and storage facilities shall be non-metallic type.
Quality assurance (QA)
6.1 The key quality objective of application of protective coatings and linings is to ensure that all related activities, as a minimum, meet the relevant requirements from clients, industry standards, health, safety and environment, and local and national regulations. The implementation of the objective should follow the MS ISO 9001. 6.2 The operational techniques and activities that are used to fulfil quality requirements of application of protective coatings and linings can be achieved through establishment of a quality assurance system. The quality assurance system may include but not necessarily limited to the following: a) b) 16 analysis or estimation of corrosivity of environment; basic design criteria for corrosion protection purposes;
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In case of repairing damage on fully cured epoxy coatings and aged epoxy coating, the coating work shall only be carried out after the surface has been suitably abraded to provide an adequate anchor for the coating to be applied. The repair coating shall be compatible with the existing coating. A test for compatibility is described in ASTM D 5064.
5.4.5
Repair of fully cured epoxy coating
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c) d) e) f) g) h)
selection of durability of paint system; selection of protective paint system; laboratory performance test methods; health, safety and environment protection; execution and supervision of paint work; and final documentation.
Annex C provides the example of a sample inspection and test plan for the quality control system.
7.1 7.1.1
Coating systems selection General
The coating systems generally acceptable for the intended service are listed in 7.2 for external application and 7.3 for internal application. Selection and acceptance of coating systems and products for a specific and specialised application which are not listed herein shall be the prerogative of individual owners in consultation with the respective paint manufacturers. When selecting painting system for a particular project, the contractor in consultation with the owner shall consider the following factors: a) Coating characteristics: i) ii) iii) iv) v) vi)
theoretical coverage;
drying time;
curing time; overcoating time; recoating time; and
vii) compatibility. The maintenance and touch-up coating systems shall be compatible with the initial/new construction coating systems. Coating system compatibility shall be tested using patch test methods described in ASTM D5064. b) material of substrate;
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application time;
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Painting and coating systems
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c) d)
basic function of coating on substrate; accessibility (time or space) and availability of appropriate equipment for satisfactory surface preparation and application; environmental factors (refer to ISO 12944-2:1998); and design life/durability.
e) f)
The level of coating failure before the first major maintenance painting shall be agreed by the interested parties and shall be assessed in accordance with ISO 4628-1 and ISO 4628-5, unless otherwise agreed between the interested parties. In this standard, durability is expressed in terms of three ranges: a) b) c) Low (L): 5 to 10 years. Medium (M): 10 to 15 years. High (H): more than 15 years.
Any new formulation related to zinc coating shall be subjected to qualification testing stated in this standard. The zinc coating systems shall pass the respective tests in accordance with ASTM D6580. If shop primer (for temporary protection) is applied, then it must be 100 % full blasted to the requirement stated in Clause 4 prior to the application of the full coating system. For secondary surface preparation on primed surface; all zinc salt formation shall be removed by sweep blasting or sanding down. All other possible contaminants shall be sanded down and solvent cleaned before subsequent coating. For damaged surfaces, unprimed welding joints and rusty area, spot blast to Sa 2 followed by one coat of epoxy zinc rich or power tool cleaned to St3 and followed by surface tolerant epoxy or relevant materials upon owner approval. 18
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Zinc content by percentage weight for inorganic zinc silicate and epoxy zinc should comply with SSPC-Paint 20 (zinc rich primer, Type I 'inorganic ' and Type II 'organic') requirement or equivalent.
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Zinc-rich primers, Zn (R), are those in which the zinc dust pigment content of the non-volatile portion of the paint is equal to or greater than 80 % by mass. The value of 80 % zinc dust by mass in the dry film for zinc-rich primers Zn (R) is the basis for the durability given for the paint systems. The zinc dust pigment shall comply with the requirements specified in ISO 3549.
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7.1.2
Organic and inorganic zinc-filled coatings
The durability range is not a guarantee time. Durability is a technical consideration that can help the owner (need to be consistent) to set up a maintenance program. A guarantee time is a consideration that is legal subject of clauses in the administrative part of the contract. The guarantee time is usually shorter than the durability range. There are no rules that link the two periods of time.
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7.1.3
Selection and application of top coats
For areas to be applied with polyester glass flake, all shop primer shall be removed completely, i.e. Sa 2. Prior to top coating zinc rich primers, SSPC-PS Guide 8 shall be consulted to select compatible topcoats. The selection process requires identification of the generic type of primer, compatibility considerations, and selection of compatible topcoats. The minimum volume solids for high solid epoxy shall be 75 %. As an alternative, surface tolerant high solid epoxy paint can be applied. When top coating inorganic zinc silicate primed surface a mist coat (wet to wet technique) shall be required to eliminate pin holing. 7.2 Painting and coating system schedules for external application
The minimum requirement of the painting and coating schedule is given in Table E.1 of Annex E. 7.3 Painting and coating system schedules for internal application
The minimum requirement of the painting and coating schedule is given in Table E.2 of Annex E.
7.4.2
Hot dip galvanising
Where applicable, hot-dip galvanizing specification shall refer to MS 1196, MS 2384 and MS 2385.
8
8.1
Resource requirements
Painting contractor
Painting contractors shall have the organization structure, qualified personnel, procedures, knowledge and capability to produce surface preparation and coating application of the requirements. Unless otherwise agreed, the contractors shall provide the client with extract of all execution and supervision standards given in his quality manual that are relevant to the specifications. The procedure for evaluating qualifications of painting contractors are described in SSPC-QP1.
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Where applicable, thermal spray specification shall refer to ISO 14918, ISO 14922-1 and ISO 14922-2.
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7.4.1
Thermal Spray
7.4
Thermal spray aluminium/aluminium alloy
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Functional areas to be evaluated shall include the following: a) Management procedures: i) ii) iii) b) company policy; organisation and personnel; and administrative and management procedures.
Technical capabilities: i) ii) iii) iv) personnel qualifications; technical resources;
equipment, facilities and experience.
c)
Quality control: i) ii) personnel qualifications; and
inspection procedures and recording systems.
d)
Safety: i) ii)
safety procedure and record-keeping systems; and resource materials.
8.2 8.2.1
Painting inspector
Qualifications/experience
All painting activities shall be carried out by competence personnel demonstrating ability to execute works meeting the requirements of this standard. The painting inspector is recommended to be certified under either one of the following certification institutes, or equivalent. a) b) Institute of Materials Malaysia (IMM), Paint Inspector Level II; or Other reputable Institutes e.g. the Society for Protective Coatings (SSPC), the British Gas Approved Scheme (BGAS), NACE International Level II, FROSIO, Institute of Corrosion (ICorr).
He shall have at least one year work experience in painting, and a good working knowledge on all aspects of painting, procedures, specifications, surface preparation, paint application and inspection. He shall be able to use the inspection tools and test equipment which is associated with the works.
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procedures; and
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8.2.2
Responsibilities
The painting inspector shall be responsible for ensuring that the quality of all aspects of a painting programme is correct and according to this specification. The inspector's duty is to ensure that the requirements of the coating specification are met based on ASTM D3276 or SSPC QP 1. The inspector's function is to enforce the specifications without exception even if he deems them to be inadequate and to consult the owner's QA/QC engineer of any deviations. Besides specification enforcement, the painting inspector shall be responsible for witnessing, verifying, and documenting the work at various inspection points: a) b) c) d) e) f) g) h) i) j) k) l) m) n) 8.3 8.3.1 pre-surface preparation inspection;
evaluation of compressor (air cleanliness) and surface preparation equipment; determination of surface preparation cleanliness and profile; inspection of application equipment; witnessing paint mixing; inspecting paint/application; determination of wet film thickness; determination of dry film thickness;
evaluating cleanliness between coats; and pinhole and holiday testing. adhesion testing;
evaluating the curing of applied paints; and any other coating related activities. Blaster/painter Qualifications/experience
Blaster/painter shall be certified under either one of the following certification institutes, or equivalent: a) b) IMM, Protective Coatings Technician Level I or Level II; or Akademi Binaan Malaysia (ABM); or
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measurement of environmental conditions;
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c)
Construction Industry Development Board (CIDB).
Certified blasters and painters qualified to do blasting & painting work as required by the owners. He shall be competent and skilful with the following operations: a) blasting; and i) ii) iii) b) equipment set up (type of nozzle, compressor pressure, type of hose, after cooler); abrasive (type, size); and surface quality achieved.
painting. i) ii) equipment (application method, air pressure, tip size); and paint used (product used, generic name, mixing ratio, mixing method, thinner, percent thinning, expected pot life, thickness required).
8.3.2
Responsibilities
Level I technician shall be allowed to carry out either blasting or painting work depending on his category of certification (i.e. Blaster Level I and Painter Level I).
Performance of all blasting and painting works shall be monitored/inspected by the painting inspector. 8.4 Inspection equipment
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The painting inspection equipment shall be provided by the Inspection agency and the contractor. The appropriate instruments with valid calibration where applicable, to be used at various inspection points are, but not limited to the following equipment as specifies in Table 4. Table 4. Inspection equipment Purpose Weather condition check Blasting equipment check
Item no 1 2 3 4 5 6 7 8 9 10
Item Description Sling psychrometer Surface thermometer 0 C to 150 C Psychometric tables Hypodermic needle pressure gauge Blast nozzle aperture gauge Surface profile gauge Surface preparation standards Inspection mirror Illuminated Magnifier Salinity refractometer/salt contamination meter
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Level II technician shall be allowed to carry out both blasting and painting works (i.e. Multiskill Blaster and Painter Level II).
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Surface quality test
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Table 4. Inspection equipment (continued) Item no 11 12 13 14 15 16 Item Description Wet Film Thickness (WFT) gauge Dry Film Thickness (DFT) gauge for ferrous or non-ferrous Low voltage holiday detector High voltage holiday detector Cutter for tape adhesion test Hydraulic adhesion tester Purpose Paint thickness test Holiday detection test Adhesion test
9
9.1
Health, safety and environment (HSE) protection

General
a) b) c)
not specifying or using toxic or carcinogenic substances;
reduction of emissions of volatile organic compounds (VOC);
d) e) f) 9.2
protection of the body, including the eyes, the skin, the ears and the respiratory system; protection of water and soil during coating application work; and recycling of materials and waste disposal. Occupational safety and health regulations
All stake holders must ensure capability to comply with health and safety regulations, and those hazardous operations in the protective coatings industry are recognized such as: a) materials; i) ii) b) c) fire hazards and explosions; and health hazards.
paint application; surface preparation; and
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measures against harmful effects of fumes, dust, vapours and noise, as well as fire hazards;
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It is the duty of clients, specifiers, contractors, paint manufacturers, inspectors and all other personnel involved in a project to carry out work for which they are responsible in such manner that they do not endanger health and safety of themselves and others. In pursuance of this duty, each party shall ensure that all statutory requirements in which their work, or any part of their work, is to be carried out are complied with. Items that will need particular attention but not necessarily limited to the following:
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d)
access and rigging. i) ii) iii) ladders; confined spaces; and equipment grounding.
A typical hazard identification, risk assessment and risk control (HIRARC) for surface preparation and coating applications are as per Annex D. For further details, refer to Department of Occupational Safety and Health (DOSH) Guidelines for hazard identification, risk assessment and risk control (HIRARC). Guidelines on monitoring of harmful effects of fumes, dust, vapours and gases may be referred to DOSH Guidelines on monitoring of airborne contaminant for chemicals hazardous to health. Machinery used for surface preparation and coating application shall be in accordance to Factories and Machinery Act 1967 (Revised - 1974) (Act 139). Health and Safety programmes shall be designed to comply with the Occupational Safety and Health Act 1994 (Act 514) which states that it shall be the duty of every employer and every self-employed person to ensure the safety, health and welfare at work of all his employees. 9.3 Environmental regulations
10
Colour scheme
Where applicable, colour scheme shall be in accordance with local statutory rules and regulation. Where appropriate for safety reason, the following colour scheme shall be applied:
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Colour scheme of onshore and offshore installation shall comply with either OSHA or BS colour scheme, as specified in Table 5 to Table 8 and Figure 1.
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The Environmental Protection Programme for a project shall comply with the Malaysian Environmental Quality Act (EQA) 1974 relating to the prevention, abatement, control of pollution and enhancement of the environment.
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Table 5. Safety colours

Items Dangerous obstructions Colour schemes Black and OSHA yellow (in alternate bands) BS Standard BS4800 00E53 Black BS4800 10E53 Yellow
Dangerous or exposed parts of machinery Fire equipment and services First aid equipment Foam system Flare stack/communication towers
Alert (OSHA) orange OSHA red OSHA green OSHA yellow OSHA orange/white (in alternate bands)
BS4800 06E51, BS381C 557 Orange BS4800 04E53 Red BS4800 12E53 Green BS4800 10E53 Yellow BS4800 06E51, BS381C 557 Orange BS4800 00E55 White
Font and arrow Process line Gas Liquid Process Black Black
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OSHA blue OSHA blue
Items
Colour schemes
Table 6. Piping colour identification legend
Background
OSHA yellow
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OSHA yellow OSHA yellow
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Black
Drain and relief Drain, hot oil
Drain, pressurized Drain, hazard
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Black
OSHA yellow OSHA yellow OSHA hazardous/slupper yellow OSHA yellow OSHA yellow OSHA yellow
Black Black
Condensate drain Flare, high press Flare, low press vent vent, atmospheric
Black Black Black White White
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BS4800 00E53 Black BS4800 10E53 Yellow BS4800 00E53 Black BS4800 10E53 Yellow BS4800 00E53 Black BS4800 10E53 Yellow
BS4800 00E53 Black BS4800 10E53 Yellow BS4800 00E53 Black BS4800 10E53 Yellow BS4800 00E53 Black BS4800 10E53 Yellow BS4800 00E53 Black BS4800 10E53 Yellow BS4800 00E53 Black BS4800 10E53 Yellow BS4800 00E53 Black BS4800 10E53 Yellow BS4800 18E52 Blue BS4800 00E55 White BS4800 18E52 Blue BS4800 00E55 White
BS Standard
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Table 6. Piping colour identification legend (continued)
Items Colour schemes Font and arrow Steam and condensate Condensate Steam Boiler feed water Black Black White OSHA yellow OSHA yellow OSHA green BS4800 00E53 Black BS4800 10E53 Yellow BS4800 00E53 Black BS4800 10E53 Yellow BS4800 12E53 Green BS4800 00E55 White Background BS Standard
Utility water Cooling water Fire water/extinguishing Portable water/service water Ballast water/sea water wash down Chilled water White White White White White OSHA green OSHA red OSHA green OSHA green BS4800 12E53 Green BS4800 00E55 White BS4800 04E53 Red BS4800 00E55 White BS4800 12E53 Green BS4800 00E55 White
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OSHA blue OSHA blue OSHA blue
OSHA green
Utility and general Instrument air Utility air Instrument gas Utility gas Hydraulic White White Black
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OSHA yellow OSHA yellow OSHA yellow
Black
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Black
Utility gas and fuel Blanket gas Diesel fuel Aviation fuel Fuel gas Nitrogen Black Black Black Black White OSHA yellow OSHA yellow OSHA yellow OSHA yellow BS4800 00E53 Black BS4800 10E53 Yellow BS4800 00E53 Black BS4800 10E53 Yellow BS4800 00E53 Black BS4800 10E53 Yellow BS4800 00E53 Black BS4800 10E53 Yellow BS4800 18E52 Blue BS4800 00E55 White
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BS4800 12E53 Green BS4800 00E55 White BS4800 12E53 Green BS4800 00E55 White
BS4800 18E52 Blue BS4800 00E55 White BS4800 18E52 Blue BS4800 00E55 White BS4800 00E53 Black BS4800 10E53 Yellow BS4800 00E53 Black BS4800 10E53 Yellow BS4800 00E53 Black BS4800 10E53 Yellow
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Table 6. Piping colour identification legend (continued)

Items Colour schemes Font and arrow Utility oil Lube oil Seal oil Hot oil Black Black Black OSHA yellow OSHA yellow OSHA yellow BS4800 00E53 Black BS4800 10E53 Yellow BS4800 00E53 Black BS4800 10E53 Yellow BS4800 00E53 Black BS4800 10E53 Yellow Background BS Standard
Caustic and chemical Chemical Glycol Caustic Chlorine Black Black Black Black OSHA yellow OSHA yellow OSHA yellow
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B 0.75 1.00 2.25 4.00 5.00 C 8.00 8.00 12.00 24.00 32.00
OSHA yellow
General Treated water Black water Grey water Hot water White
White
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OSHA green OSHA green OSHA green
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White Black
OSHA yellow
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Table 7. Piping identification system Dimensions in inch Flow direction arrow D 0.75 1.00 2.25 4.00 5.00 E 4.00 5.00 8.00 12.00 16.00
Type 1 2 3 4 5
Pipe O.D. 0.75 - 1.25 1.50 - 2.00 2.50 - 6.00 8.00 - 10.00 Over 10.00
Identification legend A 0.5 0.75 1.25 2.25 3.75
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BS4800 00E53 Black BS4800 10E53 Yellow
BS4800 00E53 Black BS4800 10E53 Yellow BS4800 00E53 Black BS4800 10E53 Yellow
BS4800 12E53 Green BS4800 00E55 White BS4800 12E53 Green BS4800 00E55 White BS4800 12E53 Green BS4800 00E55 White BS4800 00E53 Black BS4800 10E53 Yellow
BS4800 00E53 Black BS4800 10E53 Yellow
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Table 8. Colour scheme for onshore/offshore installation and equipment

Structures Splash zone/spider deck:
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Figure 1. Piping identification system
Colour scheme Yellow
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Yellow Yellow Yellow Yellow White White
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BS Standard BS4800 10E53 Yellow Offshore structural members steel below castellation point (shim connection splash zone substructures), spider deck and boat landing. Cellar deck up to main deck including bridge structure: Structural members, from cellar deck up to the main deck, castellation point outwards, beams, girders, underside of drip pan, pipe support & cable tray and Bridge structures. Risers Footway & stairway supports Grating panel (maintenance only) Handrails Pressure vessels, columns, heat exchangers Wellheads BS4800 10E53 Yellow BS4800 10E53 Yellow BS4800 10E53 Yellow
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Alert orange BS4800 00E55 White BS4800 00E55 White
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BS4800 10E53 Yellow
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Table 8. Colour scheme for onshore/offshore installation and equipment (continued)

Structures Pipeworks except valves bodies, manifolds and firewater lines. Storage tank Chemical tank Instrument control panel, instrument and lighting stand Module (including living quarters): - Interior walls and ceiling - Exterior walls Colour scheme White White White with black stripe White White BS Standard BS4800 00E55 White BS4800 00E55 White BS4800 00E53 Black BS4800 00E55 White BS4800 00E55 White BS4800 00E55 White
Helideck: - Structure and underside helideck, footway & stairway supports, ladders, instrument & lighting stand and cable tray. - Helideck landing. Deck top of living quarters Firewater lines White
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Forest green
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Forest green OSHA red Aluminium Black Black
Conductor pipes
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Process/utility piping, temperature > 80 C
Inside drip pan including pipeworks
11
Development of specification new work and maintenance
11.1 The purpose of this section is to provide basic guidelines for development of specifications for new work and maintenance related to surface preparation and coating application. 11.2 The fabricator/contractor shall develop the specifications for surface preparation and coating in accordance to ISO12944-8 or any other equivalent standards. 11.3 The completed specifications for new work and maintenance shall be approved by the owner prior to commencing the relevant work.
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BS4800 00E55 White BS4800 12E53 Green BS4800 12E53 Green BS4800 04E53 Red N/A BS4800 00E53 Black BS4800 00E53 Black
- Production shed and equipment store.
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Annex A (normative) Normative references

MS 1196, Continuous hot-dip aluminium/zinc-coated steel sheet of commercial, drawing and structural qualities MS 2384, Continuous hot-dip zinc-coated carbon steel sheet of structural quality MS 2385, Continuous hot-dip zinc-coated carbon steel sheet of commercial and drawing qualities
ISO 8502-6, Preparation of steel substrates before application of paints and related products Tests for the assessment of surface cleanliness - Part 6: Extraction of soluble contaminants for analysis - The Bresle method ISO 8502-3, Preparation of steel substrates before application of paints and related products Tests for the assessment of surface cleanliness - Part 3: Assessment of dust on steel surfaces prepared for painting (pressure-sensitive tape method) ISO 8502-4, Preparation of steel substrates before application of paints and related products Tests for the assessment of surface cleanliness - Part 4: Guidance on the estimation of the probability of condensation prior to paint application
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ISO 8501-4, Preparation of steel substrates before application of paints and related products Visual assessment of surface cleanliness - Part 4: Initial surface conditions, preparation grades and flash rust grades in connection with high-pressure water jetting
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ISO 8501-2, Preparation of steel substrates before application of paints and related products Visual assessment of surface cleanliness - Part 2: Preparation grades of previously coated steel substrates after localized removal of previous coatings
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ISO 8501-1, Preparation of steel substrates before application of paints and related products Visual assessment of surface cleanliness - Part 1: Rust grades and preparation grades of uncoated steel substrates and of steel substrates after overall removal of previous coatings
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ISO 4628-5, Paints and varnishes - Evaluation of degradation of paint coatings - Designation of intensity, quantity and size of common types of defect - Part 5: Designation of degree of flaking.
ISO 4628-1, Paints and varnishes - Evaluation of degradation of paint coatings - Designation of intensity, quantity and size of common types of defect - Part 1: General principles and rating schemes.
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MS ISO 9001, Quality management systems - Requirements
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ISO 8504-2, Preparation of steel substrates before application of paints and related products Surface preparation methods - Part 2: Abrasive blast-cleaning ISO 8504-3, Preparation of steel substrates before application of paints and related products Surface preparation methods - Part 3: Hand- and power-tool cleaning ISO 11124 (series), Preparation of steel substrates before application of paints and related products - Specifications for metallic blast-cleaning abrasives ISO 11125 (series), Preparation of steel substrates before application of paints and related products - Test methods for metallic blast-cleaning abrasives ISO 11126 (series), Preparation of steel substrates before application of paints and related products - Specifications for non-metallic blast-cleaning abrasives ISO 11127 (series), Preparation of steel substrates before application of paints and related products - Test methods for non-metallic blast-cleaning abrasives ISO12944-1:1998, Paints and varnishes - Corrosion protection of steel structures by protective paint systems - Part 1: General introduction
ISO12944-6:1998, Paints and varnishes - Corrosion protection of steel structures by protective paint systems - Part 6: Laboratory performance test methods ISO12944-7, Paints and varnishes - Corrosion protection of steel structures by protective paint systems - Part 7: Execution and supervision of paint work ISO12944-8, Paints and varnishes - Corrosion protection of steel structures by protective paint systems - Part 8: Development of specifications for new work and maintenance ISO 14918, Thermal spraying - Approval testing of thermal sprayers ISO 14922-1, Thermal spraying - Quality requirements of thermally sprayed structures - Part 1: Guidance for selection and use ISO 14922-2, Thermal spraying - Quality requirements of thermally sprayed structures - Part 2: Comprehensive quality requirements ASTM D3276, Standard guide for painting inspectors (metal substrates) ASTM D4285, Standard test method for indicating oil or water in compressed air ASTM D5064, Standard practice for conducting a patch test to assess coating compatibility
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ISO12944-5, Paints and varnishes - Corrosion protection of steel structures by protective paint systems - Part 5: Protective paint systems
ISO12944-3, Paints and varnishes - Corrosion protection of steel structures by protective paint systems - Part 3: Design considerations
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ISO12944-2:1998, Paints and varnishes - Corrosion protection of steel structures by protective paint systems - Part 2: Classification of environments
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ASTM D6580, Standard test method for the determination of metallic zinc content in both zinc dust pigment and in cured films of zinc rich coatings ASTM E337, Standard test method for measuring humidity with a psychrometer (the measurement of wet- and dry-bulb temperatures NACE 6G186, Surface preparation of contaminated steel surfaces SSPC-AB1, Mineral and slag abrasives SSPC QP 1, Standard procedure for evaluating the qualifications of industrial/marine painting contractors (Field application to complex industrial and marine steel structures) SSPC-SP1, Solvent cleaning SSPC-SP2, Hand tool cleaning SSPC-SP3, Power tool cleaning SSPC-SP5/NACE No 1, White metal blast cleaning SSPC-SP6/NACE No 3, Commercial blast cleaning SSPC-SP7/NACE No 4, Brush-off blast cleaning
SSPC-TR2/NACE 6G198, Wet abrasive blast cleaning SSPC-Paint 20, Zinc-rich coating (Type I - inorganic and Type II - organic) SSPC-PS Guide 8, Guide to topcoating zinc-rich primers Environmental Quality Act (EQA) 1974 Environmental Quality (Scheduled Wastes) Regulations 2005 Environmental Quality (Industrial Effluent) Regulations 2009 Factories and Machinery Act 1967 (Revised - 1974) (Act 139) Guidelines for hazard identification, risk assessment and risk control (HIRARC) Guidelines on monitoring of airborne contaminant for chemicals hazardous to health Occupational Safety And Health Act 1994 (Act 514) Occupational Safety and Health (Classification, Packaging and Labelling of Hazardous Chemicals) Regulations 1997 32
Fo
rP ub
SSPC-SP12/NACE No 5, High- and ultra-high pressure water jetting for steel and other hard materials
lic
SSPC-SP11, Power tool cleaning to bare metal
SSPC-SP10/NACE No 2, Near white metal cleaning
om
en
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Annex B (informative) Guide for determining the anchor pattern

Where anchor patterns are not specified in the paint manufacturers technical data sheet, Table B.1 is used as a guide for determining the anchor pattern. Table B.1. Relationship between coating thickness and anchor pattern Dry film thickness 125 microns to 200 microns (5 mills to 8 mills) 200 microns to 500 microns (9 mills to 20 mills) > 500 microns (> 20 mills) Anchor pattern 25 microns to 50 microns (1 mills to 2 mills) 50 microns to 75 microns (2 mills to3 mills) 75 microns to125 microns (3 mills to 5 mills)
Fo
rP ub
lic
om
en
33
Project name: Clients name: Main contractors name: Subcontractor/suppliers name: Work QC activity description
Acceptance Criteria (procedure/drawing/ standard/specification)
C om
Scope of work: Application of coating systems at oil and gas structures Control categories P= I= S= H= W= Prepare/supply Inspection Surveillanc Inspection Witness e hold point Quality Control Points by: Stage/frequency records Main Main Subcon/ supplier contractor contractors consultant During design stage Analysis or estimation report of the corrosivity of environment H/P R N/A
m en t
2.0 2.1
Basic design criteria for corrosion protection purposes Design to facilitate surface preparation, painting, inspection and maintenance as per ISO 12944-3.
Accessibility Treatment of gaps Prevention of deposits and water Edges Weld surface imperfections Bolted connections Bolts, nuts and washers Prevention of galvanic corrosion
rP ub
During design stage
lic
Fo
34
1.0 1.1 Analysis or estimation of the corrosivity of the environment Classification of atmospheric corrosion Classification of corrosion in water and soil Atmospheric corrosivity categories as per 5.1.1 of ISO12944-2:1998. Table 2 and 5.2 of ISO 12944-2:1998.
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Annex C (informative) A typical inspection and test plan for painting application on steel structures
A typical inspection and test plan for painting application on steel structures should be in accordance to Table C.1. Table C.1. Inspection and test plan (ITP)
ITP ref no:
R= Review document Clients approval
Remarks
Design report
H/P
N/A
Table C.1. Inspection and test plan (ITP) (continued)

Project name: Clients name: Main contractors name: Subcontractor/suppliers name: Work QC activity description Scope of work: Application of coating systems at oil and gas structures Control categories P= I= S= H= W= Prepare/supply Inspection Surveillance Inspection Witness hold point Quality Control Points by: Stage/frequency records Subcon/ Main Main supplier contractor contractors consultant Prior to selection of protective paint system Selected durability range ITP ref no:
5.0 5.1
Laboratory performance test methods Tests Preparation of test panels Sampling of paints Number of test panels Paint systems Reference system Test procedures
Test panel complies with 5.1 of ISO 129446:1998. ISO 1513 3 panels (minimum) 5.4 of ISO 129446:1998 ISO 12944-5 Tables 1 and 2 of ISO 12944-6:1998
rP ub
As required by client and during selection of paint system (ISO 12994-5)
lic
Types of paint applicable for the selected environment Suitable paint systems
ISO 12944-5 and paint manufacturers specifications Clients contract specifications
Prior to application of paint system
Report on selection of paint system
C om
Fo
R= Review document Clients approval
Remarks
Acceptance criteria (procedure/drawing/ standard/specification)
3.0 3.1
Selection of durability of paint system Durability ranges - high, medium and low. 4.4 of ISO 129441:1998.
m en t
H/P R R N/A H/P R
N/A
4.0
Selection of protective paint systems
H/P
Laboratory test report
N/A
W/R
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35
5.2
Paint system assessment
6.0 6.1
Health, Safety and Environment Protection Preparation of HSE Plan Occupational Health and Safety Environment protection ISO 12944-1:1998, ISO 12944-8 OSHA Environment Quality Act Factory Machinery Act Chemical Safety Data Sheets Prior to selection of paint system
C om
Test duration Assessment before artificial ageing Assessment after artificial ageing for the specified time
6.2 of ISO 129446:1998 6.3 of ISO 129446:1998 6.4 of ISO 129446:1998
m en t
7.0 7.1
Execution and supervision plan of paint work Preconditions for execution of paint work Qualification of personnel & external inspection company Condition of substrate Abrasive, paint materials & storage Application conditions i.e. ambient, lowest and highest temperatures
7.2
Execution of paint work
Paint manufacturers data sheets, ISO 12944-7 and drawings.
Fo
Approved certification body, e.g. NACE, IMM or ISO 9001, etc. Surface preparation as per ISO 12944-4 Manufacturers data sheets
rP ub
Prior to execution of paint work
lic
36
Project name: Clients name: Main contractors name: Subcontractor/suppliers name: Work QC activity description
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Scope of work: Application of coating systems at oil and gas structures Control categories P= I= S= H= W= Prepare/supply Inspection Surveillance Inspection Witness hold point Quality Control Points by: Stage/frequency records Subcon/ Main Main supplier contractor contractors consultant As required by Laboratory test H/P R N/A client and during report selection of paint system (ISO 12994-5) ITP ref no:
R= Review document Clients approval W/R
Remarks
5.2
HSE protection report/plan
H/P
N/A
Latest DOSH Guidelines on Occupation al Health and Safety may be referred.
Personnel and company certification Inspectors certification Datasheets for paint and abrasives. Certified field records
H/P
N/A
During execution
H/P
N/A
W/R

Project name: Scope of work: Application of coating systems at oil and gas structures Control categories S= H= W= Surveillance Inspection Witness hold point Control Points by: Subcon/ Main Main supplier contractor contractors consultant H/P R N/A ITP reference no: R= Review document Clients approval W/R Remarks
7.3
Supervision of paint work
Measurement and test instruments Inspection of paint coating
Instrument manufacturers instructions and calibration Visual Wet film thickness as per paint manufacturers instruction. Dry film thickness (DFT) by nondestructive method (ISO 2808) & manufacturers instruction Adhesion by destructive method (ISO 2409) and by manufacturers instruction.
rP ub
Salt contamination
During execution
lic
Surface cleanliness Compressed air quality
During execution During execution
C om
Fo
Clients name: Main contractors name: Subcontractor/suppliers name: Work QC activity description
P= Prepare/supply Acceptance criteria (procedure/drawing/ standard/specification) ISO 12944-7 and paint manufacturers specifications Stage/frequency
I= Inspection Quality records
Application methods brush, roller, spray and other application methods Surface preparation
During execution
Abrasive standard specifications Surface prepared to Sa 2 . Surface profile specifications No blast residue and contaminants Free from oil, water and other contaminants Clients specifications
During execution
Certified field records
m en t
H/P R H/P H/P R R H/P R H/P R
Certified field records
N/A
W/R
Certified field records Certified field records
N/A N/A
W/R W/R
Certified field records Instrument calibration records Visual inspection records DFT records Adhesion test records
N/A
W/R
During execution
N/A
W/R
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37

Project name: Scope of work: Application of coating systems at oil and gas structures Control categories S= H= Surveillance Inspection hold point ITP reference no: W= Witness R= Review documen t Clients approval Remarks
7.4
Repair coating defects
8.0 8.1
Final documentations Final documentation Correctness and completeness of all documents Approved final documentation procedure Prior to hand-over to client
C om
Repair of damaged and defective coatings
Porosity by flow or high voltage detectors by manufacturers instruction. Manufacturers repair procedure
After completion of paint application
Coating repair records
m en t
Fo
rP ub
lic
38
Clients name: Main contractors name: Subcontractor/suppliers name: Work description QC activity
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P= Prepare/supply
I = Inspection
Stage/frequency
Quality records Subcon/ supplier
Control Points by: Main Main contractor contractors consultant
N/A
Minimum requirements: Surface preparation Paint datasheets Abrasive datasheet Paint application methods Environ. conditions Thickness measurements
H/P
N/A
Annex D (informative) Example of hazard identification, risk assessment and risk control (HIRARC) form
Hazard identification, risk assessment and risk control (HIRARC) form should be in accordance to Table D.1. Table D.1. Worked example: Coating application process
Company: Process/location: Approved by: (Name, designation) Date:
No.
Work activity
1. Hazard identification Hazard
Which can cause/effect Fire damage to surrounding assets and burn injury
2. Risk analysis Existing control (if any) Likelihood
C om
Health hazards namely exposure to chemicals (abrasive, paints, solvents, etc.) through skin, eye, ingestion or inhalation.
Chronic illness and bodily injury due to exposure to the chemicals
rP ub
Fo
Use of proper Personnel Protective Equipment (PPE) i.e. respirator, body suits, etc. Chemical safety data sheets i.e. toxicity data
lic
XYZ coating enterprise Coating application / exterior piping system Mr J (construction manager) 25 July 2007
HIRARC FORM Conducted by: (Name, designation) Date: (from to .)
Review date:
m en t
1. Severity Risk 3 3 9 (Medium) 4 3 12 (medium)
Mr B (coating supervisor/inspector), Mr S (blaster) and Mr R (coating applicator) 24 June 2007 to 30 July 2007
2. 3. Risk control Recommended control Person in measures charge (due date/status) Ensure fire Andy (26 July extinguishers, first aid 2007)/Completed kit, etc. available at work sites. Access to nearest medical facilities in case of emergencies. Access to nearest medical facilities Standard work procedure and periodic medical check-ups for workers. Amin (29 July 2007)/Ongoing
Identification of materials for coating
Fire & Explosion
Non-sparking tools and environment Chemical safety data sheets i.e. Lower Explosive Limit (LEL), Flash point, evaporation rate, etc.
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39
Table D.1. Worked example: Coating application process (continued)

No. Work activity
Working in confined space namely exposure to lack of oxygen environment.
Serious injury or fatality
m en t
Fo
Working in confined space namely exposure to lack of oxygen environment
rP ub
lic
Surface preparation
Exposure to mechanical equipment such as power brushes, grit blasting, etc.
Use of proper Personnel Protective Equipment (PPE) i.e. respirator, body suits, etc. Competent operating personnel. Regular maintenance of power tools, hoses and compressors etc. Use of proper Personnel Protective Equipment (PPE) i.e. respirator, body suits, etc. Competent operating personnel. Adequate ventilation. Work procedure for working in confined space. Blower for ventilation is in good operating condition.
C om
40
1. Hazard identification Hazard 2 Coating application Exposure to pressurized equipment such as water jets, airless sprays, etc.
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Which can cause/effect Serious injury or fatality
Severity
Risk
Use of proper Personnel Protective Equipment (PPE) i.e. respirator, body suits, etc. Competent operating personnel. Regular Maintenance of pressurized equipment i.e. hoses, relief valves, etc. Use of proper Personnel Protective Equipment (PPE) i.e. respirator, body suits, etc. Competent operating personnel. Adequate ventilation. Work procedure for working in confined space. Blower for ventilation is in good operating condition
12 (Medium)
3. Risk control Recommended control Person in measures charge (due date/status) Access to nearest Gunalan (29 July medical facilities 2007)/Completed Emergency shut-off system and work procedure. Regular refresher trainings for operators.
12 (Medium)
Access to nearest medical facilities Emergency response work procedure. Regular refresher trainings for operators. Stand-by ventilation equipment.
Gunalan (29 July 2007)/Completed
12 (Medium)
Access to nearest medical facilities Emergency shut-off system and work procedure. Regular refresher trainings for operators.
Amin (29 July 2007)/Completed
12 (Medium)
Access to nearest medical facilities Emergency response work procedure. Regular refresher trainings for operators. Stand-by ventilation equipment.
Amin (29 July 2007)/Completed
Table D.1. Worked example: Coating application process (continued)

No.
Fo
rP ub
lic
C om
1. Hazard identification Work activity Hazard
Which can cause/effect May cause personnel to fall down from height, may lead to serious injury or fatality
Severity
Risk
Working at height
Scaffolding, ladders, ropes and lines not safely secured
Use of high voltage holiday detection equipment to detect coating imperfections
Exposure to high voltage electric shock
Serious injury
Competent operating personnel. Regular checks of scaffolding, ladder, ropes, PPEs and lines Approved safe work procedure for use of the equipment. Competent operating personnel. Regular checks of holiday detector. Secured grounding of the holiday detector. Approved safe work procedure for use of the equipment.
12 (Medium)
3. Risk control Recommended control Person in measures charge (due date/status) Access to nearest Faisal (30 July medical facilities 2007) / Regular refresher Completed trainings for workers on working at height and related PPEs.
m en t
2 8 (Medium)
Access to nearest medical facilities Shut-off the equipment immediately Rectify the grounding system.
Faisal (30 July 2007)/Completed
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41
Annex E (informative) Proposed paint system

Table E.1. Painting and coating system schedules for external application
Areas of application Carbon steel design temperature < 100 C NON INSULATED in the atmospheric zone Coating system 1A Blast cleaning to ISO 85011:2007, Sa 2
st
1 inorganic zinc silicate/epoxy zinc rich 2

nd
m en t
C om
lic
rP ub
Fo
42
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Surface preparation
Generic type
Thickness
75
high solid epoxy
150 50 275
3 aliphatic polyurethane
rd
Alternative system Coating system 1B
Blast cleaning to ISO 85011:2007, Sa 2
1 epoxy zinc rich 2

nd
st
75 150 50 275
high solid epoxy
rd
Maintenance systems Coating system 1C
Power tool cleaning to ISO 85011:2007, St 3
1 surface tolerant high solid epoxy 2 surface tolerance high solid epoxy 3 aliphatic polyurethane
rd nd
st
125
125
50 300
Table E.1. Painting and coating system schedules for external application (continued)
Areas of application Carbon steel design temperature < 100 C INSULATED in the atmospheric zone Coating system 2A Blast cleaning to ISO 85011:2007, Sa 2 1 inorganic zinc silicate/epoxy zinc rich 2
nd st
C om
Maintenance systems Coating system 2C
rP ub
lic
Fo
Surface preparation
Generic type
Thickness
75
high solid epoxy
m en t
150 225
Alternative system Coating system 2B
Blast cleaning to ISO 85011:2007,Sa 2
1 epoxy zinc rich 2

nd
st
75 150 225
high solid epoxy
Surface tolerant high solid 1 epoxy 2 Surface tolerant High solid epoxy
nd
st
125
125 250
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43
m en t
Coating system 3B
C om
Splash zone and spray zone Coating system 4A
lic
rP ub
Alternative systems Coating system 4B
Fo
44
Coating system 3A Alternative systems
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Areas of application Offshore platform decks (including primary and secondary structures) Blast cleaning to ISO 85011:2007, Sa 2 1 polyester glass flake 2 polyester glass flake Antiskid aluminium oxide 20-30 mesh
nd st
Surface preparation
Generic type
Thickness
500 500
1 000
1 epoxy glass flake 2 epoxy glass flake Antiskid aluminium oxide 20-30 mesh
nd
st
500 500 1 000
1 polyester glass flake 2

nd
st
500 2 x 500 1 500
polyester glass flake
1 epoxy glass flake 2

nd
st
500 2 x 500 1 500
epoxy glass flake
Areas of application Carbon steel design temperature > 110 C (INSULATED and NON INSULATED) in the atmospheric zone Coating system 5A Coating system 5A(i), 110 C - 250 C Blast cleaning to ISO 85011:2007, Sa 2 1 inorganic zinc silicate 2
nd st
C om
lic
Maintenance system Coating system 5B Coating system 5B(i), 110 C - 250 C
rP ub
Fo
Surface preparation
Generic type
Thickness
75 30 30 135 75 25 25 125
modified silicone acrylics
3 modified silicone acrylics
rd
Coating system 5A(ii), 250 C - 450 C
1 inorganic zinc silicate

nd
st
silicone aluminium
3 silicone aluminium
rd
1 zinc graphite 2
nd
st
m en t
40 30 30 100
modified silicone acrylic
3 modified silicone acrylic
rd
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45
m en t
Coating system 6A
Degrease as SSPC-SP1 and wash with fresh clean water, light abrade sweep blast surface to provide anchor pattern of 25 microns.
C om
lic
Stainless steel Coating system 7A Coating system 7A(i) Non insulated facilities operating < 110 C
rP ub
Fo
46
Maintenance system Galvanised steel
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Areas of application Surface preparation Generic type Thickness
Coating system 5B(ii), 250 C - 450 C
Power tool cleaning to ISO 85011:2007, St3
1 zinc graphite 2
nd
st
40 25 25 90
silicone aluminium
3 silicone aluminium
rd
1 surface tolerance high solids epoxy 2

nd
st
150
aliphatic polyurethane
50 200
Sweep blast with dry, non-iron containing grit or roughen surface with emery paper to provide an anchor profile
1 high solids epoxy 2

nd
st
150 50 200
aliphatic polyurethane
Coating system 7A(ii) Insulated facilities operating < 110 C
Sweep blast with dry, non-iron containing grit or roughen surface with emery paper to provide an anchor profile
1 high solid epoxy
st
175
200
Areas of application Coating system 7A(iii) Insulated and non-insulated facilities operating 110 C -600 C Surface preparation Sweep blast with dry, non-iron containing grit to create an anchor profile
st
C om
lic
rP ub
Fo
Generic type 1 silicone aluminium 2

nd
Thickness 25 25 50
silicone aluminium
Coating system 8A Tank external - Operating temperature < 110 C
1 inorganic zinc silicate/epoxy zinc rich 2

nd
st
m en t
Carbon steel storage tank
75
high solids epoxy
150 50 275
rd
Bottom plate exterior Coating system 8B Blast cleaning to ISO 85011:1988, Sa 2
1 epoxy zinc rich 2

nd
st
75 200 x 2 475
high solid epoxy
Maintenance system Coating system 8C
Power tool cleaning to ISO 85011, St 3
1 surface tolerance high solids epoxy surface tolerance 2

nd
st
125
high solids epoxy
125
10H003R0
rd
50 300
47
Markings Coating system 10 Degrease and wash with fresh water. Abrade surface to provide another pattern. Living quarters, pressurised room & control room interior
st
m en t
C om
lic
rP ub
Fo
48
Timber decks Coating systems 9A Coating system 11 Coating system 12
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Light sanding to remove contaminant, sharp edges and old paints
1 aluminium wood primer 2

nd
st
50 50 50 150
alkyd semi-gloss finish
3 alkyd semi-gloss finish
rd
50
50
1 surface tolerant epoxy
st
150 150 Approval of Passive fire protection (PFP) systems shall be the discretion of individual owner(s)
Fire barriers/passive fire protection (PFP) system
Table E.2. Painting and coating system schedules for internal application
Areas of application Fuel gas Coating system 13A
Surface preparation
Generic type
Thickness
Blast cleaning to ISO 85011:1988, Sa 2 Power tool cleaning to ISO 8501-1:1988, St3 for minor touch-up painting.
1 phenolic epoxy 2
nd
st
125 125 250
phenolic epoxy
Crude/condensate, emulsion slop Coating system 14A Coating system 14A(i) Power tool cleaning to ISO 8501-1:1988, St3 for minor touch-up painting. Roof and shell plate Coating system 14A(ii) Bottom plate and vessels Blast cleaning to ISO 85011:1988, Sa 2 Power tool cleaning to ISO 8501-1:1988, St3 for minor touch-up painting. Blast cleaning to ISO 85011:1988, Sa 2
st
m en t
1 phenolic epoxy
125 125 250
C om
st
nd
phenolic epoxy
lic
1 phenolic epoxy 2
nd
100 100 100 300
rP ub
phenolic epoxy
3 phenolic epoxy
rd
Fo
Crude/condensate tank maintenance Coating system 14A(iii) Bottom plate
1 epoxy primer 2
nd
st
50 200
epoxy glass flake
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3 epoxy glass flake
rd
200 450
49
2 Power tool cleaning to ISO 8501-1:1988, St3 for minor touch-up painting. Diesel tank Roof & shell plate Coating system 16A Blast cleaning to ISO 85011:1988, Sa 2 Power tool cleaning to ISO 8501-1:1988, St3 for minor touch-up painting.
nd
amine adduct epoxy
m en t
C om
lic
rP ub
Fo
50
Coating system 15A
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Table E.2. Painting and coating system schedules for internal application (continued)
Areas of application Light naphtha, heavy naphtha, treated naphtha, reformate, Jet A1 fuel, lube oil, gasoline (leaded & unleaded)
st
Surface preparation
Generic type
Thickness
1 amine adduct epoxy
125 125 250
1 amine adduct epoxy 2

nd
st
125 125
amine adduct epoxy
250 1 amine adduct epoxy 2

nd st
Coating system 16B
100 100 100 300
amine adduct epoxy
rd
Coating system 16C
1 epoxy primer 2
nd
st
50 200 200 450
epoxy glass flake
3 epoxy glass flake
rd
Areas of application Portable (drinking, aerated, nonaerated) water Seawater (aerated & non-aerated), blackish, produced water, demineralised and brine. Coating system 17A
Surface preparation
Generic type
Thickness
2 Power tool cleaning to ISO 8501-1:1988, St3 for minor touch-up painting.
nd
amine adduct epoxy
m en t
st
125 125
250
Steam or boiler feed up to 100 C Coating system 18A Blast cleaning to ISO 85011:1988, Sa 2 Power tool cleaning to ISO 8501-1:1988, St3 for minor touch-up painting. Utility air up to 60 C Coating system 19A
C om
st
1 phenolic epoxy 2
nd
150 150 300
phenolic epoxy
rP ub
lic
1 amine adduct epoxy 2
nd st
125 125 250
amine adduct epoxy
Alternative system Utility air up to 60 C
Fo
10H003R0
Coating system 19B
Polyester/epoxy glass flake
400 400
51
Areas of application Utility air above 60 C Coating system 19C Blast cleaning to ISO 85011:1988, Sa 2 Power tool cleaning to ISO 8501-1:1988, St3 for minor touch-up painting. Alternative system Utility air above 60 C Coating system 19D Blast cleaning to ISO 85011:1988, Sa 2 1 phenolic epoxy 2
nd st
Vinyl ester glass flake
m en t
C om
lic
rP ub
Up to 60 C Coating system 21A
Fo
52
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Surface preparation
Generic type
Thickness
125 125 250
phenolic epoxy
400 400
Corrosion inhibitors, demulsifiers, scavenger Coating system 20A Blast cleaning to ISO 85011:1988, Sa 2 Power tool cleaning to ISO 8501-1:1988, St3 for minor touch-up painting. Methanol and percroethalyne
1 vinyl ester glass flake 2

nd
st
800 - 1 500 800 - 1 500 1 600 - 3 000
vinyl ester glass flake
1 epoxy phenolic 2
nd
st
125 125 250
epoxy phenolic
Areas of application Alternative system Methanol and percroethalyne Up to 60 C Surface preparation Thickness
Triethylene glycol, methylethylene glycol Up to 60 C Coating system 22A Blast cleaning to ISO 85011:1988, Sa 2
C om
lic
rP ub
Fo
Power tool cleaning to ISO 8501-1:1988, St3 for minor touch-up painting.
m en t
Coating system 21B
st
inorganic zinc silicate
75 100
75 - 100
1 2
st
amine adduct epoxy amine adduct epoxy
125 125 250
nd
Power tool cleaning to ISO 8501-1:1988, St3 for minor touch-up painting. Alternative system Up to 60 C Coating system 22B
st
epoxy phenolic
125
Blast cleaning to ISO 85011:1988, Sa 2 2 Power tool cleaning to ISO 8501-1:1988, St3 for minor touch-up painting.
nd
epoxy phenolic
125
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250
53
m en t
Fo
rP ub
lic
C om
54
Above 60 C Coating system 22C
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1 vinyl ester glass flake 2

nd
st
400 - 500 400 - 500 800 - 1 000
vinyl ester glass flake
Acknowledgements
Members of Working Group on Protective Coatings and Linings for Oil and Gas Facilities Ir A. Razak Hassan (Chairman) Mr M. Hawari Hassan (Deputy Chairman) Ms Lee Hooi Lan (Secretary) Mr Chen Keng Yew Mr Ismarul Azhar Ishak Ms Norazlina Ab. Halim Mr Abdul Kahar Hussin Mr Ahmad Badli Shah Aziz Mr Wong Ing Chiew/Mr Wong Sek Weng Mr Syed Shaharudin Syed Harun Mr Musfizree Mustaffa/Mr Hazle Ibrahim Mr Mohd. Nizam Omar/ Ms Nurul Asni Mohamed Mr Roziman Yahaya/ Mr Junaidi Ahmad@Hasan/ Mr Zaid Kamarudin Dr Saadan Mat Mr Mohd Zuhaimi Mohd Zubir/ Ms Maimunah Ismail Mr Muhammad Nurdin Ghazali AB Lathif/ Mr Abdul Aziz Haron PETRONAS Technical Services Sdn Bhd PETRONAS Technical Services Sdn Bhd SIRIM Berhad Bredero Shaw (M) Sdn Bhd Chugoku Paints (M) Sdn Bhd Department of Environment Department of Occupational Safety and Health Malaysia International Paints Sdn Bhd Jotun (M) Sdn Bhd PETRONAS Carigali Sdn Bhd PETRONAS Gas Berhad PETRONAS Penapisan (Melaka) Sdn Bhd PETRONAS Penapisan (Terengganu) Sdn Bhd PETRONAS Research Sdn Bhd Shell Refining Company (FOM) Berhad
Fo
rP ub
lic
SIRIM QAS International Sdn Bhd (Chemical and Consumer Testing Section)
om
en

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DRAFT MALAYSIAN STANDARD

STAGE : PUBLIC COMMENT (40.20) DATE : 01/03/2013-30/04/2013

Copyright 2013 DEPARTMENT OF STANDARDS MALAYSIA

Annex A Annex B Annex C Annex D Annex E

STANDARDS MALAYSIA 2013 - All rights reserved

PETRONAS Carigali Sdn Bhd PETRONAS Gas Berhad

STANDARDS MALAYSIA 2013 - All rights reserved

STANDARDS MALAYSIA 2013 - All rights reserved

the durability of the protective paint system.

STANDARDS MALAYSIA 2013 - All rights reserved

The field of application is characterised by:

coatings of more than 2 mm dry-film thickness. Type of work

Durability of the protective paint system

This standard covers both new work and maintenance.

A protective coating on the inner surface of equipment. 3.9 maintenance painting

Operators of the facilities. 3.11 paint

protective paint systems

STANDARDS MALAYSIA 2013 - All rights reserved

screws; and exposed moving parts.

Grit - angular, irregular Short - round Grit - angular, irregular

N/GA N/FE N/CU N/NI (Aluminium silicate slags) N/CS N/FA

Cast iron (CI)

Low-carbon (LCS) Cut steel wire (CW)

Fused aluminium oxide (FA)

Grit - angular, irregular

Grit - angular, irregular

Grit - angular, irregular

Grit - angular, irregular

Short - round Short - round

STANDARDS MALAYSIA 2013 - All rights reserved

Grades of surface finish

Commercial blast cleaning Brush-off blast cleaning

Power-tool cleaning (to bare metal) Power-tool cleaning Hand-tool cleaning

3. Solvent cleaning Solvent cleaning

STANDARDS MALAYSIA 2013 - All rights reserved

Table 3. Surface finish grades (continued)

Alternative methods of surface cleaning General

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Centrifugal abrasive blasting

Material Mixing and Thinning

the surface temperature is less than 3 C above dew point;

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Paints shall be applied by air spray or airless spray.

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Repairs and touch up painting

spraying is not feasible; and

Damaged coating exposing substrate surface

Inadequate coating thickness

Quality assurance (QA)

Repair of fully cured epoxy coating

Coating systems selection General

curing time; overcoating time; recoating time; and

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Painting and coating systems

Organic and inorganic zinc-filled coatings

Selection and application of top coats

Hot dip galvanising

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Thermal spray aluminium/aluminium alloy

Technical capabilities: i) ii) iii) iv) personnel qualifications; technical resources;

equipment, facilities and experience.

Quality control: i) ii) personnel qualifications; and

inspection procedures and recording systems.