CARIGALI STANDARD PROCEDURE NO. : CSP-10 CARIGALT PROCEDURE 8 __| REVISION. | 1 JACKET / TOPSIDES TEST PANEL / COATING SYSTEM QUALIFICATION PROCEDURE. 3 FOR PETRONAS CARIGALI SDN BHD KUALA LUMPUR In the event of any ambiguity, inconsistency or conflict between this procedure and the Contract Document and / or the Petronas Technical Standards (PTS), the Contract Document and / or PTS shall take precedence over this procedure. CARIGALI's interpretation shall be final REV. | DATE PREPARED BY REVIEWED BY ‘APPROVED BY NAME SIGNATURE | DATE || NaME | SIGNATURE | DATE || NAME | SIGNATURE] DATE © fcadara | Arn |ys-acleve | -@\_ [aed aco] p= []é/a0 Lib 4-5-0 HE | Iw |3.6-40 | aK 3/5]ee| MSM £ [s.€ 2004}iS 'TEST PANEL / COATING SYSTEM| QUALIFICATION PROCEDURE | REVISION: PROCEDURE NO: CSP-10 JACKET / TOPSIDES PAGE 1 OF 15 TABLE OF CONTENTS SECTION DESCRIPTION PAGE 10 PURPOSE 2 2.0 SCOPE 2 3.0 REFERENCES 2 4.0 DEFINITIONS 2 5.0 PROCEDURES 3 5.1 Test Panel 3 5.2 Surface Preparation 3 53 Coating / Painting 4 5.4 Inspection / Testing 5 5.5 Inspection Equipment n 5.6 Calibration 2 5.7 Painting System 5.7.1 Two-Coat System 2B 5.1.2 Three-Coat System 4 5.7.3 Galvanized Steel 14 5.7.4 Stainless Steel 15 60 SPECIAL REQUIREMENTS 16 70 RECORDS 16 APPENDICES Appendix! : Test Panel Inspection Report Appendix II : Adhesive Strength Test Appendix I: = X+Cut AppendixIV : Holiday Test Result Filename | CSP-10_LLWPPROCEDURE NO : CSP-10 2.0 SCOPE PTS 30.48.00.31-P 3.0 REFERENCES rerronas TEST PANEL / COATING SYSTEM| CARIGAL QUALIFICATION PROCEDURE | REVISION: 1 JACKET / TOPSIDES PAGE 2 OF 15 1.0 PURPOSE To demonstrate by trial, the surface preparation and coating requirements of steel structures based on CARIGALI's specification and in accordance to paint manufacturer's recommendation on the coating systems. ‘This procedure covers the qualification of coating systems prior to applica- tion on steel materials for offshore facilities Protective Coatings and Lining Standard Test Method for Pull-Off Strength of Coatings using Portable ASTM D4541 Adhesion Testers. ASTM D3359MethodA:——-X-Cut Tape Test SSPC-SP1 Solvent Cleaning ISO 8501-1 Visual Assessment of Surface Cleanliness 4.0 DEFINITIONS DFT - Dry Film Thickness WET - Wet Film Thickness Filename » CSP-10_LLWPa caRIGALI © OCEDURE NO : CSP-! LEST PANEL / COATING SYSTEM] is QUALIFICATION PROCEDURE |REVISION: 1 JACKET / TOPSIDES PAGE 3 OF 15 ii. ii, iv. iil. 5.0 PROCEDURE 5.1 Test Panel A minimum of one (1) panel shall be prepared for each different paint system, each panel shall not be less than 1 metre square area, Each panel shall be surface treated and cleaned to the correct standard, ‘Two (2) coats of clear varnish shall be applied to preserve the surface preparation approximately one third of the panel area. ‘The remaining area shall then be painted with the appropriate primer in the manner prescribed in this procedure. Succeeding coats shall be applied in the specified manner and to the specified thickness as described in this procedure, CONTRACTOR shall notify CARIGALI at least one (1) week in advance prior to conduct the qualification tests of each paint system, 52. Surface Preparation Check the test panel on its suitability for use. Solvent cleaning in accordance with SSPC-SP1 shall be used to remove any oil, grease and other contamination present on the steel surface before blasting. Ensure that correct size of abrasive is being used. It shall be dry and uncontaminated. Suitable abrasives for use in blast cleaning are : Steel grit Steel shot Malleable iron shot Crushed chilled-iron grit Chopped steel wire Aluminium oxide (corundum) meee oe Filename : CSP-10_L.LWPPROCEDURE NO: CSP-10 [TEST PANEL / COATING SYSTEM| QUALIFICATION PROCEDURE |REVISION: 1 JACKET / TOPSIDES PAGE 4 OF 15 53 iv. Be oe Blast furnace slag Copper slag, Asilgrit Gamet Record down weather conditions prior to blasting. ‘The grade of surface finished shall be in accordance to ISO 8501-1:1988 Sa 2.5. Check surface profile measurements using a surface profile gauge or profile comparator, ensuring that they are within specifications. Relationship Between Coating Thickness and Anchor Pattern Dry Film Thickness ‘Anchor Pattern 125 - 200 m (5-8 mils ) 25 - 50m (1-2 mils ) 200 - 500 m (9-20 mils ) ‘50 - 75 m (2-3 mils ) 500 m or more ( over 20 mils ) 75 - 125 m(3-5 mils ) Prior to application of paint, record the substrate temperature. Spraying may commence when the steel temperature is 3°C above dew point and when the relative humidity is lower than 85% or does not exceed the paint manufacturer's recommendation. Coating and Painting ii, iii, Check spray gun tip size on its suitability for use with the coating concemed, Ensure that equipment (Conventional / Airless) used is as per Paint Manufacturer's recommendation. Agitate paint base with solvent proof mechanical stirrer for a sufficient time followed by addition of curing agent and bring the paint to a uniform consistency. Filename + CSP-10_LLWPPeTROMAS CARIGALI PROCEDURE NO : CSP-10 [TEST PANEL / COATING SYSTEM| QUALIFICATION PROCEDURE |REVISION: 1 JACKET / TOPSIDES PAGE 5 OF 15 54 iv. xii Record down batch numbers of base and curing agent, and percentage of thinning if required in the test panel inspection report (see Appendix I), Determine volume solids of the paint in order to determine required WFT to obtain minimum specified DFT. Spray the paint on a sample plate/beam to ensure that correct atomization and flow of paint is obtained before spraying onto test plate. The spray gun shall not closer than 200 mm or more than 600 mm from the surface to be coated. Record number of passes made to obtain required WFT. Clean system with recommended cleaner immediately after spraying. Allow the coating to cure for a minimum of 12 hours at 32°C or in accordance with the paint manufacturer's recommendation before application of the subsequent paint or coating. ‘Tape-up a minimum 200 mm portion of painted surface and lightly abrade the remaining area prior to application of subsequent coat, to distinguish the different coating application. Please refer to sample test panel Figure 1. Observe overcoating intervals as specified by the paint ‘manufacturer's recommendation. Repeat steps (i) to (x.) when spraying subsequent coats. Inspection / Testing 5.4.1 Visual Inspection Individual coat and completed coatings shall be visually inspected for appearance. Coats and coatings shall be smooth and free from dry spray, pinholes, blisters, craters and exces- sive sagging. Filename : CSP-10_LLWPPROCEDURE NO : CSP- remows [TEST PANEL / COATING SYSTEM Renae 8 CARIGAL QUALIFICATION PROCEDURE |REVISION: 1 JACKET / TOPSIDES PAGE 6 OF 15 5.4.2 Surface Profile Measurements Surface profile height shall be spot check and documented “Using approved surface profile gauge. The following methods are used to measure the required surface profile of abrasive blasted steel surface. i) Surface Profile Comparator Method A keane-Tator comparator 372 or its approved equiva- lent consists of a reference disc, with blasted segments for which the roughness is given within an interval. The roughness shall be determined by comparing the comparator segment and the blast-cleaned surface. ii) _Press-O-Film Method 3 This method consists of a compressible plastic tape which is placed on the blast-cleaned stee! surface and compressed with a roller so that the tape retains a print of the surface. The replica shall then be removed and its thickness be measured in a micrometer screw gauge, the reading obtained is the maximum peak to valley heights of the blasted surface. 5.43 Wet Film Thickness (WFT) Measurements ‘The comb-type gauge shall be used. The surface selected for measurement should be smooth. The comb is placed in the newly applied wet paint film. The wet film thickness will be indicated where the tooth has touched the paint, To calculate the desired wet film thickness from Dry Film Thickness, the formula is : Wet Film Thickness = Dry Film Thickness x 100% ‘Volume % solids Filename : CSP-10_LLWPEI E NO : CSP-1 TEST PANEL / COATING SYSTEM| “OPDURE 10 QUALIFICATION PROCEDURE | REVISION: 1 JACKET / TOPSIDES PAGE 7 OF 15 544 5.4.5 5.4.6 Dry Film Thickness (DFT) Measurements The DFT of a non-magnetic coating applied on a magnetic ‘Substrate shall be determined or checked with calibrated film thickness gauges, using the magnetic resistance gauge or eddy current principle, such as 'Elcometer’, 'Lepstoskop’, "Mikrotest, etc. The gauges for DFT checks shall be calibrated at least twice daily in accordance with the manufacturer's recommendation. To determine the dry film thickness (DFT) from the measured wet film thickness, the formula is : DFT = Wet Film Thickness x Volume % solids 100% Temperature and Relative Humidity Temperature and Relative Humidity shall be measured by means of a temperature gauge and a hygrometer (e.g. Elcome- ter type 113 and 116 respectively). Readings shall be taken at regular intervals depending on changes in climatic conditions. Inspection of Coating Continuity i. Wet Sponge - Low Voltage - Inspection This method of detecting discontinuities such as pinholes and holidays in internal linings shall be used to check coating systems having a DFT less than 500, microns. The instrument is earthed to the object. The surface shall be well wetted with normal tap water, preferably containing a small amount of wetting agent (Such as Teepol) to ensure penetration of faults or pinholes. The saturated sponge of the tester shall then be systematically passed over the entire coated surface and as a coating discontinuity is approached, the detec- tor will give a visual and / or audible alarm mode. All such indications shall be suitably marked immediately for repair purposes. Filename : CSP-10_LLWPPeTROMAS CARIGALL PROCEDURE NO : CSP-10 [TEST PANEL / COATING SYSTEM| QUALIFICATION PROCEDURE | REVISION: 1 JACKET / TOPSIDES PAGE 8 OF 15 ii, High Voltage Electrical Inspection Detectors of this type are most often used on all coating systems having a DFT of 500 microns or higher. It is to be used only for the detection of discountinuities in the coating film such as pinholes, holidays, cracks, etc., and to detect hidden or non-visible defects such bubble or blister type voids, thin spots and foreign inclusions or contaminants. ‘The holiday detector instrument shall be a portable, low amperage and adjustable high voltage pulse type with an audible signal device. In order to avoid bum through of the coating, the testing equipment should be carefully and frequently calibrated as follows : 8) Make a small pinhole in the coating. The coating thickness at this pinhole should be at least the average thickness specified b) Using the same procedure and conditions, humidity and travel speed, etc., increase the voltage on the pinhole tester until pinhole alarm is obtained at the manufactured pinhole. The minimum voltage required to detect manufactured pinholes should be doubled for the actual pinhole inspection. 54.7 Curing ‘The degree of curing of epoxy resin-based paint system can be checked by the determination of coating resistance to methyl ethyl ketone (MEK). Afier rubbing the coating for one minute with a rag soaked in MEK, the coating shall not be softened, then test by scraping with a finger nail Filename © CSP-10_1.LWPPROCEDURE NO : CSP-10 Note 5.4.9 remowas |TEST PANEL / COATING SYSTEM| CARIGALI QUALIFICATION PROCEDURE | REVISION: 1 JACKET / TOPSIDES PAGE 9 OF 15 548 Pull-Off Test Adhesion Test is performed on a flat surface in accordance “with ASTM D4541. This method is used to measure the adhesive / cohesive strength of coating systems using adhesive tester for coating total DFT above 200 microns... The test is required to obtain the specific value of the strength of adhesion to the substrate or between coats. Listed below are the minimum steps to conduct a pull-off test : Seven days after application of final coat, attached dollies on each coating; three (3) dollies per coating. ii, Ensure that the dollies are cleaned and abraded with sand paper before applying epoxy glue e.g. Araldite ‘two pack epoxy glue. iii, Lightly abrade the area of attachment and record the coating thickness. iv. Press down dolly firmly on coating and remove exces- sive glue. v. Allow glue to be cured with a minimum of 24 hours before commencing pull-off test. vi. The force required to remove the dollies shall be recorded and reported as an average of at least three pull-offs. The area and mode of failure shall also be reported. ‘The minimum required adhesion strength for glassflake polyester coating is 500 psi (35kg/em:) and 300 psi ( 21 kg/cm?) and for all other paints. X-Cut Tape Test ‘The X-Cut technique and the use of pressure sensitive adhesive tape shall be performed for coating DFT less than 200 microns ( mainly to single pack coatings ). This method Filename + CSP-10_LLWPPROCEDURE NO : CSP-10 pemows ITEST PANEL / COATING SYSTEM q CARIGAL! QUALIFICATION PROCEDURE | REVISION: 1 JACKET / TOPSIDES PAGE 10 OF 15 shall be performed in accordance to ASTM D3359 Method A. Standard test method for measuring adhesion by tape test. “Listed below are the minimum steps in conducting a X-Cut Test: i. The area to be tested is free of blemishes and minor surface imperfection. ii. Ensure that the surface is clean and dry which affect the adhesion of the tape. iii, Make two cuts in the film each about 1.5 inches (40 mm) long that intersection near their middle with a smaller angle of between 30 to 45 degrees. iv. Use a straight edge and cut through the coating to the 9 substrate in one steady motion. ¥. Inspect the incisions for reflection of light from the metal substrate to establish that the coating film has been penetrated. If the substrate has not been reached make another X-Cut in a different location. vi. Remove two complete laps of the pressure sensitive tape from the roll and discard. Remove an additional length at a steady rate and cut a piece about 3 inches (75 mm) long. vii. Place the centre of the tape at the intersection of the cuts with the tape running in the same direction as the smaller angles, viii, Smooth the tape into place by finger in the area of the incisions and then rub firmly with the eraser on the end of a pencil until a indication of when a good contact has been made. xi, With one hour of application remove the tape by seizing the free end and pulling it off rapidly back Filename © CSP-10_LLWP-EDURE NO : CSP-1 renonas TEST PANEL / COATING sysTEM|"*°° : CARIGALI QUALIFICATION PROCEDURE |REVISION: 1 JACKET / TOPSIDES PAGE 11 OF 15 upon itself at as close to an angle of 180 degrees as possible. '%. Inspect the X-Cut area for removal of coating from the substrate or previous coating and rate the adhesion in, accordance with the following scale: 5A No peeling or removal 4A Trace peeling or removal along incisions or at their intersection 3A Jagged removal along incisions up to 1/16 inches (1.6 mm ) on either side 2A Jagged removal along most of incisions up to 1/8 inches (3.2 mm ) on either side. 1A Removal from most of the area of the X under the tape 0A Removal beyond the area of the X xi, Repeat the test in two other locations on each test panel. 55 Inspection Equipment Contractor may utilise approved inspection equipment or its equiva- lent, ie. Eleometer, Mikrotest, ete. other than describe herein for the inspection of test panel / coating system. 5.5.1 Surface Profile Surface Profile Gauge Model 123, provides reliable measurements peak-to-valley height 0-600 microns after blasting. A Keane Tator Profile comparator may also be used to assess the surface profile Filename © CSP-10_1.LWPPROCEDURE NO : CSP-10 553 554 55.5 55.6 55.7 rermonas TEST PANEL / COATING SYSTEM| CARIGALI QUALIFICATION PROCEDURE | REVISION: 1 JACKET / TOPSIDES PAGE 12 OF 15 55.2. Wet-Film Thickness Gauge The Wet Film Thickness Gauge (comb type) Model 115 is a “measuring instrument which resembles a comb with teeth in between decreasing in length from one to the other. It is used to monitor the wet film thickness on newly applied paint. Dry-Film Thickness Gauge ‘A magnetic or electro-magnetic gauge maybe used to determine the dry coating thickness, i.e. elcometer 245, A-345 digital thickness gauge, electro physiks digital thickness gauge model 3001 complete with F5-Probe (0-5 mm range). Wet and Dry Bulb Hydrometer ‘The Elcometer 116 Whirling Hygrometer employs the wet-and-dry bulb principle to determine the relative humidity of the atmosphere (together with necessary table charts, etc.) ‘Temperature Gauge The Eleometer Model 113 magnetic steel thermometer indicates the substrate surface temperature. Pressure Gauge A needle pressure gauge is used to detect air pressure at blasting nozzles. Pull-Off Test The Elcometer 106 is used to measure the adhesive / cohesive strength of coating system. 5.6 Calibration Profile height and film thickness gauges shall be calibrated on each occasion before use on individual items and thereafter, dependent on frequency of use. Filename : C5P-10_LLWP