Overseas Technical Coatings & Services Company (LLC)

SAUDI ARAMCO CONTRACT

METHOD STATEMENT
FOR
APPLICATION OF VARIOUS APCS SYSTEM FOR INTERNAL, EXTERNAL & UNDERSIDE OF FLOOR PLATE COATING OF CARBON STEEL TANKS

MS -KHI- 001

Prepared for Approval

21 Feb, 2012

Rev

00

Date

Prepared By Hertel OTC

Reviewed By

Approved By

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Overseas Technical Coatings & Services Company (LLC)

Index
1. 2. 3. 4. 5. 6. 7. 8. 9. Scope Purpose Definitions References General Access Equipments Procedure Personnel Qualification

10. Safety 11. Attachment

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1. SCOPE This method statement covers the minimum requirements for shop & field applications of various APCS systems for internal and external coating of CS storage tanks. 2. PURPOSE This method statement and quality control procedure covers the painting work to be carried out for tankage for Wasit-SAUDI ARAMCO Project 3. DEFINITIONS 3.1.1. 3.1.2. 3.1.3. 3.1.4. 3.1.5. 3.1.6. 4. COMPANY EPC CONTRACTOR CLIENT PROJECT JOB NO. : SAUDI ARAMCO : S.K. ENGINEERING : AL KHODARI HEAVY INDUSTRIES : :

COATING CONTRACTOR : Overseas Technical Coatings & Services (OTC)

REFERENCES 4.1 SAUDI ARAMCO Engineering Standard H-001, Coating Selection & Application Requirements for Industrial Plants & Equipment

4.2 SAUDI ARAMCO Engineering Standard H-102. Safety Requirements for Coating Applications 4.3 SAUDI ARAMCO Engineering Procedure 316 Performance Qualification of Coating Personnel SUADI ARAMCO material system specification 09-SAMSS-067 Steel Structure Painting Council (SSPC-SP1) Swedish Standards Institution SIS 05 59 00 Manufacturers Product Data Sheets & MSDS National Association of Corrosion Engineers (NACE) British standard for protective coating of iron and steel structures against corrosion (BS 5493)

4.4 4.5 4.6 4.7 4.8 4.9

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Overseas Technical Coatings & Services Company (LLC)

5.0 GENERAL 5.1 The plant will be under construction while painting work is being carried out safety will be a main consideration while working at construction site. The work permit will be required all the time while the sky climber shall be used for surface preparation and painting activity is going on OTC supervisor will ensure that the work permit is in place before starting the work in the designated area.

5.2

5.3

OTC will deploy trained and skilled manpower for the project. Such manpower will have experience of working in operational petrochemical / refinery plant. All the manpower being mobilized for the project will go the safety orientation programme of S. K. engineering /KHI prior to start working in the plant. OTC will ensure sufficient supervision for the project. Separate QA/QC & safety officer shall be deployed and shall report directly to KHI Project Manager. Sky climbers motor and control panel shall be covered by sheeting or tarpaulin to prevent the ingress of dust or paint wherever practical. The immediate work area will be barricade with tube and No Entry & danger painting work is progress Sign will be posted.

5.4

5.6

5.7

6.0

ACCESS 6.1 Access to coating work for external shall be by suspended plateform such as sky climber and man lift. Sky climber access shall comply safety requirement of Saudi Kayan. Sky climber shall meet or exceed all OSHA and ANSI standard. Fixed and mobile scaffold shall be used for internal painting work. Scaffold shall meet Saudi Aramco requirement.

6.2 6.3 6.4 6.5

7.0

EQUIPMENT. 7.1 Air operated Alpha 500 Sky Climber hoists with 2/3/4 meter suspended plateform will be used. 7.2 Sufficient 375/800 CFM compressor will be used to supply free air to motor of the Sky climber. 7.3 All compressed air hoses and steel wire ropes shall be circular in section, free of cuts, kinks and twists. Any change in direction shall be by long radius curves to maintain constant and unrestricted flow where possible.

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Overseas Technical Coatings & Services Company (LLC)

7.4 7.5 The following equipment part shall be inspected in field prior to operations of sky climber. Safety Equipment (Such as Rolling Roof Rigging, Safety Life line & Full body harness) Rope Condition Sky Lock (Coupling nuts & Bolts) Hoist Unit (Coupling nuts, Bolts & Rope Housing Drain) Work Platform (All joints,Roller Wheel & Control Panel) Air Connection ( All Hoses, Air Valve & Connection) The sky climber is equipped with sky lock overspeed device which sense the speed of rope passing through its mechanism and if preset speed is exceeded the Sky Lock brake will lock onto the wire rope and rope can not be release until the load on the Sky Lock brake is released. Abrasive blasting machines will be fitted with an abrasive regulating valve and moisture and oil separators to ensure all air passing through the equipment is clean and dry. Breathing air fed to operators blast helmets will be filtered through approved filters.

7.6

7.7

7.8

7.9

Spray painting machine will be of the airless type and will be fitted with moisture and oil separators and pressure control valves. Vacuum cleaners for internal dust removal will be of industrial quality and will be of 220/110 voltage. Spotlight and background lights for internal blasting will be of 110 voltages. Lighting for spray painting will be of the explosion proof type. Venturi air movers and extractors fans will be utilized for dust removal during internal blasting operations. All major equipment will be run to ground. Power tool & paint mixer shall by air driven (Pneumatic)

7.10

7.11

7.12

7.13 7.14 8

PROCEDURE

Pre-Blast Check 8.1.1 QC Inspector shall carry out checks before blasting to determine if cleaning is required either with the use of chemicals or solvents. If required solvent cleaning shall be carried out in accordance with SSPC - SPI. 8.1.2 No abrasive blasting shall be carried out unless the steel surface is at least minimum 3C above the Dew Point. 8.1.3 Prior to start for blasting, all sharp edges and cut-offs shall be rounded to a smooth radius and all weld spatters shall be removed.

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Overseas Technical Coatings & Services Company (LLC)

8.1.4 The compressed air supply shall be checked free of oil, moisture and contamination. As a minimum the inspector shall check and approve the air quality at the start of each 4-hour period. The method of checking shall be in accordance with SAES-H-100 Para 5.4

8.1.5 All compressed air hoses and paint lines shall be circular in section, free of cuts, kinks and twists. Any change in direction shall be by long radius curves to maintain constant and unrestricted flow where possible. 8.1.6 All hoses and nozzle connections shall be inspected prior to commencement of work to ensure they are secured. Any defective connection will be immediately replaced. Surface Preparation: (Shop & Field) 8.1.7 Surface preparation shall be carried out to achieve Sa-3 and Sa-2.5 as per SAES H-101. All abrasive blasting shall be carried out by regular blasting equipment and Track blasting equipment for the Floor Plates.

8.1.8 The type of abrasive to be used shall be determined by the surface Profile and cleanliness requirements as per SAES H-100 item 5.1. All inspection and tests shall be carried out on accessible areas only. 8.1.9 Approved Abrasives (GARNET, Steel Shot & Steel Grit) shall be kept dry and free of contamination as per SAES-H-100 Para 5.2.1 8.1.10 Sufficient capacity compressors shall be used to supply free air to all elements of the abrasive and coating operation as per SAES-H-100 Para 5.4 8.1.11 The Blast profile shall be measured for internal surface of pipes on accessible areas only using Profile thickness gauge with PRESS-O-FILM Testex tape (X coarse replica tape). The same replica tape shall be attached with inspection report as a permanent record. 8.2 Abrasive Blasting : 8.2.1 Abrasive shall be kept clean and dry and free of contamination and shall be an approved mineral abrasive such as Garnet, Coal Slag or Steel shot and grit. 8.2.2 Surface preparation shall be carried out by manual blasting to required surface cleanliness level. Tank floor plate shall be blasted using Blast Track Machine. On internal surfaces the abrasive will be removed, the area swept with clean soft brooms and finally vacuum cleaned. Salt contamination test shall be carried out in accessible areas for internal tanks surface. Blasted surfaces will be primed in accordance with the relevant specifications and before the surfaces conditions degrades below the specified cleanliness level.

8.2.3

8.2.4 8.2.5

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8.2.6 Whenever work is ongoing, one man will be allocated as lookout and will be stationed outside the working area. On completion of blasting surfaces will be checked for chloride contamination and if required decontamination shall be carried out.

8.2.7

8.3 Cleaning: 8.3.1 Used abrasives shall be removed from blasted surfaces using a dry brush, blowing down with clean dry compressed air or vacuum cleaner.

8.4 Coating: 8.4.1 Paint Storage: a. Paints and thinners shall be stored in air-conditioned container. Warnings signs Danger, flammable, no smoking, no naked lights will be posted. The storage temperature shall be below 270C. Containers that show signs of leakage or materials that have gelled shall be discarded. The date of manufacture shall be clearly marked on each paint container and paints that have exceeded their shelf life shall be discarded. Manufactures data sheets and MSDS on all materials will be readily available at the job site.

b. c.

d.

8.5 Paint Preparation: a. b. c. d. All paints shall be thoroughly mixed using a power mixer. All paints shall be mixed or thinned in strict accordance with the manufactures instructions. The prepared surface shall be inspected for cleanliness and profile prior to coating. Prepared surface shall be coated within a maximum of six hours and before any deterioration begins. Surfaces that have begun to deteriorate, or have exceeded the six hours shall be reblasted. Paint shall only be applied if the following conditions are met (or as specified by the paint manufacturers.) * Surface temperature to be at least 30C above dew points. * Surface to be free of oil, grease and other contaminants. * Protection from adverse weather conditions

e.

8.6 Paint Application (Shop & Field): a. All full coat will be applied by spray or brush / roller. The spray application shall be preferred method.

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Overseas Technical Coatings & Services Company (LLC)

b. Each coat to be applied to the specified DFT and in accordance with the relevant manufactures guidelines. c. Recoating and drying times will be observed as per the manufactures recommendations. d. Dry film thickness of each coat shall be measured in accordance with SSPC-PA2 using a suitable magnetic thickness gauge. e. Coating System shall be followed as par attached Coating System Detail Chart (Attached) 8.7 Paint Repairs: a. Areas less than 1.0 M2 shall be cleaned to ST.2 using hand wire brush or power brush to ground back to the metal surface, using at least an 80 grit disc sander. The edges being feathered back at least 50mm beyond the clean metal surface. b. Area greater than 5.0 M2 shall be blast cleaned or ST 3 using power tool. The conditions to be obtained are as the original requirements, with the edges being feathered back at least 50 mm beyond the clean metal surface. c. For areas less than 5.0 M2 brush coating is acceptable, but for areas above 5.0 M2, the paint shall be applied as per the original specification. d. Recoating intervals shall be as per manufacturers data sheet recommendations. e. All the work shall be documented for future reference. 8.8 Quality Control / Inspection & Acceptance Criteria a. Quality Control, Inspection & Acceptance Criteria shall be in accordance with approved ITP as par SATIP-H-100-01. Holiday / Pinhole test shall be carried out as per ASTM D 5162 for internal surface only Final DFT shall be checked with magnetic gauge as per SSPC-PA-2. The total dry film thickness should not exceed 120 percent of the maximum dry film thickness nor shall it be less than 80 percent of the minimum specified dry film thickness.

b. c.

9. PERSONNEL QUALIFICATION OTC personnel involved in preparation, application, direct supervision or inspection of coatings shall be qualified and certified by Hertel-OTC and ARAMCO as per SAEP-316. This includes abrasive blasters, coating applicators, crew supervisors and QC inspectors. 10.SAFETY. 10.1 Safety Requirements for Painting shall be observed at all times and shall be strictly followed in accordance with SAES-H-102 10.2 The Project safety plan will be fully enforced during the duration of the work.
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10.3 During lining operations, all lighting will be of the explosion proof type as per SAES-H-102 Item 4.1 A standby man will be at the work at all times during the work. His role will be observing activities in the painting work and to stop the work immediately while any safety concern arises. All operators will wear full personal protective equipment including coveralls, safety boots, gloves, helmets and positive air feed breathing masks in accordance with SAES-H-102 item 4.3

10.4

10.5

10.6 All recommendations of the Material/Equipments manufacturers concerning the safe handling and application of their products shall be followed as per SAES-H-102 item 4.4. 10.7 Forced air ventilation during abrasive blasting, solvent cleaning, paint application and curing shall be followed as per SAES-H-102 item 4.2 & SAES-H-001 item 8.3.4

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11 11.1 ATTACHMENT(S) Coating Systems Detail Chart

COATING SYSTEMS DETAILS CHART AL KHODARI TANKS

SR. NO . 1 ITEM NO. SERVICE NAME Lean MEG Storage Tank Fresh MEG Storage Tank ARG Fresh MDEA Storage Tank ARG Solvent Storage Tank Sour Water Feed Tank Rich Sulfer Solvent Storage Tank Stabilized Rich Solvent Storage Tank Sulfer Storage Tank Demin Water Storage Tank Drinking Water Tank INT. DIA (mm) 11735 HEIG HT (mm) 1093 7 NO. OF TANKS COATING SYSTEM Floor U/S SAES H-001 APCS-3 SAES H-001 APCS-3 Internal SAES H-001 APCS-21 SAES H-001 APCS-2A External SAES H-001 APCS-4 SAES H-001 APCS-4 PINHOLE/HOLI DAY TEST FOR INT. SURFACE As par ASTMD5162 As par ASTMD5162

Q68-D011A/B

Q68 D 12

15240

7315

Q70-D031

7315

7315

SAES H-001 APCS-3

SAES H-001 APCS-27

SAES H-001 APCS-4

As par ASTMD5162

Q70-D032 Q68-D106/206

18288

1341 1 2011 7

SAES H-001 APCS-3 SAES H-001 APCS-3

SAES H-001 APCS-27 SAES H-001 APCS-2A SAES H-001 Epoxy Lining SAES H-001 Epoxy Lining

SAES H-001 APCS-4 SAES H-001 APCS-4

As par ASTMD5162 As par ASTMD5162

25603

Q68-D061A/B

30480

1402 1

SAES H-001 APCS-3 Painting is NOT Possible Due to PWHT SAES H-001 APCS-113

SAES H-001 APCS-4

As par ASTMD5162

Q68-D062A/B

24993

1402 1

SAES H-001 APCS-4

As par ASTMD5162

Q72-D001A/B

25908

9754

No

SAES H-001 APCS-2H

As par ASTMD5162

Q73-D108

21945

1280 1

SAES H-001 APCS-3

SAES H-001 APCS-2B

SAES H-001 APCS-4

As par ASTMD5162

10

Q73-D200A/B

7010

4876

SAES H-001 APCS-3

SAES H-001 APCS-2B

SAES H-001 APCS-4

As par ASTMD5162

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11 Q73-D300A/B Q73-D401A/B Cooling Water Surge Tank Condensate Storage Tank Utility & Fire Water Storage Tank Industrial Water Storage Tank 7% Wt Caustic Supply Tank 9144 7315 2 SAES H-001 APCS-3 SAES H-001 APCS-113 SAES H-001 APCS-2E SAES H-001 APCS-27 SAES H-001 APCS-4 SAES H-001 APCS-2H As par ASTMD5162 As par ASTMD5162

12

51816

1280 2

13

Q73-D901A/B

29260

1371 6

SAES H-001 APCS-3

SAES H-001 APCS-2E

SAES H-001 APCS-4

As par ASTMD5162

14

Q73-D101A/B

36576

1828 8

SAES H-001 APCS-3 Painting is NOT Possible Due to PWHT

SAES H-001 APCS-2E

SAES H-001 APCS-4

As par ASTMD5162

15

Q69-D182

8686

8686

SAES H-001 Belzona 1591

SAES H-001 APCS-1E

As par ASTMD5162

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