Procedure For Painting of Tanks
Procedure For Painting of Tanks
Procedure For Painting of Tanks
No.
Date
Rev
Date
Cause of Revision
23-Nov-2015
First Submission
Prepared by
Reviewed by
Authorized by
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TABLE OF CONTENTS
1
GENERAL
DEFINITIONS
REFERENCE DOCUMENTS
SCOPE OF WORK
RESPONSIBILITIES
MATERIALS
WORK PROCEDURE
12
10
14
11
STORAGE
16
12
WASTE DISPOSAL
17
13
SAFETY
17
14
18
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1. GENERAL
This procedure provides information concerning the materials, equipment, tools and method of
application to ensure compliance with project specification, contract requirements, regulatory
requirements, drawings and quality control for Surface Preparation, Supply & application of Paint on
external of tanks for Al Taweelah Alumina refinery.
2. DEFINITIONS
COMPANY
means
CONSULTANT
means
CONTRACTOR
means
SUB-CONTRACTOR
3. REFERENCE DOCUMENTS
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4. SCOPE OF WORK
The paint shall be applied on the external surface of the tanks where insulation will be installed to prevent
corrosion. The painting of structural supports is not included in this procedure.
Table -1
5. RESPONSIBILITIES
1. Shall make sure the personnel for execution of the job are well aware of the procedure.
2. Shall ensure all the personnel are capable to operate the equipments (like Compressors, Blasting
& Painting units, etc.) for which they are deployed.
3. Shall ensure only approved coating and blasting materials are used.
4. Shall ensure that only calibrated equipment (Compressor, blasting/painting units, etc.), blasting
and paint material are received at site. Calibration shall be done by third party.
5. Shall ensure the coating materials are stored at site as per the manufacturer technical data
sheet/MSDS.
6. Shall check and ensure that the weather conditions are acceptable as per contract specification
requirements.
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7. Shall check and ensure surface cleanliness, profiles, salt contamination, WFT, DFT, visual
conditions are as per the approved procedure
8. Shall ensure the time lapse between abrasive blasting and coating and curing time between each
coat.
9. Shall ensure and monitor the good working condition of blasting and painting equipments.
These equipments needs to be cleaned before and after each shift.
10. Shall keep the MSDS at work and paint storage area
11. Shall ensure all the coating activities are carried out as per project specification.
12. Shall ensure all the personnels involving coating operations are wearing PPE and all Safety
equipments / tools are available.
13. Shall inspect and ensure safety requirements are implemented.
14. Shall ensure all the activities are recorded and signed off by the authorized personnel.
1. QA & QC Inspector shall ensure that all work are executed as per project specification, project
quality plan and procedures.
2. Shall ensure all the measuring and testing equipments are available and duly calibrated and risk
analysis carried out before induction in to service.
3. Shall ensure the approved procedure is followed as per Project specification.
4. Shall monitor the environmental condition as per Project specification
5. Shall inspect blasted and painted surfaces (cleanliness, surface profile, salt contamination, WFT,
DFT, painted surface finish)
6. Shall prepare the daily painting inspection reports.
7. Shall ensure that all tests are undertaken and, in the case of witness tests and inspections that the
Companys representative is present
8. Shall ensure only approved and accepted blasting and coating materials are used.
9. Issuing final acceptance for coating and releasing the items to Contractor for further process
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1.
Shall verify the works are carried out in accordance with the Project and Abu Dhabi HSE
regulations and site requirements.
2.
Shall ensure only authorized personnel are permitted to enter into work place and it is prohibited
without an authorized permit to work (PTW).
3.
Shall verify the availability of material safety data sheet at site and store room and implement all
the provisions stipulated in the data sheet.
4.
Shall verify that all personnel are wearing PPE and fire extinguishers are available at site / store
room.
5.
Shall verify that the hoses and equipment are in good and safe working condition.
6.
5.5 Blaster
1.
Shall ensure the blasting equipments and hoses are in good working condition on daily basis
before starting the works.
2.
Shall ensure that all blasting accessories are in working condition before starting the works
on daily basis
3.
Shall ensure that specified surface finish and profile are achieved.
4.
Shall ensure blasting air is free from moisture, oil and dust
5.
6.
Shall ensure all correct respiratory protective equipment and coveralls are used to complete
the job. Respiratory protective equipment is to be stored in a hygienic manner
7.
5.6 Painters
1. Shall ensure by daily pre-work check that all tools and equipments are in good working
condition. All tools and equipments are to be cleaned at the end of each shift
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5.7 Scaffolders
5.8 Helpers
1. Shall verify all the equipments are in a ready condition to use and ensure the quality of air,
control pressure, condition of coupling, hoses, etc. and free from any leakages.
2. Shall ensure all the helps whatever necessary for the execution of this project
Blasting & Painting shall be carried out using following equipments, whichever is suitable.
Airless Spray Pump with hoses and tip sizes as per recommendation of the paint
manufacturer in their data sheet.
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Painting Inspection Equipments (like profile gauge, DFT meter, Testex Tape)
7. MATERIALS
7.1 Abrasives
The abrasive used for blasting carbon steel shall be garnet 30/60 for surface preparation. Batch
Certificates of abrasive will be documented for each abrasive batch received at site. MSDS
shall be approved by BPJV ES&H prior to site use.
1. All paints and paint materials used must be obtained from Manufactures approved by BPJV.
2. All paint materials shall be factory tinted, sealed, and labeled. Thinners and solvents shall be
identified in the paint Manufacturers data sheets.
3. The paint container must need the batch number, date of manufacture, the shelf-life expiry date
and the Manufacturers name or trade mark. All paint materials shall be used on a first-in, first-out
basis.
4. MSDS shall be approved by BPJV ES&H prior to delivery to site.
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8. WORK PROCEDURE
All required permits /approvals need to be obtained from BPJV prior to start of work
1.
Painting shall be done after the completion of erection works for each tank.
2.
3.
Erect necessary screens (green net) around the work area to prevent contamination and to
prevent the spreading of garnet and paint.
4.
Before abrasive blast cleaning, all area which does not require painting shall be suitably
protected by wrapping, taping, or other means.
5.
Remove all weld burrs, weld spatters and flux, protrusions and other foreign matters by
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grinding.
6.
Dust, dirt and debris shall be removed from the substrate by high pressure water washing.
Where necessary, stubborn deposits shall be removed by scrubbing with stiff plastic brushes.
7.
Surface contaminants such as oil, grease, hydrocarbons etc. shall be removed by water based
cleaner. Cleaner concentration shall be according to manufacturers recommendations.
The compressed air supply used for blast cleaning shall be free from water and oil.
2.
When the surface is dry, blast clean the surface to blasting standard as per specification and
requirement.
3.
Weld spatters, laminations or other surface irregularities if found shall be ground out and reblast cleaned.
4.
5.
6.
Blast cleaning shall only be conducted when the steel surface temperatures are minimum 3
degree Celsius above the dew point.
7.
Prior to commencing of any blasting operation previously coated surfaces shall be adequately
protected to avoid damage of coated surfaces and surface irregularities shall be removed.
8.
9.
After surface preparation is accomplished, visually check in day light, the surface is free of metal
defects, dust & debris or any remaining traces of abrasives.
Use the correct paint system specified for the materials. Apply the type and colour of paint as
required by the system number.
2.
Do not paint the surfaces that will undergo welding or bolts and area next to field welds.
3.
Painting shall not take place during bad weather conditions specified in quality control
measures.
4.
Immediately after blast cleaning or within 4 hours from commencement of blast cleaning and
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after QC approval, the first coat shall be applied as per manufacturer's recommendations
5.
6.
Clean the spray pump, hoses etc. using cleaners before painting. Hose and containers shall be
thoroughly cleaned before addition of new materials.
7.
Thinning, mixing and handling, of paint materials shall be in accordance with the paint data sheet.
8.
9.
10.
Each paint coat shall be applied in a manner that will produce an even, continuous film of uniform
thickness.
11.
Edges, corners, joints, welds and other surface irregularities shall receive special attention to
ensure that they receive adequate thickness of paint.
12.
No coating shall be applied until the preceding layer has dried thoroughly. The over coating
intervals as recommended by manufacturer must be followed.
1.
The repair procedure for each system shall be as recommended by paint manufacturer.
2.
Visually Inspect surface areas for contamination such as oil, grease, dust / dirt etc.
3.
Mechanically clean the area using wire brush or spot blast as per paint manufacturer
recommendation.
4.
5.
Paints shall be applied by brush, roller or spray pump in accordance with paint specification
and paint manufactures instruction.
6.
7.
8.
Make sure to keep the minimum and the maximum recoating interval.
9.
If the surface being prepared lies adjacent to a coated surface which is not to be repaired, the
surface preparation shall overlap the coated surface by at least 25mm.
10.
Areas with inadequate coating thickness shall be thoroughly cleaned and additional compatible
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coats applied until they meet the specification. These additional coats shall blend in with the
final coating on adjoining areas. Color match shall be achieved.
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1.
2.
The paint container must contain the batch number, date of manufacture, the shelf-life expiry date
and the manufacturers name or trade mark.
3.
Store the paint material in a pre-assigned area at the temperature range specified in the material
data sheet and site requirements.
4.
Stainless steel, nonferrous materials etc. which do not require painting shall be effectively masked
to protect from overspray and drips of paint.
5.
Thinning, mixing and handling, of paint materials shall be in accordance with the paint data sheet.
6.
For paint materials, manufacturers pot-life and induction time requirements shall be followed.
7.
8.
All containers shall remain closed in factory sealed containers until required for use.
9.
Hose and containers shall be thoroughly cleaned before addition of new materials.
10.
Before priming verify that elapsed time from blasting has not exceeded specified time
between blasting and painting.
11.
The spray gun shall be held no closer than 200mm or more than 600mm from the surface to be
coated. Each pass shall overlap the previous one by 50%. When large surface areas are being
coated, spray application shall be made in two directions so that the passes are at right angles to
each other.
12.
The spray equipment, nozzles and sizes of tips for the spray guns shall meet the paint
manufacturers recommendation for a specific paint material.
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13.
Prior to the application of each coat, all weld joints, corners etc. stripe coated by a brush to ensure
that these areas have the minimum film thickness specified for each coat.
14.
Extra coats of paint shall be applied on areas where shape and/or plane of application results in
thinly applied coating; e.g. at edges, welds, corners, etc. To compensate for these effects, a stripe
coat of paint shall be brush applied before applying the finish coat.
15.
All coatings shall be uniformly applied without runs, sags, solvent blisters, dry spray or other
blemishes.
16.
No coating shall be applied until the preceding layer has dried thoroughly. The over coating
intervals as recommended by manufacturer must be followed.
17.
Coatings that have been left to cure past the manufacturers recommended re-coat interval must be
abraded to roughen the surface to allow adhesion of the new coating. The manufacturers re-coat
instructions should be followed.
18.
Inter coat contamination shall be minimized by maintaining proper cleanliness and by applying
intermediate and finish coats within the time period recommended by the Manufacturer. If
contaminants are present, they shall be removed before applying succeeding coats.
19.
Document and submit daily progress report, daily weather report, and daily inspection report.
The following inspections should be conducted during blasting and painting activities.
1.
All paint materials and abrasive delivered to site shall be accompanied with the batch certificates.
2.
The Technical data sheets and material data sheets must be readily available at site.
3.
Verify that the paint material is stored in a pre-assigned area at the temperature range specified in
the material data sheet.
4.
Verify that surfaces not to be coated are masked off or otherwise protected.
5.
6.
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7.
Scaffolding is in good condition and ready for use. Scaffolding needs to be inspected and signed
daily
8.
Blast containment media are in good condition and there are no escape route for blast media to
enter atmosphere.
1.
Inspections shall be carried out to verify that weather conditions are within the specified limits for
blasting and painting, and shall be recorded at every 2 hours interval, more frequently during
adverse weather conditions.
2.
Verify the pressure and cleanliness of compressed air used for blasting using blotting paper.
3.
Blasting of the steel surfaces Visual inspection to ascertain the degree of cleaning as per SSPCVis-1.
4.
The profile of blasted surfaces shall be checked by Profile gauge and Tape.
5.
6.
Ensure that the correct grade of Tape is used to record the profile. Tape shall be added to the
daily QC report as permanent record.
7.
Substrate shall be checked for soluble salt contamination using an approved salt contamination
meter. The maximum allowable level of contamination shall be 50mg/m2. Surfaces that do not
meet this criterion shall be reprocessed.
8.
Surface preparation shall be inspected before prime coat is applied to ensure all traces of dust
and foreign matter have been removed by brushing, blowing with clean compressed air.
1.
Record batch numbers of the paint materials for each painting activity.
2.
Verify that the shelf life of the paint material has not been exceeded before application.
3.
4.
5.
Verify that the substrate, ambient and material temperatures are within the range specified in the
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Verify the humidity and dew points are within the specified limits.
7.
Verify the method of application, time interval between coats, number of coats applied and the
minimum cure time of paint materials are according to material data sheet.
8.
Verify that pot life of mixed materials has not been exceeded.
9.
Verify by spot checking the wet film thickness (WFT) during the course of the paint application to
ensure that the film thickness is maintained.
10.
11.
The required dry film thickness of each coat shall be in accordance with the requirements stated in
the Shaheen project specification.
12.
13.
Verify the gauges are properly calibrated and the readings obtained are recorded.
14.
The DFT inspection for the paints on the various items shall be as per paint system tables as per
SSPC PA2 and should be attached in the inspection report.
15.
Each coat of a system and the complete system shall be visually inspected for the surface
imperfections.
16. The adhesion of the primer to the substrate and the intercoat adhesion of the subsequent coats
after curing must be tested for adhesion qualification test by the application of either a cross-cut
test or a pull-off test on test panels. The test panels shall be coated at the same time and under
same conditions as the production work.
17. Approved Inspection and Test plan (ITP), and Daily Inspection reports must be prepared and kept
up to date.
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Storage of paints shall be as per MSDS from manufacturer for the specified paint
All empty paints, thinner drums shall be safely stored in a designated place at the site approved
by the client. Necessary sign board, warning and barricading shall be provided at this designated
waste storage area.
2.
Ensure no flammable thinners, paints are present in the designated area that may catch fire. The
waste storage area shall be away from direct sunlight and sources of heat.
3.
Used Abrasives shall be collected in Jumbo bags and shall be taken back by subcontractor.
4.
All waste shall be disposed as per the requirements stipulated by the regulatory authorities.
13. HSE
Ensure the following points
1.
2.
3.
4.
5.
6.
The nearby facilities should be covered if required to avoid impact from blasting.
7.
8.
Trained and competent persons are allow to do Blasting and painting job.
9.
Blasting hose nozzle and clamps to be checked on regular basis and ensure the daily
checklist signed by operator.
10.
No persons except blaster and his helper are allowed around the Blast cleaning area.
11.
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12.
13.
14.
Hot works are not allowed in the vicinity of the painting area.
15.
Identification of hazards. Ensure that all concerned are aware of all the hazards and control
methods.
16.
Working area safety barricading must be required to avoid incidents & accidents.
17.
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