1. INTRODUCTION
This specification defines minimum quality and technical
standards governing materials procurement, application, testing and inspection
of anti-corrosion coatings applied to piping used in a marine environment. This specification is to be used in
conjunction with the following documents:
•
Basis of Design 84506-60-00-2L-060
•
General Specification
84506-60-00-2L-000 - Definitions and Specification Directory
•
General Specification 84506-60-00-2L-010
- Quality Assurance / Quality Control
•
SSPC-SP1, “Solvent Cleaning”
•
SSPC-SP2, “Hand Tool Cleaning”
•
SSPC-SP3, “Power Tool Cleaning”
•
SSPC-SP5, “White Metal Blast Cleaning”
•
SSPC-SP6, “Commercial Blast Cleaning”
•
SSPC-SP7, “Brush Off Blast Cleaning”
•
SSPC-SP10, “Near White Blast Cleaning”
•
SSPC-SP10, “Anchor Profile”
•
SSPC-SP-63, “Solvent Cleaning”
•
SSPC-PA-2 “Measurement of Dry Paint
Thickness with Non-Destructive Magnetic Gauges”
•
ASTM A153, “Zinc Coating (Hot Dip) on
Iron and Steel Hardware”
•
National Association of Corrosion
Engineers
•
NACE RP-01, “Corrosion Control of
Steel, Fixed Offshore Platforms Associated with Petroleum Production”
•
DNV-OS-F101 Submarine Pipeline System,
2000
1.1
CONTRACTOR shall submit to COMPANY for
approval, detailed procedures and all quality control pro-formas.
2. GENERAL REQUIREMENTS
2.2 All
CONTRACTOR personnel involved in surface preparation or coating work shall be
qualified and thoroughly trained as to the materials and specifications
pertaining to the coating systems and shall be provided with breathing
apparatus and skin protection as necessary.
This shall be demonstrated to the COMPANY’s satisfaction.
2.3 The
CONTRACTOR and/or sub-CONTRACTOR shall be responsible for the proper storage,
transportation and disposal of any and all waste material (hazardous or
otherwise) generated as a result of his operation. All handling of waste
material, including but not limited to paints, thinners, solvents and cleaners
shall be in a safe and legal manner and shall comply with all applicable
Regulations and Laws.
2.4 CONTRACTOR
shall ensure that the coating system(s) specified herein fully complies with
any local and/or regional air quality or VOC emission standards or
requirements. All materials shall comply with 3.50 lbs per gallon VOC
(maximum), except for high temperature products. Should modifications or
alternate coating systems be required to meet such standards or regulations,
CONTRACTOR shall immediately notify COMPANY and submit details of the proposed
alternate system to COMPANY for approval.
2.5
All paint supplied is to be lead &
chromate and crystalline silicon free formulation.
2.6 Scaffolding
or staging shall be used, where required, to provide easy access for surface
preparation and paint application. Scaffolding shall be such that operator’s
arms and body will be free to perform the necessary work and shall be provided
with safety features that will prevent accidents.
2.7 These
Specifications and NACE Standard RP-01 shall govern the procedures and
materials required for surface preparation and coating of the specified
structures and/or equipment. No deviations or exceptions from the
specifications shall be made without prior written approval of COMPANY.
2.8 The
paint manufacturer’s product data sheets and specifications for mixing,
application and curing shall be considered an integral part of this
specification.
2.9 The
coating systems to be used are specified in Section 4. If a coating option is
indicated, the selected option shall be used as specified throughout the
coating operation in accordance with these Specifications.
2.10 COMPANY
reserves the right to approve any and all subCONTRACTORs proposed by
CONTRACTOR, prior to beginning the work.
2.12 All
equipment to be used shall be subject to inspection by COMPANY. All equipment
including gauges, shall be completely operable and completely free of any
foreign matter.
2.13 Installation
CONTRACTOR shall perform all touch-up painting to provide a completely painted
assembly unless specified otherwise. All field tie-ins, exposed surfaces of
piling, field splices, weld area, etc. shall be painted. The coating system
used for field touch-up painting shall be from the same manufacturer as used
during the fabrication of the structure and as specified in Section 4. All
coating materials required for offshore touch-up shall be furnished by the
Installation CONTRACTOR.
2.14 The
CONTRACTOR shall arrange, at CONTRACTOR’s expense, to have a technical
representative from the coatings manufacturer present to assist and witness the
initial application of each coating system for all subsea structures. Further
technical assistance from the coatings manufacturer shall be obtained, at
CONTRACTOR’s expense, when problems arise or when COMPANY requests such
assistance.
2.15 Succeeding
coats of paint shall be of colors approved by COMPANY which contrast to the
color of the previous coat. CONTRACTOR shall verify the finish coat color with
COMPANY prior to the initiation of material procurement.
2.16 Prepainted
equipment provided to or purchased by the CONTRACTOR shall be recoated by the
CONTRACTOR if the existing paint system does not meet or exceed those of this
specification. The COMPANY shall determine if the existing system of a
prepainted item meets of exceeds this specification.
2.18 The
following surfaces shall not be sandblasted, coated or painted unless otherwise
specified: aluminum, brass, rubber, glass, plastic, concrete, stainless steel,
monel, copper-nickel alloys, bronze, fiberglass reinforced plastic, PVC,
stainless steel weather jacketing, insulation, plated surfaces, machined flange
faces or instrument cases.
2.19 Inorganic
zinc primers may be used as preconstruction primers, but weld bevels must be
free of all the primer before welding. This can be done by masking prior to
coating or by grinding or sandblasting before welding. The coating-free area
shall extend a minimum of 6 inches from the weld bevel.
2.21 Weld-through
shall not be used unless welding qualification tests show no detrimental
effects such as unacceptable porosity. The use of any weld-through primers must
be approved by COMPANY in writing prior to their use.
3. SURFACE PREPARATION
3.1 All
surfaces to be coated shall be abrasive blasted prior to coating application.
3.2 Prior
to abrasive blasting, grease or oil shall be removed with chemical emulsifying
solvents and the surface washed down with potable water.
3.3 All
rough welds, sharp edges, cutoffs, spatter and slag, burned, scarred or scored
areas shall be removed by grinding.
Power tool cleaning shall be in accordance with SSPC SP 3 "Power
Tool Cleaning".
3.4 Abrasive
blasting shall be permitted only on dry steel surfaces at least 3oC
(5oF) above dew point.
CONTRACTOR shall use a dew point calculator, hygrometer and surface
pyrometer, to verify compliance at the coating site.
3.5 Abrasive
blasting shall only be performed when ambient temperature is above 4.5oC
(40oF) and when relative humidity is less than eighty-five percent
(85%).
3.6 Abrasive
blasting shall be to a minimum standard of near white metal SSPC-SP-10 / SIS-Sa
2.5. The acceptable surface profile
after blasting shall be as recommended by the coating supplier and checked in
random positions selected by COMPANY with Testex Press-O-Film and a calibrated
micrometer.
Note: Sa 2.5 (near-white metal blast) is defined as
surface areas where at least ninety-five percent (95%) is in white metal
condition. Oil, grease, dirt, mill
scale, rust, corrosion products, oxides, paint or other foreign matter shall be
completely removed from surfaces, except very light shadows, very slight
streaks, or slight discoloration caused by rust stain, mill scale oxides, or
slight, tight residues of paint or coating that may remain.
3.7 Blasting
abrasive shall be a manufactured, or manufactured by-product, such as aluminum,
mineral slag or steel grit and shall be completely free of all-deleterious
salts, soluble sulfates, and chlorides.
It shall be angular, contaminant free, correctly stored, dry and of
sufficient particle size, hardness and density to provide the specified surface
profile, and shall be COMPANY approved prior to blasting. Use of reclaimed grit or sand is prohibited.
3.8 Compressed
air used for nozzle blasting shall be free of contamination. First and second stage moisture and oil
separators and dryers shall be provided and these shall be kept emptied of
contaminants. The nozzle shall be regularly maintained and inspected by COMPANY
representative during the execution of phase of the work.
3.9 Nozzle
size shall be 9.5 to 12.7 mm (3/8 to 1/2 inch) inside diameter and shall be
CONTRACTOR certified and COMPANY approved. Nozzles will be held 150 to 300 mm
(6 to 12 inch) from the surface, with a minimum abrasive discharge pressure of
629 kPa (90-psi). Nozzles shall be
discarded and replaced when wear affects surface preparation quality.
3.10 CONTRACTOR
shall ensure that residual abrasive dust does not contaminate bearing assemblies,
sealing surfaces or identification plates.
3.11 Surfaces
susceptible to particle contamination shall be screened to COMPANY satisfaction
prior to commencement of abrasive blasting.
3.12 All
surface defects revealed by blast cleaning shall be properly dressed to a
degree that will not be detrimental to coating performance or structural
integrity. The area shall then be
re-blasted to the required standard.
3.13 All
dust, grit, shot and other particular matter shall be removed before coating
application using an air lance or COMPANY approved equivalent.
3.14
Coating shall be applied within 4 hours
of abrasive blasting. Any surface that
shows rust indications after blasting or is not within 4 hours of blastings
shall be re-blasted to a white metal surface prior to coating application.
4. COATING SYSTEM
4.1 CONTRACTOR
shall apply one of the following coating systems or COMPANY approved
equivalent.
|
Manufacturer
|
Primer Coat(s)
|
Tie Coat(s)
|
Finish Coat(s)
|
|
Ameron
|
Amercoat 83HS
|
Amercoat 83HS
|
Amercoat 78HB
|
|
Carboline
|
Carboline 890
|
Carboline 890
|
Carboline 890
|
|
Hempel
|
Hempadur 4515
|
Hempadur 4515
|
Hempadur 4520
|
Note:
Refer to the material manufacturer's
data sheets for minimum and maximum thickness per coat. Minimum total Dry Film Thickness (DFT) shall
be 500 microns (20 mils)
CONTRACTOR shall propose the colour for
COMPANY approval.
5. COATING APPLICATION
5.1 Coating
shall be applied by airless spray in accordance with material manufacturer's
recommendations.
5.2 Coatings
shall only be applied when relative humidity is within material manufacturer’s
specified limits for each particular coating system.
5.3 CONTRACTOR
shall only apply coatings when the substrate is prepared dry, the ambient
temperature is above 10oC (50oF) and the ambient
temperature is greater than 3oC (5oF) above dewpoint.
5.4 Coatings
shall not be applied when weather conditions are likely to deteriorate within
two (2) hours after application.
CONTRACTOR shall suspend coating application when coating damage may
result from actual or impending weather conditions.
5.5 Coating
materials shall be mixed with a power mixer, and strained (if necessary), in a
safe, dust-free environment before pouring into a pressure pot for conventional
spraying.
5.6 Primer,
intermediate coat, and topcoats shall be of contrasting colors.
5.7 Only
material manufacturer's specified thinners shall be used. Thinning is not allowed in excess of material
manufacturer's recommendations.
5.8 Spraying
shall be performed in a safe, dust-free environment free from strong winds. Surfaces
that have been coated shall not be disturbed until the coating is completely
cured.
5.9 When
spraying is performed in any enclosed areas, adequate ventilation must be
provided during application and curing periods.
5.10 Each
coat shall be applied uniformly to clean, prepared surfaces, to produce smooth,
even coats of uniform thickness completely covering all corners and
crevices. Skips, runs, sags and drips
shall not be accepted. When these occur,
they shall be brushed out or the material shall be removed and the surface
recoated.
5.11 When
painting has started, all coats including primer and topcoats shall be
completed as soon as possible allowing for material manufacturer’s recommended
minimum and maximum overcoating times for the material type, thickness and
ambient temperature.
5.12 Weld
seams, fillets, edges, bolts and other similar features shall be given an extra
intermediate epoxy coat. This should be
applied by brush and before commencing epoxy coating.
5.13 Surfaces
that will be difficult to paint or inspect properly after fabrication or
installation must be coated prior to assembly.
5.14 When
the coating material pot life limit is reached, the paint shall be rejected and
material discarded.
5.15
Spray guns shall be cleaned only in
solvents.
6. INSPECTION AND TESTING
6.0 CONTRACTOR
shall establish and maintain quality assurance and quality control systems
necessary to ensure that coating complies with specification requirements.
6.1 The
Quality Systems shall include, as a minimum, the following:
•
Checking material storage conditions
are in accordance with material manufacturer’s recommendations.
•
Checking substrate cleanliness prior to
blasting, including removal of weld splatter and protrusions.
•
Checking surface dewpoint immediately
before blasting and coating.
•
Checking ambient temperature and
relative humidity.
•
Checking the removal of oil and grease.
•
Monitoring abrasive size, shape,
dryness and cleanliness.
•
Monitoring material selection and pot
life.
•
Monitoring air pressure and blasting
equipment.
•
Visually checking the surface for
cleanliness metal defects, dust, and surface debris after blasting.
•
Checking surface blast profile.
•
Checking coat thickness and system
thickness.
•
Checking for poor adhesion.
•
Visually checking for holidays, coating
color, appearances and uniformity and other defects.
•
Checking that adequate and proper
repair of all defects has been undertaken.
•
Contractor shall supply calibrated
instruments and certification to facilitate these tests.
6.2 Each
coat dry film thickness shall be checked with magnetic gauges in accordance
with Steel Structures Painting Council SSPC-PA2, Measurement of Paint
Thickness.
6.3 Each
coat wet film thickness shall be checked regularly during coating application.
6.4 COMPANY
may at any time require CONTRACTOR to prepare a set of test panels and average
tests of panels at a COMPANY approved laboratory.
6.5 Adhesion
shall be checked on completion of coating as requested by COMPANY. Adhesion shall be checked by scoring two
lines intersecting at 30º through the coating and trying to pick the coating
from the intersection using a sharp blade.
Any lack of adhesion to the steel surface or between paint layers shall
constitute failure and shall require the extent of the failure to be determined
and recoated. CONTRACTOR shall repair
coating damage caused by the adhesion checks.
7. REPAIR OF LACK OF ADHESION TO METAL SUBSTRATE / MAJOR DAMAGE
7.1 All
surfaces showing lack of adhesion or damage through to metal shall have all
defective coating removed and shall be re-prepared in accordance with Section
2.
7.2 Surfaces
shall be re-coated in accordance with Section 4.
7.3 Repair
coating overlap on to acceptable original coating shall be 50 mm minimum.
8. REPAIR OF LACK OF ADHESION TO PRIMER / MINOR DAMAGE
8.1 Damaged
areas with loss of topcoat adhesion or topcoat damage shall be sweep-blasted or
cleaned with a power tool to remove defective topcoats.
8.2 Surfaces
shall be thoroughly cleaned to remove all contaminants such as oil and grease
and edges of the existing sound coating shall be feathered. The existing sound coatings shall be lightly
abraded using hand tools.
8.3 Intermediate
and topcoats shall be re-applied as in Section 4 above.
8.4
Repair coating overlap on to acceptable
original coating shall be 50 mm minimum.
9. HANDLING OF COATED STEEL
Coating repair is inevitably inferior to the original
application, therefore, every possible precaution shall be taken to minimize
such repairs. Care shall be exercised
when handling coated steel, using suitable slings and hooks designed to
minimize damage at the pick-up points.
Suitable supports shall be provided for the coated steel when stacked
prior to construction.
10. RECORDS
CONTRACTOR shall submit to COMPANY for approval a painting
and anti-corrosion coating databook containing the following information as a
minimum:
•
Material certificates
•
Inspection equipment and calibration
certificates
•
Inspection and testing reports
•
Release certificates
All data shall be supplied in hard copy and electronic
format.