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AL HASSAN TECNICAS REUNIDAS

PROJECT LLC

PETROLEUM DEVELOPMENT OMAN

FRAMES GAS PROCESSING B.V.

PETROLEUM DEVELOPMENT OMAN


ZAULIYAH GAS PLANT PROJECT (ZGP)
PDO CONTRACT NO. C311388
APPLICATION PROCEDURE AND METHOD STATEMENT FOR EPOXY
INTUMESCENT FIREPROOFING OF SKIDS & EQUIPMENTS SADDLES .

Frames Gas Processing International B.V.


Dr. A.D. Sacharovlaan 2
2405 WB Alphen aan den Rijn
The Netherlands
Applicator:
KJ Enclave,P.O. Box :1940,
03

DD/MM/YY

Approved for
Construction

02

DD/MM/YY

Issued for Approval

01

12/09/15

Issued for Review

REV

DATE

REASON FOR
ISSUE

JV PROJECT No.: JV 912


JV PO. No.:JV 912
VENDOR PROJECT No: GGO-40083

PREPARED

CHECKED

APPROVED

AUTHORISED

JA
DISCIPLINE
ENGINEER

JA
DISCIPLINE
CHECK

JA
LDE/DH/TA2

JA
PROJECT

REVIEWED

APPROVED

JV

PDO

VENDOR DOC. No. :SIS/MS/357/R0/15:


This document
Processing

is the property

B.V.

and

Al

of Frames Gas
Hassan

Tecnicas

Reunidas Project LLC. It is not to be copied or


shown
The

to

third

approvals

Reunidas

Project

party
from
LLC

without

prior

Al

Hassan

do

not

manner

purchase

to

meet

specification

the
as

the

UNIT/PLANT
CODE

ZAU

-84

ORIGINATOR
CODE

DISCIPLINE
CODE

DOC.
TYPE

SEQUENCE
NO

SHEET
NO.

-00550

-000

consent.

absolve

requirements
well

AREA
CODE

Tecnicas
the

responsibility of Frames Gas Processing B.V. in


any

Al Swiss Insulation Co LLC

of

the

-104810

-ZV

-J04

correctness

and adequacy of the content of the document.

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Table of Contents

1.0.
2.0.
3.0.
4.0.
5.0.
6.0.
7.0.
8.0.
9.0.
10.0.
11.0.
12.0.
13.0.
14.0.
15.0.

Scope & Objectives


Standards and References
Materials
Definitions
Roles & Responsibilities
Materials Delivery, Storage & Handling
Site Preparations
Ambient Conditions
Application Method
9.1. Chartek 7 Application Using Plural Spray Equipment
9.2. Chartek 7 Application Using Hand Trowel
Quality Assurance & Control
Repair Procedure
Safety Measures
Manpower Requirements
Tools and Equipment Requirements
PPE Requirements

16.0. Warranty
Appendix A - Applicator Approval from International Paint

Page
3
3
3
3
4
4
5
5
6
6
7
8
9
9
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Appendix B Recommended Chartek 7 Thickness


Appendix C Scope of PFP Work
Appendix D Standard Quality Control Manual of International Paint
Appendix E Chartek 7 Application Manual
Appendix F Technical Specification of HK- 1
Appendix G Applicator training Certificates from International Paints

1.0. Scope & Objectives :This method statement details the application procedure for Epoxy Intumescent
Fireproofing System (Chartek 7 System) to protect the skids and the equipment
supports (saddles) from fire and corrosion at Perfect International workshop, Sharjah,
UAE and Zauliyah Gas Plant Project (ZGP), the PDO site at Zauliyah.
Ref. Appendix C for drawings of the detailed scope of PFP work.
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2.0. Standards and References:- Chartek 7 Application Manual (Ch7wp_uk, rev. 7, date 24/12/2014).
- Technical Data Sheets of Chartek 7, Intergard 251 and Interthane 990.
- Passive Fire Protection Specification (ZAU-84-104810-HS-2180-00002-000).
- ZAU-84-104810-ZV-L03-01022-000: ITP for Painting 8470.
- ZAU-84-104810-ZV-J04-01012-000: External Painting Procedure 8470.
- SP 1246.
- DEP 34.19.20.1.
- DEP 80.47.10.20.
- DEP30.48.00.3.

3.0. Materials :-

Application

Type of materials

Product Name

Applicator

Primer Coat

Epoxy

CS Substrate: Intergard 251


SS Substrate: Intergard 259

Perfect
/FRAMES

First Layer Chartek 7

Epoxy Intumescent

Chartek-7

Al Swiss

HK-1 Mesh

Glass / Carbon Hybrid


Fabric Mesh

HK-1 Mesh

Al Swiss

Second Layer Chartek 7

Epoxy Intumescent

Chartek-7

Al Swiss

Top Coat

Polyurethane

Interthane 990 for CS &


SS Substrate

Perfect
/FRAMES

4.0. Definitions :MS Method Statement


ITP Inspection & Test Plan.
MAS Material Approval Sheet.
QCP Quality Control Procedure.
QCF Quality Control Format.
TDS Technical Data Sheet.
MSDS Material Safety Data Sheet.
WFT Wet Film Thickness.
DFT Dry Film Thickness.
PDO Petroleum Development Oman LLC.
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PPE Personnel Protective Equipment.


FIFO First In First Out.
ISO International Organization for Standardization.
SSPC Society of Protective Coatings.

5.0. Roles & Responsibilities :5.1. The Projects Engineer has over-all responsibility to implement this method
statement, ensure that the QC Engineer, Supervisor and Safety Officer are aware of
this MS and also ensure that proper working resources (labours, materials and
equipments) are available to carry out the work as planned.
5.2. The Project Engineer, QC Engineer, and Supervisor are responsible to ensure that
work has been carried out as per the specification, drawings and approved MS and
all works are offered for inspection as per Inspection & Test plan.
5.3. The Project Engineer/Supervisor/Safety Officer shall be responsible to ensure that all
safety precautions are in place, and that all personnel are using the required
personal protective equipments. Must also ensure that all relevant permissions are
available for the works.
5.4. The Project Engineer/Supervisor/Safety Officer shall be responsible to ensure that
the requirements of Section 12.0 of this MS are met properly.
5.5. The Project Engineer/QC Engineer/Supervisor shall perform the activities as
specified in Section 10.0 of this MS.
5.6. The Project Engineer/Supervisor/Safety Officer shall conduct tool box talk prior to
starting any blasting and painting activity.

6.0. Materials Delivery, Storage & Handling :6.1. All the materials shall be delivered at site in original unopened packages. Only
approved materials shall be in the storage.
6.2. Expired or damaged materials shall not be stored in the materials storage.
6.3. The material shall be stored indoors and out of direct sunlight. Storage temperature
should not be more than 300C.
6.4. Packages of material shall be kept off the ground by means of wooden pallets or
others. Materials shall be grouped according to delivery at site.
6.5. While performing materials handling, extra care must be taken to avoid damages and
injuries.

7.0. Site Preparations :7.1. Ensure that adequate power, water, safe scaffolding, lighting, protection items, etc.
are available before the application process.
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7.2. Ergonomically setup equipments/machineries at working area before starting


painting activities.
7.3. Ensure that only trained and certified personnel to be used.
7.4. Prior to start the work, ensure that all the equipments are third party certified.
7.5. Identify modes of transportation of material to work areas etc.
7.6. Ensure protection of surrounding areas, machineries, tools, environment etc from
over spray of paint.
7.7. Ensure adequate ventilation at spraying area(s) prior to initiation of paint spraying.
7.8. Prepare a list of items (Traceability List/Release Note) to be painted, which shall be
confirmed by FRAMES.
7.9. Other trades shall be kept away during spraying of paint.

8.0. Ambient Conditions :Suitable application conditions are of critical importance for the successful
application of coating. Painting should only be carried out when the ambient
conditions are within the following parameters:
-

Air temperature: minimum 100C, maximum 500C.

Relative humidity: maximum 85%.

Surface temperature: at least 30C above dew point temperature, less than 500C

Blasting and painting activities shall not be carried out under the following conditions:
-

High wind speed.

Airborne dust/sand.

Rain, fog, mist.

Insufficient lighting.

Likelihood that weather will change within 2 hours

9.0. Application Method


All the work will be done at the Perfect International workshop at Sharjah, UAE. Only the
area in the skid structure where the split joint is available needs to be painted after the
alignment of the structure at Zauliyah Gas Plant site, Oman.
9.1. Chartek 7 Application Using Plural Spray Equipment :9.1.1. Weather conditions shall be monitored and confirmed as per Section 8.0. of this MS
prior to start of application of Chartek 7.
9.1.2. Before over-coating with Chartek 7, ensure that primer has reached sufficient levels
of cure prior to over-coating. The minimum overcoating time of Chartek 7 with the
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primer shall be 16 hours. If there is any chalking on primed surface or the surface
has exceeded its maximum over-coating period, the primed surface shall be
roughened prior to over-coating. Hand abrasion is only recommended in small areas
and care should be taken that the surface is not polished when using abrasive paper.
In case of hand abrasion, P80 P100 grade aluminium oxide abrasive paper shall
be used.
9.1.3. Before start of application of Chartek 7, all visible oil, grease and other soluble
contaminants must be removed from primed surfaces. Water jetting may be used to
clean previously primed surfaces. Cleaning and degreasing shall be carried out as
per SSPC-SP1.
9.1.4. To ensure good bonding of Chartek 7, dry film thickness of primer should not be
more than 75microns, up to 150 microns is acceptable in overlap areas. If there is
any excessive thickness, primer thickness shall be reduced to maximum 75 microns
using P80 P100 grade aluminium oxide abrasive paper. Care should be taken to
prevent polishing of the surface which would lead to inadequate adhesion of the
Chartek 7. Frequent changes of abrasive paper should be made. After primer
reduction, surfaces should be cleaned of dust and contaminants and thoroughly dry
prior to the application of Chartek 7.
9.1.5. Use heated plural component airless spray machine approved by International Paint
to spray Chartek 7. Application parameters shall be as below:
Parameters
Materials temp in storage tanks
In-line heater temp

Value
Part A: 50 600C
Part B: 40 500C
Part A: 60 700C
Part B: 45 550C
60 700C
57 630C
Part A: 5 bar (70psi)

Hose heater temp


Gun exit temp
Storage tank pressure

Part B: 4 bar (60psi)


Part A: 20rpm minimum

Tank stir speed


Displacement pump pressure

Part B: 15rpm minimum


175 to 240 bar (2500 to 3500psi)

Note: Spray unit parameters may vary depending on the spray unit used and environmental conditions.

9.1.6. As the mesh shall be at mid of specified DFT (as attached Appendix B), build up first
coat of approx. 3mm thickness. Where a good spray fan is not immediately
achievable, first coat of sprayed Chartek 7 shall be quickly trowelled into the surface
to ensure good wetting and even thickness.

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9.1.7. Trowel marks and high points shall be reduced with a short nap roller dampened with
GTA 123. Rolling shall be carried out, if the sprayed Chartek 7 has gelled sufficiently.
Also avoid use of excessive solvent while rolling of Chartek 7.
9.1.8. Cut mesh to required sizes before starting Chartek 7 application.
9.1.9. Install HK-1 mesh to wet Chartek 7 and rolled the mesh thoroughly into the wet
Chartek 7 with short nap rollers dampened with GTA123 solvent. Maintain mesh
overlap of minimum 150mm.
9.1.10. Apply subsequent coat of Chartek 7 to achieve required final thickness. Refer to
Chartek 7 data sheet for minimum over-coating intervals for plural spray application.
Before recoating application surface cleanliness shall be ensured.
9.1.11. A holding coat should be applied to HK-1 mesh when the remaining Chartek 7 coat
shall not be possible to apply on the same day. The holding coat shall be produced
by a faster than normal spray pass, resulting in a coarse finish that promotes good
bonding with subsequent coats.
9.2.

Chartek 7 Application Using Hand Trowel :9.2.1. There area(s), where Chartek 7 application by Plural Component Equipment is not
practicable, shall be fireproofed by hand/trowel method.
9.2.2. To facilitate application by hand/trowel the Chartek 7 Part A and Part B materials
should be maintained at a temperature of 21-27 0C for a minimum of 24 hours prior to
use.
9.2.3. A small amount (max. 1 litre for 20kg kit of Chartek 7) of GTA123 thinner may be
added into Part A to reduce viscosity for mixing and spraying. When Part A has
reached a smooth consistency, Part B is then poured into the Part A container,
scraping the sides of Part B container to empty it completely. The two parts are
thoroughly mixed using powered paint mixer. Always a full kit should be mixed.
For hand/trowel application, 20 kg kit should be used instead of 50kg kit.
9.2.4. The well mixed Chartek 7 shall be spread out onto the clean boards or steel surfaces
using hand trowel. This prevents the material from curing too quickly and allows
sufficient working time.
9.2.5. Trowel marks and high points shall be reduced with a short nap roller dampened with
GTA 123. Rolling shall be carried out, if the sprayed Chartek 7 has gelled sufficiently.
Also avoid use of excessive solvent while rolling of Chartek 7.
9.2.6. Subsequent coats to reach final thickness as per Appendix B shall be applied when
previous coat is still tacky.
Note: During hand trowel application, clauses 11.6, 11.8, and 11.9 shall be followed for mesh
installation.

10.0. Quality Assurance & Control :ZAU-84-104810-ZV-J04-00550-000

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10.1. Ensure that all the incoming materials are as per approved material sheet (MAS) and
has been offered for inspection.
10.2. Ensure that all materials shall be grouped according to delivery date and stored
properly in storage facility.
10.3. Materials shall be used on FIFO basis and all the materials shall be used before its
date of expiry. Expired paint must be removed from storage facility.
10.4. It shall be ensured that approved MS, MAS, drawings, QCP, Technical Data Sheets
etc to be followed and must always be available at the working area.
10.5. Coatings shall be offered for inspection as per Inspection & Testing Plan (ITP).
10.6. DFT and WFT shall be measured using International Protective Coatings
recommended gauges and keep records of it. Individual DFT shall not be less than
85% of recommended DFT( as per Appendix B).
10.7. Ensure that all the quality control instruments are calibrated from approved third
party and calibration certificates shall be available at site.
10.8. Ensure that all activities are carried our in controlled manner.
10.9. After application of Chartek 7, coating shall be inspected visually. The coating may
be even and rolled finish.
10.10.It shall be ensured that the coating shall be free from cracks, runs, discontinuity,
sags, voids or isolated deposit of excess thickness. Caulking or sealing of free edges
and terminations is not required.
Note: This project specific quality assurance and control plan has been developed based on
the standard Quality control manual of International Paints. Ref Appendix D for standard
Quality control manual of International Paints.

11.0. Repair Procedure :11.1. Check the border area of surrounding Chartek 7 for soundness and adhesion in joint
area.
11.2. Mark out the area to be repaired. Masking should be done around the area to be
repaired in a square or rectangular shape. This will give the patch a clean
appearance once completed.
11.3. Using a disc grinder, cut through the Chartek 7. Care should be taken not to damage
the substrate.
11.4. Using chosen tools (hammer and chisel etc), cut into patch to remove damaged
Chartek 7. Make sure all uncured material is removed.
11.5. Small areas, for example, welds and local repair areas may be prepared by power
tools to achieve a clean, roughened surface in accordance with SSPC SP11 and
maintain a minimum profile of 50microns. Power tool cleaning should not be used as
a primary surface preparation method for large areas.

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11.6. Abrade adjacent surfaces for a distance of 150mm from edge of repair area. After
roughening GTA123 thinner should be used to ensure the area is clean.
11.7. Reinstate primer to specification, if required. For repairs, Chartek 7 may also be
applied to blast cleaned steel.
11.8. Reinstate Chartek 7 to specification, taking care to smooth over the repair area
edges. Trowel application of Chartek 7 is acceptable for repair areas.
11.9. Topcoat (Interthane 990) replacement and repair should follow its TDS.

12.0. Safety Measures :12.1. Project Engineer, QC Engineer, Site Supervisor and workers shall be well aware of
typical worksite hazards (mechanical equipment, lifting equipment, scaffolding,
painting, blasting etc).
12.2. Tool box talk shall be conducted by Site Supervisor/Safety Officer prior to
commencing of work every day and made all aware of the possible hazards in the
painting activities.
12.3. Eye, face, hearing and respiratory protection shall be supplied to all personnel
working at site.
12.4. All painting equipments shall be properly earthed.
12.5. Hazard related information such as MSDSs shall be labelling near the material
storage area.
12.6. Paint and thinner shall be placed in designated storage area away from smoking
zone to prevent fire and explosion.

13.0. Manpower Requirements :a)

Project Engineer

b)

QA/QC Engineer

c)

Safety officer

d)

Supervisor

e)

Spray Painter.

f) Painter.
g)

Mason.

h)

Helper.

14.0. Tools and Equipment Requirements :a)

CoverCat PFP Spray Machine.

b)

Compressor.

c)

Airless Spray Machine.

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15.0. PPE Requirements :Helmet, Goggles, Visor, Face Shield, Dust mask, Disposable Painting Coverall, Ear
Protectors, Safety foot wear, Apron, Chemical Protecting Gloves.
16.0 Warranty :Warranty for the PFP product will be ten (10) years by applicator. This warranty will include
the supply of the material and application in line with Manufacturers conditions. Warranty
shall be started from the date of completion of PFP scope of work.

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