PIPING PAINTING

SPECIFICATION

DOC NO : D-12001-4-PPS1001
DATE
REV

D-12001-4-PPS1001
: 17/09/2012

:1

PIPING
PAINTING SPECIFICATION

A
REV
NO.

26/07/2012
DATE

CONFIDENTIAL

ANM
PREPARED
BY

SVR

ASU

PRELIMINARY

CHECKED
BY

APPROVED
BY

REMARKS

THIS DOCUMENT IS THE PROPERTY OF PRAJ INDUSTRIES LTD., INDIA AND SHOULD NOT BE REPRODUCED WITHOUT
WRITTEN CONSENT FROM. PRAJ INDUSTRIED LTD,PRAJ HOUSE, BAVDHAN, PUNE 411021, INDIA

D-12001-4-PPS1001
INDEX
Sr. No.

Description

Page No.

SCOPE

SURFACES TO BE PAINTED

SURFACES NOT TO BE PAINTED

REFERENCE CODES AND STANDARDS

GENERAL REQUIREMENTS

SURFACE PREPARATION

CLEANING OF WELD JOINTS STAINLESS STEEL

i) ACID CLEANING & PICKLING PASSIVATION OF JOINTS

ii) POLISHING OF JOINTS

PAINT APPLICATION

8.1) HANDLING OF PAINT

8.2) APPLICATION OF PAINT

PAINT APPLICATION PROCEDURE

9.1) PIPE SUPPORT

9.2) UNINSULATED CARBON STEEL PIPING

9.3) INSULATED CARBON STEEL PIPING

9.4) STAINLESS STEEL PIPING

10

COLOUR SCHEDULE

11

PIPE MARKING AND IDENTIFICATION

12

TOUCH-UP OF DAMAGES ON GALVANIZED PIPES

13

INSPECTION & QUALITY CONTROL

13.1) SURFACE PREPARATION

13.2) VISUAL CHECK OF THE COATING

13.3) DRY FILM THICKNESS

13.4) COLOUR OF TOP COAT

PAINT MATERIAL

ANNEXURE I COLOUR SCHEDULE FOR PIPING

14

D-12001-4-PPS1001
1. SCOPE
This Specification covers the requirement of the painting systems for above ground piping including
surface preparation, type of application, paints, procedure and inspection. This specification will be
supplemented by special instruction, if any.
Deviation from this specification shall be agreed upon in writing.
2.

SURFACES TO BE PAINTED

Carbon Steel Pipe and Fittings.

Carbon steel Pipe Supports.
Manual Valve & Special parts like Strainer, Trap etc shall be painted as per Manufacturers Standard.
3.

SURFACES NOT TO BE PAINTED

Unless otherwise specified, weather resisting material such as aluminium, stainless steel, brass & glass.
Galvanized carbon steel surfaces.
Non-metallic Piping.
Inline instruments & Inline process equipments.
Nut bolts associated with piping components.
4.

REFERENCE CODES AND STANDARDS

The following Codes & Standards shall be followed as applicable in their latest editions.

AS-1345-1995 for Identification of the contents of Pipes, Conduits and ducts.

International Organization of Standardization (ISO) & Steel Structures Painting Council Manual
(S.S.P.C.). for Surface Preparation
Manufacturers technical data sheets, and written recommendations or published instructions.
Local regulations for safety and air quality
If any conflict between the requirements of above reference standards and this specification, the
requirements of this specification shall prevail.
5.

GENERAL REQUIREMENTS

All surface preparation and coating work shall be in strict accordance with local safety and health
requirements
The primer, intermediate and finish coat should be of contrasting colour.
Refer Annexure-I for Painting Schedule and Colour Codes.

D-12001-4-PPS1001

6.

SURFACE PREPARATION

Surface preparation shall not take place when the air temperature is below 5 deg C, and when the steel
temperature is less than 3 deg C above the dew point or the relative humidity is greater than 85%, in
condition of strong or gusty winds or of poor visibility.
The surfaces should be cleaned by blasting. Unless prohibited under local rules, blasting materials i.e
sand of high hardness (e.g. corundum, quartz, olivine) shall be used. Dry oil-free compressed air shall be
used for blasting. The mean peak-to-valley height of the blasted surface should be maintained as
applicable. If the mean peak-to-valley height exceeds the specified dry film thickness of the prime coat
(70 micron), the contractor shall inform the site management. The contractor shall not commence with
the application of the coating materials until the orderer has decided on an adequate increase of the film
thickness.
Blast cleaning operations must conform to all regulations of local Air Quality Management, districts and
other regulatory agencies
Prior to any blast cleaning, all surfaces that are to be painted shall be cleaned of any dirt, oil or grease by
solvent cleaning and allowed to dry. The surfaces that are not to be coated (e.g. markings, designation
plates, flange faces, sight glasses, Instruments, etc) shall be suitably protected by wrapping, taping or
other means to prevent damages.
Welded areas shall be dressed where necessary to remove slag, spatter, etc, and prevent sharp rough
areas. Weld reinforcement shall not be removed.
Blast cleaned surfaces shall be primed on the same day and before occurrence of any trace of moisture
or visible rust. If rust forms, the surface must be re-blast cleaned before painting.
The surfaces to be coated shall be free from contamination (e.g. welding slag, welding spatter, dust, oil,
grease, salt, mill scale, rust, old coatings). Surface defects (e.g. cracks, lamination, burrs, pitting) shall be
removed by suitable methods. Sharp edges (e.g. saw cuts, oxygen cutting) shall be adequately rounded
by grinding
After surface preparation, contact surfaces of structural joints (e.g. of steel structures) with high strength
bolts shall be adequately protected until painting.
Any of following methods to be opted for surface preparation,

7.

a)

Surface Cleaning by Wire Brush - For Carbon Steel

b)

Surface Cleaning by Sand Blasting - For Carbon Steel

CLEANING OF WELD JOINTS STAINLESS STEEL

Irrespective of the fluid service, all stainless steel piping external weld joints shall undergo chemical
cleaning and passivation process after fabrication. Indeed even the most adapted stainless steel can
corrode in service if there is contamination of the surface. Both pickling and passivation are chemical
treatments applied to the surface of stainless steel to remove contaminants and assist the formation of a

D-12001-4-PPS1001
continuous chromium-oxide passive film. Pickling and passivation are both acid treatments and neither
will remove grease or oil. If the fabrication is dirty, it may be necessary to use a detergent or alkaline

cleaning before pickling or passivation. After welding, clean all the Welded Joints properly by any of the
following Methods,

i)

i)

Acid Cleaning & Pickling Passivation.

ii)

Polishing.
Acid Cleaning & Pickling Passivation of Joints

Following steps to be carried out for Acid Cleaning.

a)

Clean all the spatters, slag, dust and foreign particles.

b)

Prepare the cleaning solution with commercial Nitric Acid (HNO3), Hydrofluoric acid (HF) and
Water. Proportion shall be 4:3:4 (HNO3: HF: Water).

c)
d)

Piping shall be wetted with above solution for a period of 10 to 15 Min.

Use Stainless steel wire brush to clean up the weld joints. Clean the entire pipeline thoroughly by
rinsing with water. Chloride content of this water shall not be exceeding than 25 ppm.

e)

Ensure Water shall not be entrapped inside the pipeline & Pipe should be completely Dry.
After acid cleaning of weld joints, clean the joint, apply Passivation Paste on weld joint & burned area,
wait for 30 Minutes & clean it by water with soft brush.

ii)

Polishing of Joints
After welding, welding joints should be first cleaned by using Power Tool with Sand Paper wheel and
then polished it by Buffing Wheel.

8.

PAINTING APPLICATION

8.1 Handling of Paint

Storing, thinning, mixing, safety, handling and application of paint materials shall be in

accordance

with manufacturers instructions. All paint containers shall remain closed until required for use.
Manufacturers pot-life requirements shall be strictly adhered to.
Pigmented and catalysed materials shall be thoroughly mixed before being applied. Each component of
multi-component materials shall be thoroughly mixed prior to being combined and mixed as a unit.
8.2 Application of Paint
Paint shall be applied to dry, clean, prepared surfaces and under favourable conditions in accordance
with manufacturers instructions. Unless otherwise accepted in coating manufacturers technical data
sheets, coating application shall be done when the ambient temperature is above 4C and below 38C,
the relative humidity is less than 85 percent, and the surface temperature is 3C above the dew point.
Effective moisture and oil traps shall be used in compressed air lines for both conventional and airless
spray equipment.

D-12001-4-PPS1001

Each piece of Pipe / Fitting shall be masked off 50mm from an end which is to be welded, so that the

area remains bare prior to installation. It shall be the Fabricator / Applicators responsibility to see that all
masking material is thoroughly removed from the Pipe / Fitting and any damage to the coated surface is
repaired.

All coatings shall be applied by Spray / Brush / Roller. Brush or roller application will be used for touchup and to areas inaccessible by spray gun.
The coating materials shall be applied with a uniform thickness. Corners, edges, both heads, etc. which
are not easily accessible shall be pre-coated with small brushes.
9.

PAINT APPLICATION PROCEDURE

9.1 Pipe Supports

Primer coat shall be applied by brush or any suitable method. Coat should be of D.F.T. 70 Microns.
After Primer coatings, apply Enamel Paint as specified in Colour schedule of Annexure-I
Paint should be applied in TWO coats for entire Pipe Supports. First Coat should be of D.F.T. 70 Microns
& other of 50 Microns. Interval between these two coats should be minimum 10 Hrs at 27-30 deg.C
9.2 Uninsulated Carbon steel Piping
Primer coat shall be applied by brush or any suitable method. Coat should be of D.F.T. 70 Microns.
Enamel Paint to be applied in Two Coats, First of 70 Micron D.F.T & other of 50 Micron.
Application of Colour Band & Direction Arrow should be as specified in Specifications.(refer clause - 10)
9.3 Insulated Carbon steel Piping
Primer coat shall be applied by brush or any suitable method. Coat should be of D.F.T. 70 Microns.
Flanges to be painted in accordance with colour schedule of Annexure-I
Application of Colour Band & Direction Arrow should be as specified in Specifications.(refer clause - 10)
9.4 Stainless Steel Piping
Stainless Steel surfaces need not be Painted, Only Carbon Steel fittings (Flanges) & supports installed
on Stainless Steel Pipe lines should be painted (excluding Valves & Instruments) in accordance with
colour schedule of Annexure-I
Application of Colour Band & Direction Arrow for Insulated & Non-Insulated Stainless Steel lines
should be as specified in clause. 11 of this document.
10. COLOUR SCHEDULE
Refer `Annexure-I for colour schedule

D-12001-4-PPS1001
11. PIPE MARKING & IDENTIFICATION
Pipe marking & identification system shall be followed as per AS-1345,1995,Clause-6,7,8 & 9.
The flow direction of each service fluid shall be indicated by arrow & fluid name.
Refer Annexure-I for Colour schedule along with Pipe marking & Identification specified in the
AS-1345-1995.

12. TOUCH-UP OF DAMAGES ON GALVANIZED PIPES

-

When galvanizing is damaged during manufacturing, transport, erection or any other operation, a
touch-up providing a corrosion resistance as close as possible by Zinc metal spraying
(thermal spraying of zinc)

13. INSPECTION & QUALITY CONTROL

Painting shall be done by skilled applicators. The criteria governing good workmanship shall be proper
surface preparation and a neat appearance, free of blisters, bubble, craters, sags, runs, loss of adhesion,
overspray, embedded particles, dry spray, lap marks and unnecessary brush marks.
Other criteria are thorough mixing, straining, uniformity of film thickness, removal of dust, grease and
other foreign matter; proper drying time between coats should be maintained.
13.1 Surface Preparation
The preparation grade of surface should be checked according to the clause 6.
13.2 Visual Check of the coating
Prior to any other test, the coating shall be subjected to a visual check. The visual check should be
limited to coating defects (e.g. spray drizzle, areas left uncoated, inclusions of dirt, blisters, porosity,
sags, tears & brush marks)
13.3 Dry film Thickness
The dry film thickness shall be measured after adequate hardening or curing of the coating. To observe
the specified total film thickness, the thickness of each individual coat should be measured. Dry Film
Thickness measurement shall be made of each coat and total system by appropriate procedure.
13.4 Colour of Top Coat
The colour of the top coat shall be as per colour schedule.( AnnexureI)
14 PAINT MATERIAL
Appropriate quality of enamel paints conforming to relevant vendor specifications & standards
shall be used. It is recommended that the paints used should produce a Glossy Finish. All paint
and coating materials must have an attached technical data sheet and material safety data
sheet to be kept for future reference and personnel safety

D-12001-4-PPS1001

ANNEXURE I COLOUR SCHEDULE FOR PIPING

FLUID
CODE
AAL1
AAL2
AAV

SERVICE FLUID
DESCRIPTION
Fuel Grade Ethanol
(Anhydrous Alcohol
Liquid)
Fuel Grade Ethanol
(Anhydrous Alcohol
Liquid)
Anhydrous Alcohol
Vapor

RAL
NUMBER

BASE
IDENTIFICATION
COLOUR

LEGEND
COLOUR

CHEVRON
(ARROW)
COLOUR

RAL 8023

BROWN

WHITE

BROWN

AS-1345,Clause8.2.C

RAL 803

BROWN

WHITE

BROWN

AS-1345,Clause8.2.C

RAL 1014

YELLOW
OCHRE

BLACK

BLACK

ACM1

Activated Cell Mass

RAL 9017

BLACK

WHITE

BLACK

ACM2

Activated Cell Mass

RAL 9017

BLACK

WHITE

BLACK

ACM3

Activated Cell Mass

RAL 9017

BLACK

WHITE

BLACK

ADD1

Additive Solution

RAL 9017

BLACK

WHITE

BLACK

ADD2

Additive Solution

RAL 9017

BLACK

WHITE

BLACK

AFS1

Antifoam Solution

RAL 9017

BLACK

WHITE

BLACK

AFS2

Antifoam Solution

RAL 9017

BLACK

WHITE

BLACK

AIR

AIR (Atmospheric)

RAL 9017

BLACK

WHITE

BLACK

AWL

Alcohol Water Liquid

RAL 6034

LIGHT BLUE

WHITE

LIGHT
BLUE

AWV

Alcohol Water Vapors

RAL 8023

BROWN

WHITE

BROWN

CAS

Conc. Sulphuric Acid

RAL 1014

YELLOW
OCHRE

BLACK

BLACK

CAV

Caustic Lye
( 45% Solution )

RAL 4001

VIOLET

WHITE

VIOLET

CDO

Carbon Di Oxide

RAL 4001

VIOLET

WHITE

VIOLET

CIP1

CIP Solution (Caustic)

RAL 1014

YELLOW
OCHRE

BLACK

BLACK

CIP2

CIP Solution (Caustic)

RAL 4001

VIOLET

WHITE

VIOLET

CIS1

CIP Solution (Nitric)

RAL 4001

VIOLET

WHITE

VIOLET

CIS2

CIP Solution (Nitric)

RAL 4001

VIOLET

WHITE

VIOLET

COM

Steam Condensate
(Medium Pressure)

RAL 6010

GREEN

WHITE

GREEN

SUPPLEMENTRY
COLOUR

AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C

D-12001-4-PPS1001
CON
CSW

Steam Condensate
(Low Pressure)
Concentrated Spent
Wash
( Concentrated
Vinasse )

RAL 6010

GREEN

WHITE

GREEN

RAL 9017

BLACK

WHITE

BLACK

FLUID
CODE

SERVICE FLUID
DESCRIPTION

RAL
NUMBER

BASE
IDENTIFICATION
COLOUR

LEGEND
COLOUR

CHEVRON
(ARROW)
COLOUR

CWR

Cooling Water Return

RAL 6010

GREEN

WHITE

GREEN

CWS

Cooling Water Supply

RAL 6010

GREEN

WHITE

GREEN

DEN

Denaturant

RAL 8023

BROWN

WHITE

BROWN

EFF1

Effluent

RAL 9017

BLACK

WHITE

BLACK

EFF2

Effluent

RAL 9017

BLACK

WHITE

BLACK

FOL1

Fusel Oil

RAL 8023

BROWN

WHITE

BROWN

FOL2

Fusel Oil

RAL 8023

BROWN

WHITE

BROWN

FOM

Fusel Oil Mixture

RAL 8023

BROWN

WHITE

BROWN

FOW

Fusel Oil Washing

RAL 8023

BROWN

WHITE

BROWN

FWH1

Fermented Wash

RAL 9017

BLACK

WHITE

BLACK

FWH2

Fermented Wash

RAL 9017

BLACK

WHITE

BLACK

HFO

Heavy Fusel oil

RAL 8023

BROWN

WHITE

BROWN

HWR

Hot Water Return

RAL 6010

GREEN

WHITE

GREEN

HWS

Hot Water Supply

RAL 6010

GREEN

WHITE

GREEN

IAR

Instrument Air

RAL 6034

LIGHT BLUE

WHITE

LIGHT
BLUE

JCL

Juice Vapor
Condensate

RAL 9017

BLACK

WHITE

BLACK

JUV

Juice Vapor

RAL 7047

SILVER GREY

BLACK

BLACK

LFO

Light Fusel Oil

RAL 8023

BROWN

WHITE

BROWN

LPS

Low Pressure Steam

RAL 7047

SILVER GREY

BLACK

BLACK

MPS

Medium Pressure
Steam

RAL 7047

SILVER GREY

BLACK

BLACK

NAC

Conc. Nitric Acid

RAL 4001

VIOLET

WHITE

VIOLET

NUT

Nutrient Solution

RAL 9017

BLACK

WHITE

BLACK

PAR1

Process Air

RAL 6034

LIGHT BLUE

WHITE

PAR2

Process Air

RAL 6034

LIGHT BLUE

WHITE

LIGHT
BLUE
LIGHT
BLUE

AS-1345,Clause8.2.C
AS-1345,Clause8.2.C

SUPPLEMENTRY
COLOUR
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C

D-12001-4-PPS1001
PCL

Process Condensate

RAL 9017

BLACK

WHITE

BLACK

PRW1

Process Water

RAL 6010

GREEN

WHITE

GREEN

PRW2

Process Water

RAL 6010

GREEN

WHITE

GREEN

RAL
NUMBER

BASE
IDENTIFICATION
COLOUR

LEGEND
COLOUR

CHEVRON
(ARROW)
COLOUR

FLUID
CODE

SERVICE FLUID
DESCRIPTION

RML1

Raw Molasses

RAL 9017

BLACK

WHITE

BLACK

RML2

Raw Molasses

RAL 9017

BLACK

WHITE

BLACK

RSL1

Rectified Spirit

RAL 8023

BROWN

WHITE

BROWN

RSL2

Rectified Spirit

RAL 8023

BROWN

WHITE

BROWN

SCJ

Sugar Cane Juice

RAL 9017

BLACK

WHITE

BLACK

SCW

Scrubbed Water

RAL 6010

GREEN

WHITE

GREEN

SEW

Sealing Water

RAL 6010

GREEN

WHITE

GREEN

SLD

CIP Sludge

RAL 9017

BLACK

WHITE

BLACK

SPL

Spent Lees

RAL 9017

BLACK

WHITE

BLACK

SPV

Spent Lees vapors

RAL 1014

YELLOW
OCHRE

BLACK

BLACK

SPW

Spent Wash
( Vinasse )

RAL 9017

BLACK

WHITE

BLACK

SWC

Soft Water

RAL 6010

GREEN

WHITE

GREEN

RAL 9017

BLACK

WHITE

BLACK

RAL 9017

BLACK

WHITE

BLACK

SYP1
SYP2

Clarified Concentrated
Juice
Clarified Concentrated
Juice

TAL1

Technical Alcohol

RAL 8023

BROWN

WHITE

BROWN

TAL2

Technical Alcohol

RAL 8023

BROWN

WHITE

BROWN

VIV

Vinnasse Vapors

RAL 1014

YELLOW
OCHRE

BLACK

BLACK

YCR1

Yeast Cream

RAL 9017

BLACK

WHITE

BLACK

YCR2

Yeast Cream

RAL 9017

BLACK

WHITE

BLACK

Note: - Above colour codes are as per AS-1345-1995.

AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C

SUPPLEMENTRY
COLOUR
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C
AS-1345,Clause8.2.C