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A gub.ldbr, l K0rlll Pctobunr Corporllhn

STANDARDS PUBLICATION

KOC STANDARD
FOR

PATNTING Al\D COATII\G OF

BXTERNAL METAL SURFACES

DOC. N(). KOC-P-001


(Revision 3)

STANDARDS TEAM

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DOC. NO. KOC-P-001 Page 1 of50 REV.3

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STANDARDS PUBLIGATION

KOC STANDARD

FOR

PAINTING AND COATING OF

EXTERNAL METAL SURFACES

DOC.NO. KOC-P-001

STANDARDS TEAM

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DOC. NO. KOC-P-001 Page 2 of 60 REV.3

KOC STANT}ARD

FOR

PAINTING AND COATING OF

EXTERNAL METAL SURFACES

DOC.NO, KOC'P-001

ISSUING AUTHORITY:

STANDARDS TEAM

3 17.07.1 1 Revised nd re$sued a$


Finl KC Slndard
Task F rc j
{TF-FC102 )

Rev. Date Deecription Prepared by Snr. Engr, Standardg Team I


el. No.65434 Tel. No.6{407 l No.6{896

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TABLE OF CONTENTS
Page No.

FOREWORD 5

1,0 scoPE 7

2.0 APPLICATION 7

3.0 TERMINOLOGY 7
3.1 Definitions 7
3.2 Abbreviations I
4.0 REFERENCE STANDARDS, COQES AND SPECIFICATIONS I
4.1 Conflicts I
4.2 List of Standards, Codes and Specifications I
5.0 ENVIRONMENTAL CONDITIONS l3
6.0 HEALTH, SAFETY AND ENV|RONTIENT I S I 13
6.4 Storage, Handling and Mxing Safety Precautions 13
6.5 Manufacturer's Health / Safety Precautions 14
6.6 Safety Precautions for Blasting / Painting Equipment 14

7.0 PAINTING / COATING MATERIALS 15


7.1 General 15
7.2 Zinc-Rich Epoxy Primer 16
7.3 lnorganic Zinc Silicate Primer 16
7.4 Zinc Phosphate Primer 16
7.5 Mordant Solutions [-Wash) Pre-Treatment Primer 17
7.6 High Build Epoxy lntermediate 17
7.7 Coal Tar Epoxy Primer / lntermediate / Finish 17
7.8 Two-Pack Polyurethane Finish 18
7.9 "Zinc/Aluminium Free" lnorganic Silicate Finish 18
7.1A High Temperature Aluminium Silicone Finish 18
7.11 Glass Flake Epoxy 18
7.12 High Build Solvent Free Epoxy 18
7.13 Surface Tolerant High Build Epoxy 19
7.14 Hot / Cold Sprayed Aluminum Coatings 19
7.15 Hot Dip Galvanizing 20

8.0 SURFACE PREP,ARATION 20


8.1 General 20
8.2 Workng Restrictions 20
8.3 Surface lmperfections Removal 21
8.4 Surface Contaminants Removal 21
q9 Dry Abrasive Blast Cleaning Practice le I 22
8.6 Blast Cleaning Standard 24
8.7 Restrictions on Alternative Techniques to Blast Cleaning
- 24
8.8 Power Tool Cleaning 25
8.9 Hand Tool Cleaning 25
8.10 Acid Pickling (Etching) Preparation 25
8.11 Preparation of Stainless Steels 25

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9.0 PAINTING / COATING APPLICATION 26


9.1 GeneralRequirements 26
9.2 Selection of Painting and Coating System 27
9,3 Paint Mixing and Thinning 27
9.4 Restrictions on Paintng 27
9.5 Paint Application Practice 28
9.6 Priming 30
9.7 Shop Painting 30
9.8 Repar of Damages / Defects 31

r0.0 MATNTENANCE COATTNG l I


32
10.1 Surface Preparation 32
10.2 Coating Application - Maintenance 33

11.0 GALVANTZTNG lgl 33


11.1 Surface Preparation 33
11.2 Galvanizing Process 34
11.3 lnspection 34
11.4 Repair 35

12.0 NSPECTION AND TESTING 35


12.1 GeneralRequirements 35
12.2 lnspection / Testing Equipment 36
12.3 EnvironmentalConditionsTesting 37
12.4 Blasted Surface lnspection / Testing 37
12.5 Painted Surface lnspection / Testng 37

13.0 QUALITY ASSURANCE 39

14.0 DOCUMENTATION 39
14.1 General 39
14.2 Work Proposal 39
14.3 Work Records / Reports 40
14.4 Final Report 40

15.0 PAINTING / COATING SCHEDULES 40

16.0 COLOR SCHEDULES 40

17.0 APPENDICES 40.48


Appendix 1 : /
Daily Surface Preparation Painting Report 41
Appendix 2 : Color Schedules 42
Appendix 3 : Painting / Coating Schedules for Onshore 43-48
and Offshore Structures and Equipment

ACKNOWLEDGEMENT 49-50

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FOREWORD

The previous document 'KOC Standard for Painting and Coating for Metal Surfaces -
New Construction" (Rev.2) issued in July'1999 has been generally revised and updated
now, which is intended to provide the minimum basic technical requirements of
appropriate and proven materals for the different painting and coating systems to protect
the exposed steel surfaces from external corrosion.

This present revised document'KOC Standard for Painting and Goating for External
Metal Surfaces" (Rev.3) has been approved by Standards Team in consultation with
Standards Technical Committee (STC) for consistent use by KOC User Teams
throughout the corporate engineering and operational functions of Kuwait Oil Company
(K.S.C)within Kuwat.

The purpose of this Standard sets out to achieve the following objectives.

a) To establish the basic technical requirements for surFace preparation, painting


materials, methods of application and inspection/testing of protective external
coating / painting of metal surfaces aboveground in oil, gas and sea water facilities
and related utilities under both onshore and offshore conditions.
b) To provide the general techncal guidance for developing project specifications in
order to achieve reliability, quality and safety in an economical manner.

c) To set out clear requirements to monitor compliance in design, material selection,


application, inspection & testing with a contract.

d) To maintain the KOC requirements of safety, integrity, asset protection against


corrosion and environmental protection as established by KOC regulations and
procedures.

Feedback as well as any comments or suggestions from the application of ths standard
derived at any stage of design, construction, maintenance and field experiences are
encouraged and should be directed to:

The Team Leader Standards


(Chairman, Standards Technical Committee)
P.O.Box-9758, Ahmadi - 61008
State of Kuwait

Task Force Responsible for Revision of this Standard

The revision of ths Standard (Rev.3) has been entrusted by the Standards Technical
Committee (STC) of the Task Force No. (TF-PC/O2) comprsing of the following
members:

Mr. A,R. Al-Shamari lnsp.&Corr (N&WK) Specialist I (Corr.) TF Leader Te|.66394


Mr. Mohd Emam lnsp.&Corr (SAEK) Snr Specialist I (lnsp.) Member Tel. 65254
Mr. Hasan Sabri lnsp.&Corr (S&EK) Specialist I (Corr,) Member Tel. 65434
Mr. Amer Jaragh lnsp.&Corr (N&WK) Snr Corr. Engineer Member Tel. 65428

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SUMMARY OF MAJOR CHANGES I s I

s. Clause Description of the Major Changes


No. No.
Amended the Scope to cover the painting / coating for
1 1.0 existing and newly constructed onshore and offshore
facilities.
Revised and updated the list of National/ Int'l Standards
2 4.2.1
and Codes
Added list of relevant KOC HSE documents as
3 4.2.3
aoorooriate and aoolicable.
Revised HSE requirements and added safety
4 6.0 precautions for blasting / painting equipment.
Amended the coating / painting material requirements for
5 7.2 to 7.15
aooroval.
Added the requirement that the top coat shall be pure
7.8.3,
6 white (RAL 9010) or Aluminum (RAL 9006) or else as
Appendix 2
required bv KOC.
7 7.14 Added Hot / Cold Sprayed Aluminum Coatinqs
Added to the Standard the dust level testing on the
I blasted service, water soluble salts test and the
8.5,2
requirements for not allowing the use of sand or copper
slaq as abrasive material for blast cleaninq.
Added the requirements for approving the personnel
I 9.1,1 involved the blasting, coating & lining activities as per
KOC Standard KOC-P-006 by KOC I & CT.
Added surface preparation and paintng application for
10 10.0
maintenance purposes.
11 11.0
Added more details about Galvanizing (Surface
Preparation, Galvanizinq Process, lnspection & Repair).

12 12.1.2

13 Appendix 3

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1.0 scoPE lsl


1.1 This Standard specifies the minimum basc requirements for coating materials,
surface preparaton, method of applcation and nspection/testing for
painting/coating of external above ground metallic surfaces for existing and
newly constructed onshore and offshore facilites. lt also covers the repair of
defects or damages to the existing and newly painted items.

2.0 APPLICATION

2.1 All the materials and equipment used for surface preparation, coating
application, inspection and testing shall conforrn to the requirements of this
Standard and the referenced standards and codes.

2.2 Any exception or deviations from this Standard, along with their merits &
justification, shall be brought to the attention of KOC Controlling Team, for ther
review, consideration and amendment by Standards Team (if required).

2.3 Compliance with this Standard does not of itself confer immunity from legal or
statutory obligations

3.0 TERMINOLOGY

3.1 Definitions

For the purposes of this Standard, the following definitions apply

3.1 .1 Abrasive
Natural or synthetic solid material used as a medium in abrasive blast-cleaning

3.1.2 Atmospheric Zone


The part of an ofishore structure above the splash zone (also the unburied
portion of an onshore structure).

3.1.3 Coat
One layer of coating applied to a surface in a single continuous application to
form a uniform film when dry.

3.1.4 Gomparator
A specimen surface or surfaces of known average profile, representing a
particular abrasive blast-cleaned process.

3.1.5 Cure
The chemical, solvent evaporaton, and/or coalescence reaction resulting in the
applied film changing from its liquid state to a solid state of the final polymerized
product in the painVcoating systern.

3.1.6 Discontinuity (Holiday)


A void, crack, thin spot, foreign inclusion or contamnation in the coating film that
significantly lowers the delectric strength of the coating

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3.1.7 Dry Film Thickness (DFT)


The dry flm thickness of paint is the thickness of paint afier all the solvent has
evaporated and the coating has cured

3.1.8 Pot Life


The elapsed time within which a coating can be effectively applied after all
components of the coating has been thoroughly mixed.

3.1.9 Grit
A term used to describe the angular or irregularly shaped particles of abrasives
used.

3. 1.10 Rust Grade (degree of rusting)


A classification describing the degree of rust formation on a steel surface prior to
cleaning.

3.1.1 1 Shot
A term used to describe the spherically shaped particles of abrasive used for
blast cleaning.

3.1.12 Splash Zone


The zone of a structure that is alternately in and out of the water because of the
influence of astronomical tides, winds, and sea waves.

3.1.13 Submerged Zone


The zone that extends downward from the splash zone and includes that
structure below the mudline.

3.1 .14 Surface Profile (Anchor Pattern)


The micro-roughness of a surface, generally expressed as the average height of
the major peaks relative to the major valleys,

3.2 Abbreviations

AI Aluminum
API American Petroleum lnstitute
ASTM American Society for Testing & Materials
cs Carbon Steel
DFT Dry Film Thickness of coating / lining
HSE Health, Safety and Environment
rso lnternational Organization for Standardization
KOC Kuwait Oil Company (K.S.C.)
HSEMS Health Safety Environment Management System
LAT Lowest Astronomical Tide
MO Micaceous lron Oxide
MSDS Material Safety Data Sheet
NACE National Association of Conosion Engineers
QA Quali$ Assurance
oc Quality Control
RH Relative Humidity
SS Stainless Steel


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SSPC The Society for Protective Coatings


urn Microns (Unit of Thin Film Thickness)
pS MicroSiemen/cm (Unit of Conductivity)
WFT Wet Film Thickness of coating / lining

4.0 REFERENCE STANDARDS. CODES AND SPECIFICATONS

4.1 Conflicts

ln the event of conflicts between this Standard and the Standards / codes
referenced herein, or other contractual requirements, the most stringent
requirement shall apply. ln case further clarifications are required, the subject
shall be brought to the attention of KOC Controlling Team.

4,2 List of Standards. Codes and Specifications

The latest editions of the following standards, codes and specifications shall
apply
4.2.1 National / lnternational Standards and Codes I 3l
ASTM 8117 Standard Practice For Operating Salt Spray (Fog) Apparatus

ASTM D52O Specification for Zinc Dust Pigment


ASTM D61O Standard Test Method for Evaluating Degree of Rusting on
Painted Steel Surfaces
ASTM D661 Standard Test Method for Evaluating Degree of Cracking on
Exterior Paints.
ASTM D1212 Standard Test Methods for Measurement of Wet Film
Thickness of Organlc Coatings
ASTM Dl653 Standard Test Methods for Water Vapour Transmission of
Organic Coatings Films
ASTM D2247 Standard Practice for esting Water Resistance of Coatings
in 100% Relative Humidity
ASTM D2697 Standard Test Method for Volume Nonvolatile Matter in
Clear or Pigmented Coatings
ASTM D3276 Standard Guide for Painting lnspectors (Metal Substrates)
ASTM D3359 Standard Test Methods for Measuring Adhesion by Tape
Test.
ASTM D3686 Standard Practice for sampling Atmospheres to collect
Organic Compound Vapours (Activated Charcoal Tube
Absorption Method)
ASTM D4O6O Standard Test Method for Abrasion Resistance of Organic
Coatings by the TaberAbraser.
ASTM D4417 Field Measurement of Surface Profile of Blast Cleaned
Steel

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ASTM 4541 Standard Test Method for Pull-Off Strength of Coatings


Using Portable Adhesion Testers.
ASTM 4752 Standard Practice for Measuring MEK Resistance of Ethyl
Silicate (lnorganic) Zinc-Rich Primers by Solvent Rub
ASTM D5064 Standard Practice for Conducting a Patch Test to Assess
Coating Compatibrli$

ASTM D6386 Standard Practice for Preparation of Zinc (Hot{ip


Galvanized) Coated lron and Steel Product and Hardware
Surfaces for Painting

ASTM D7091 Standard Practice for Nondestructive Measurement of Dry


Film thickness of Nonmagnetic Coatings Applied to Ferrous
Metals and Nonmagnetic, Nonconductive Coatings Applied
to Non -Ferrous Metals

ASTM D7393 Standard Practice for lndicating Oil in Abrasives

BS 381C Colours for ldentification, Coding and Special Purposes

BS 4800 Schedule of paint colours for building purposes

BS 5378-2 Safety Signs and Colours - Part 2: Specificaton for


Colourmetric and Photometric Properties of Materials

BS 5499-5 Graphical Symbols and Signs - Safety Signs, lncluding Fire


Safe$ Signs - Part 5 : Signs with Specific Safety Meanings

BS EN 1089-3 Transportable gas cylinders Gas cylinder identification


(excluding LPG) Part 3: Colour coding

BS EN ISO 407 Small medical gas cylinders Pin - index yoke type valve
connections

BS EN 1S022063 Thermal spraying Metallic and other inorganic coatings


Zinc, Aluminum and ther alloys

rso 1461 Hot dip galvanized coatings on fabricated iron and steel
articles - Specifications and test methods
tso 4618-3 Paints and varnishes - Terms and definitions for coating
materials - Part 3: Surface preparaton and methods of
application

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tso 8501-1 Preparation of Steel Substrates Before Application of Paints


and Related Products - Visual Assessment of Surface
Cleanliness - Part 1: Rust Grades and Preparation Grades
of Uncoated Steel Substrates and of Steel Substrates After
Overall Removal of Previous Coatings

rso 8501-2 Preparation of Steel Substrates Before Application of Paints


and Related Products - Visual Assessment of Surface
Cleanliness - Part 2: Preparation Grades of Previously
Coated Steel Substrates After Localized Removal of
Previous Coatings First Edition
rso 8501-3 Preparation of steel substrates before applcation of paints
and related products Visual assessment of surface
cleanliness Part 3: Preparation grades of welds, edges and
other areas with surface imperfections - Second Edition
tso 8502-3 Preparation of Steel Substrates Before Application of Paint
and Related Products - Tests for the Assessment of Surface
Cleanliness - Part 3: Assessment of Dust on Steel Surfaces
Prepared for Painting (Pressure-Sensitive Tape Method)
lso 8502-6 Preparation of steel substrates before application of paints
and related products Tests for the assessment of surface
cleanfiness Part 6: Extraction of soluble contaminants for
analysis The Bresle method
rso 8502-9 Preparation of Steel Substrates Before Application of Paints
and Related Products - Tests for the Assessment of $urface
Cleanliness - Part 9: Field Method for the Conductometric
Determination of Water-Soluble Salts - First Edition:
Corrected and Reprinted 1 2/1 5/1999
tso 8503-2 Preparation of Steel Substrates Before Application of Paints
and Related Products - Surface Roughness Characteristics
of Blast-Cleaned Steel Substrates - Part 2: Method for the
Grading of Surface Profile of Abrasive Blast-Cleaned Steel
Comparator Procedure
rso 8503-5 Preparation of steel substrates before application of pants
and related products Surface roughness characteristics of
blast-cleaned steel substrates Part 5: Replica tape method
for the determination of the surface profile
tso 8504-2 Preparation of Steel Substrates Before Application of Paints
and Related Products - Surface Preparation Methods - Part
2: Abrasive Blast-Cleaning
lso 9000 Quality Management Systems - Fundamentals &
Vocabulary
tso 10684 Fasteners - Hot Dip Galvanized Coatings.
rso 12944 Paints and Varnishes - Corroson Protection of Steel
structures by Protective Pants Systems (Parts 1-8)

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rso 17025 General requirements for the competence of testing and


calbration la boratories
NACE No. 3 Joint Surface Preparation Standard Commercial Blast
Cleaning
NACE No. 12 Specification for the Application of Thermal Spray Coatings
(Metallizing) of Aluminum, Zinc, and Their Alloys, and
Composites for the Corrosion Protection of Steel
NACE RPO287 Field Measurement of Suface Profile of Abrasive Blast
Cleaned SteelSurface using a Replica Tape
NACE SPO188 Discontinuity (Holiday) Testing of New Protective Coatings
on Conductive Substrates
SSPC PA 2 Measurement of Dry Film Thickness with Magnetic Gauges
SSPC Paint 20 Znc-Rich Coating Type I - lnorganic and Type ll - Organic

SSPC SP 1 Solvent Cleaning


SSPC SP 3 Power Tool Cleaning
SSPC SP 6 Commercial Blast Cleaning
SSPC SP 8 Pickling
ssPc sP 1 1 Power Tool Cleaning to Bare Metal

4.2.2 KOC Standards and Recommended Practices


KOC-G-002 KOC Standard for Hazardous Area Classification
KOC-G-007 KOC Standard for Basic Design Data
KOC-L-009 KOC Standard for Fire Protection Systems and Safety
Equipment

KOC-P-006 KOC Standard for Evaluation and Certification of Blasting &


Coating Contractor/ Applicator Personnel

4.2.3 Other KOC Documents I s I

KOC HSE MS Procedures (latest as applicable)


KOC.EV.005 ChemicalClean Up Procedure
KOC.EV.007 Transport, Storage and Handling of Hazardous Material
KOC.EV.008 Waste Management Procedure
KOC.HE.004 Occupational Health and Hygiene - First Aid
KOC.HE.008 ChemicalHazardCommunicationProcedure
KOC.HE,O15 RespiratoryProtectionlnspectionProcedure

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KOC.SA.005 Breathing Apparatus and Use


KOC.SA.011 High Pressure Water Jetting, Abrasive Blast Cleaning and
Steam Cleaning
KOC.SA.030 Painting and Coating HSE Procedure
KOC.SA.031 Working at Height Procedure

5.0 ENVIRONMENTAL CONDITIONS

5.1 The environment of Kuwait is severe, and must be considered carefully for
selection and before procurement of coating materials. lt must be assumed that,
unless otherwise specified, coating system may be subjected to sand and fine
particle dust storms, humid salt laden winds and in some areas to airborne
corrosive chemical contaminants (e.9., HzS, SOz etc.).

5.2 For environmental conditions in Kuwait, refer to KOC-G-007'KOC Standard for


Basic Design Data", which provides the detailed design information regarding
the environmental, site and utility supply conditions prevailing throughout the
KOC facilties.

5.0 HEALTH, SAFETY ANp ENVTRONMENT lgl


6.1 The Designer / Contractor shall assure the compliance of necessary HSE
design requirements with a view to minimize the consequences and impacts of
hazards on the surrounding environment and adjoining facilities as well as the
occupational health and safety of working personnel.

6.2 Job Safety Analysis (JSA) document for the work to be canied out shall be
prepared by the Contractor and submitted to KOC for revew and approval prior
to starting work. The JSA document will address all relevant HSE requirements
specified by the coating Manufacturer, applicable KOC Health, Safety and
Environment Management System (HSE MS) Procedures and KOC Health,
Safety and Environment System (HSE Policy) that shall be adhered to within
KOC areas.

6.3 Where there is a risk of flammable atmosphere being present in a particular


work area, KOC may, with relevant safety authority, impose restrictions on
methods of surface preparation. Flame heating equipment shall not be used
in hazardous areas. Refer to KOC-G-002, which describes area classification
for facilities and equipment. KOC approval shall be obtained in all cases before
the use of flame heating.

6.4 Storaoe. Handlinq and Mixinq Safetv Precautions

6.4.1 All paints, coatings and thinners shall be stored in enclosed storage areas or
structures that protect workers, reduce fire risks and improve productivity by
storing hazardous liquids in code compliant safety cabinets designed to meet
OSHA and NFPA standards, High performance, self-latching doors should close
easily and securely for maximum protection under fire conditions.

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6.4.2 Paints and coatings shall be protected from temperatures exceeding


Manufacturer's recommendations; and from open flames, electrical discharge
and direct sunlight. Air condtioned storage areas shall be provided where
excessive ambient temperatures are expected. ln view of the potential for the
accidental release of the stored material containing flammable hydrocarbon,
enclosed areas where paints, coatings and thinners are stored, shall be
designated as electrically classified area as per applicable KOC Standard KOC-
G-002.

6.4.3 The storage area shall be secluded and no other materials shall be stored in the
enclosed place. The enclosure shall be strictly demarcated as "NO SMOKING'
area. The storage area must be supplied with fire detectors.

6.4.4 All paints, coatings, solvents, oil and equipment cleaners shall be stored in
closed labeled original containers. Arrangement for containment of accidental
spill shall be provided in storage area.

6.4.5 Portable fire extinguishers of suitable quality and appropriate quantity as per
KOC Standard KOC-L-009 and other fre protection measures (First aid, kitchen
shower & eye wash units etc.) shall be provided at the storage areas; and such
extinguishers shall be inspected and approved by KOC Fire & Safety eams.

6.4.6 All the Applicator/Contractor personnel performing any painting i coating


application(s) shall use all the necessary personnel protective
equipment(SXPPE) and clothing appropriate for that application.

6.4.7 Original containers after being emptied shall not be reused for any other
purpose and shall be disposed off as per hazardous waste as per KOC HSE MS
Procedure, KOC-EV-008.

6.4.9 As safety preventive measurements, eating and drinking shall be prohibited in


confined spaces.

6.5 Manufacture/s Health / Safetv Precautions

6.5.1 Manufacturer's health / safety precautions and procedures for mixing, handling,
storage and application of paints and coating materals shall be strictly adhered
to. Safety precautions shall be clearly described on the Technical Data Sheet
and the Material Safety Data Sheets (MSDS) of painting and coating materials
supplied as well as on the containers.

6.6 Safetv Precautions for Blastinq / Paintinq Equipment I


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6.6.1 Blast cleaning pot, nozzles and spray painting machine shall be earthed
(grounded, spark proofed) to prevent building up of an electrostatic charge.

6.6.2 All blasting equipment shall be inspected and certified by an authorized


competent third party inspectors. Pressurized hoses shall be tested and certified
for maximum safe working pressure. Hoses and other pressure items shall be
checked periodically to make sure that any damage or loss of electrical
conductivity will not lead to a safety hazard.

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6.6.3 Pressurized hose and blasting guns shall be compulsorily equipped with an
operational "Dead-man Switch" located immediately behind the nozzle / gun. No
maintenance job shall be performed on a pressurized or energized blasting pot.

6.6.4 Enclosures shall be provded all around the area, where shoUgrit blasting will be
carried out.

6.6.5 Clean Positive Pressure type air masks (hoods) and all other appropriate PPE
shall be worn by the painting / blasting crew members while blasting or spray
painting.

6.6.6 Operators must only remove their supplied air breathing equipment when they
are well away from the work location as dust and other contaminants can
remain suspended in air for long periods of time.

6.6.7 Operators shallwear Coveralls that provide suitable protection from rebounding
abrasives and shall wear Work gloves that protect the full forearm.

6.6.8 All personnel involved in the blasting and painting operations shall be provided
the necessary awareness and training on the hazards and risks of their pertinent
operations and the respective risk control measures. All such personnel shall be
able to produce valid documentary evidences at the time of evaluations

7.0 PATNTTNTTNG COATfNG MATEBIALS


'
7.1 General

7 .1.1 All painting / coatng materials shall be chemically pure, and free from foreign
contaminants. The age of coating material component shall not exceed the
Manufacturer's recommended shellife during storage and pot-life during mixing
and application.

7 .1.2 All painting / coating materials shall be delivered to the Site in original sealed
Manufacturer's containers with batch / code numbers and date of manufacture
clearly marked thereon.

7.1.3 All painting / coating materials, including thinners and equpment cleaners, in
any single system shall originate from only one Manufacturer.

7 .1.4 The KOC approved schemes are tabulated in the painting I coating schedules
A-D (Appendix 3) and as defined in clauses 7 .2 to 7.14 ol this Standard. The
use of alternative schemes must be approved in writing by KOC prior to
commencing work. (Only for the items like valves, electrical items, movng
parts... etc at vendor facility).

7.1.5 The Contractor's submittal for painting / coating material shall include details of
generalized composition, service temperature and technical specifications of the
products intended to e used for KOC review and approval prior to commencing
work on any job ste.

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7.1.6 The selected composition of painting / coating materials shall comply with the
relevant clauses pertaining to the materials gven below in this Standard.

7 .1.7 The certifications in original shall be submitted to KOC from independent testing
laboratory certified according to the requirements of ISO 17025.

7.2 Zinc-Rich Epoxv Primer l3 |

Zinc-rich Epoxy Primer shall be based on polyamide or polyamine cured 2 pqck


epoxy and shall meet the following requirements as per the Table I of this
Standard.

Table - l : Testinq Requirements

sl. Reference Standard Acceptance Criteria


Test Requirement
No.
1 Total zinc dust SSPC Paint 20 Level-1 Minimum 85% by Weight
Type ll & maximum lead level
2 Znc dust purity ASTM D52O shall not exceed 0.01% by

3 Adhesion ASTM D3359 Method B Minimum 4B


Salt spray
ASTM 8117 No Blisters or Rusting
4 resistance (min No undercutting from the scribe.
SSPC Paint 20
1000 hours)

7.3 lnorqanic Zinc Silicate Primer I s I

The inorganic Zinc Silicate Primer shall be solvent borne products and based on
Ethyl Siticate media. l_t shall be capable of withstandng continuous high
temperature (up to 40OoC) having excellent abrasion and chemical resistance.
The lnorganic Zinc Silicate Primer shall be tested and meet the following
requirements as per the Table ll of this Standard:

Table-ll :@
sl. Tegt Reference Standard Acceptance Criteria
No. Requirement
1 otal zinc dust SSPC Paint20 Level -1 Minimum 85% bv Weisht
Type ll & maximum lead level shall
2 Zinc dust purity ASTM D52O
not exceed 0.01% bv weight.
Mud cracking @ SSPC Paint 20 No crack when viewed under 10X
3 '100um magnifications.(curing of l4 days
at 25o c)
4 Adhesion ASTM D3359 Method B Minimum 4B
Salt spray No Blisters or Rusting
ASTM B 117
5 resistance (min
SSPC Paint 20 No undercutting from the scribe.
1000 hours)

7.4 Zinc Phosphate Primer l3 |

The Zinc Phosphate Primer may be either polyamide or polyamine cured epoxy
pigmented with zinc phosphate inhibitive pigments or combnations of zinc
phosphate and other inhibitive pigments.

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7.5 Mordant Solution ff-Wash) Pre-Treatment-Primer l3 |

Used for preparation of galvanized surfaces. lt is a two component etch primer,


based on phosphoric acid solution incorporating copper salts and corrosion
inhibitive pgments in a solvenUwater solution. Minimum volume solids shall be
9% as per ASTM D2697.

7.6 Hiqh Build Epoxv lntermediate l3 |

The intermediate coat shall be a High build Epoxy, pigmented with Micaceous
lron Oxide (MlO)and can be either polyamide or polyamine cured.

7.6.1 The lntermediate coating must have a stated maximum recoat time at 200C on
the product data sheet. ln the absence of a maximum recoat time, if there is any
residual gloss on the surface, the coating must be abraded prior to recoating.

7.6.2 The High Build Epoxy lntermediate shall be tested and meet the following
requirements as per the Table lll of this Standard.

Table - lll : Testinq Requirements

sr. Test Requirement Reference Standard Acceptance Griteria


No.
I Minimum volume solids ASTM D2697 Minimum 75olo
Adhesion
(To zinc rich epoxy Minmum 3 MPa
2 ASTM D 4541
prmed to a thickness of
mnimum '100 microns).
3 % of MIO As per Manufacturer 220a/o

7.7 Goal Tar Enoxv Primer / lntermediate / Finish |3 |

7.7,1 The forrnulation of the fwo pack versions shall incorporate:

Pack 1 . Epoxy resin and suitable pigments.

Pack 2 : Polyamide or polyamine curing agent and coal tar pitch. Hydrocarbon
resins may be substituted for coal tar pitch to meet toxici$
restrictions.

7.7.2 For contrasting colour of intermediate coats, red oxide pigments may be
incorporated by the Manufacturer. Adding pigments of any kind by the
Contractor is expressly prohibted. When used as an intermediate coat, the
preceding coat must not be glossy prior to over coating. lf t has exceeded the
Manufacturer's recoat window or is glossy, it must be abraded prior to over
eoating.

7.7.3 The epoxy resin shall comprise at least 350/o by weight in the resin / coal tar
blend as perASTM 2697.

7.7.4 When tested as ASTM 4541, the adhesion value shall not be less than 7 MPa.

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7.8 Two - Pack Polvurethane Finish l3l

7.8.1 Pack A shall be based on acrylic resin. lt can be pigmented with rutile titanium
dioxide, MIO or other appropriate colour pigments according to the specific
requirements.

Pack B shall be based on aliphatic isocyanate curng agent with appropriate film
forming additives.

7.8.2 An ultra-violet absorber shall be used for gloss and colour retention purposes.

7.8.3 The top coat shall be pure white (RAL 9010) or Aluminum (RAL 9006) or else as
required by KOC.

7.8.4 A semi or high gloss and colour retentive finish is requred.

7.9 "Zinc / Aluminum Free" lnorqanic Silicate Finish l3 |

Air curing zinc free inorganic silicate based coating; capable of withstanding
continuous high temperature (up to 500'C) and have excellent abrasion and
chemical resistance.

7.10 Hish Temoerature Aluminum Silicone Finish lg I

7.1 0.1 It shall be based on modified silicone, acrylic or polysiloxane resin pigmented
with leafing aluminium.

7.14.2 Minimum volume solids shall be 29o/o s per ASTM D 2697.

7,10.3 It shall be capable of withstanding continuous high temperature up to 5500C and


must be capable of "curing" to handle without severe damage at ambient
temperature.

7.11 Glass Flake Epoxv lg I

Glass Flake Epoxies shall be specified as per KOC Standard KOC-P'002 Part 2.

7.12 High Build Solvent Free Epoxv l3 |

7.12.1 It shall be two pack, High Build, Solvent free Epoxy, preferably amine adduct
cured.

7.12.2 The epoxy shall have excellent adhesion, chemical resistance and water
resistance.

7.12.3 It shall be self priming and compatble to apply UV resistant top coats.

7.12.4 The coating shall have a proven track history for being used for the protection of
offshore structures.

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7.13 Surface Tolerant Hiqh Build Epoxv l3 |

7.13.1 It shall be high build polyamine cured epoxy with barrier pigmentation.

7.13.2 The coating shall be capable to cure in low temperature conditions.

7.13.3 The coating shall be capable to be applied over poorly prepared surface, damp
surface or previously coated surfaces.

7.13.4 The coating shatl be tested and meet the requirements as given in the Table lV
of this Standard.

Table - lV : Testinq Requirements

st. Test Requirement Reference Standard


Acceptance Criteria
No.
ASTM D4060, CS17
1 Abrasion Resistance wheel, 1000 cycles, 1 kg < 80 mg loss
lod
2 Adhesion ASTM D4541 3 MPa
Direct lmpac-t
3 ASTM G14 20 in lb.
Resistance
4 Permeabilitv Ratinq ASTM D1653 0.154 mo/cm.
Rating '10 perASTM D610
for rusting & Rating 9 per
5 Salt Fog Resistance ASTM 8117,2000 hours
ASTM D1654 for corrosion.

7.14 Hot / Cold Spraved Aluminum Coatinqs I


g
I

7.14.1 The application procedure for Thermal Spray Aluminium shall be as per NACE
No. 12.

7.14.2 Based on molten aluminium or znc/aluminium metal sprayed on surfaces


prepared in accordance with BS EN ISO 22063.

7.14.3 Thermal spray aluminium coatngs shall be suitable for high temperature (up to
5500C surfacs with restriction). The sprayed metal shalf be silicone sealed for
temperatures up to 2500C.

7.14.4 The cold spray aluminium shall be high buld and capable to apply directly on
blast cleaned surface without any primer.

7.14.5 The coating shall be suitable for high temperatures up to 5500C.

7.14.6 The product shall cure to handle at ambient temperature.

7.14.7 The cold spray aluminum coating shall be tested and shall meet the following
requirements as given in the Table V of this Standard:


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Table - V: Testinq Requirements

sl. Test Requirement Reference Standard Acceptance Griteria


No.
1 Minimum volume solids ASTM D 2697 Minimum 600/o
Adhesion
2 (To blast cleaned surface, ASTM D 4541
Mnimum I MPa
sA 2.5).
4000 hou without Blisters or
3 Water Resistance ASTM D 2247
Rustinol
3000 hours wthout Blsters or
4 Salt Spray ASTM 8117
Rustino)
40 months exposure (No flm
5 Coastal xposure ISO 12944 i Cs-M defects)

7,15 Hot Dip Galvanizinq lal


7.15.1 The molten metal in the working volume of the galvanizing bath shall contain not
less than an average value of 98% zinc by weight.

7.15.2 The trace elements (aluminium, nickel, and tin) can be added to the galvanizing
bath only as part of a pre-alloyed znc feed, or can be added to the bath using a
master feed alloy to enhance the cosmetic appearance of the finished product.
However, the total impurities in the molten zinc shall not exceed the
requirements of ISO 1461 and shall be less than 1.5o/oby mass.

8.0 SURFAC.E PREPARATTON

8.1 General

B.1.1 All surface preparation activities shall be carried out only by those who are
certified after trade test by KOC lnspection & Corrosion Team as per KOC
Standard KOC-P-006. The qualified personnel shall be issued relevant
Qualification cards,

8.1.2 All fabrcation works including cutting and drilling of holes shall be completed
prior to surface preparation. ln special areas, however, preparation and priming
of structured steel members and piping may be approved by KOC prior to flnal
assembly.

8.1.3 Surface preparation shall preferably, for optimum coating performance, be


carried out by dry abrasive blast cleaning. Alternative techniques shall only be
applied in some circumstances as described in clause 8.7 of this Standard.

8.1.4 The surface preparation requirements for painting systems are indicated in the
painting schedules A-D - Appendix 3 of this Standard and shall be carried out as
detailed in the following clauses.

8.2 Workinq Restrictions

8.2.1 Weather Conditions

Surface preparation shall not be conducted in the following conditions

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a. When the relative humidity (RH) 85% or higher

b. Under adverse weather conditions, e.g. rain, fog, sandstorm, high wind velocity
(56 km/hr. or higher), high wave tide, high ambient temperature (>50"C) or
when such conditions are likely to occur prior to completion of the work (i.e.
abrasive blast cleaning).

8.2.2 Work Conditions

Field surface preparation shall not be conducted in the following conditions:

a. Outside daylight hours on exterior locations, unless permitted by KOC


Approved special lighting shall be arranged for night blast cleaning.

b. When the initial primer coat cannot be completed wthin four (4) hours of
surface preparation. Surfaces which remain uncoated for longer than this
period, shall be re-blasted prior to priming.

c. When adjacent areas or equipment are insufficiently protected from damage


or contamination by abrasive dust or debris.

d. ln areas close to painting operations, to prevent damage or contamination of


wet paint films by abrasive material.

8.3 Surface lmperfections Removal

8.3.1 Surface imperfections or irregularities shall be removed completely (made flush


or uniform) prior to blast cleaning. lmperfections shall be considered as follows:

a. Weld spatter and slivers shall be removed as per ISO 8501-3. Sharp or
rough welds shall be rounded and contoured. Any other observed defects in
welds and material should be referred to KOC for disposition.

b. Porosity (weld voids) shall be cleaned and filled with acceptable filler
material or closed over by a suitable mechanical method approved by
KOC.

c. Sharp or rough edges shall be rounded, chamfered or broken.

d. Such imperfections that appear after blast cleaning or acid pickling shall be
similarly removed. lf grinding is needed, checking of the remaining wall
thickness and KOC approval are required.

8.4 Surface Contaminants Removal

8.4.1 The metal surface shall be cleaned to remove any oil, grease, dirt, etc. by using
solvent and / or suitable emulsifying alkaline cleaners, followed by washing with
clean water or wet steam rinsing. SSPC SP 1 outlines these methods.

8.4.2 Degreasing by wiping the surface with solvent only is not recommended in
heavily ol / grease surface contamination, because this invariably leads to the

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deposition of a thin film of oil over wide area. The solvent / emulsifying agent
cleaned surface shall be allowed to dry before proceeding with further
preparation or painting.

8.4.3 Soluble salts on steel surface exposed to a salt laden atmosphere shall be
removed by washing or by any other suitable technique. Refer to clause 12.4.3
of this Standard for iron salts contaminant free testing.

8.5 Dry Abrasive Blast Cleaninq Practice lg I

8.5,I Dry abrasive blast cleaning shall be used to remove all coatings, rust and mill
scale and to achieve the required visual standard and surface profile defined in
the approved painting / coating schedules in Appendix 3 of this Standard.

8.5.2 Abrasive material shall satisfy the following requirements:

a. Abrasive material for mild / carbon steel preparation shall be of the following:

(i) lndustrial grade metal angular grit or shot (generally iron, aluminum, or
steel).

(ii) Less-dust generating abrasive media such as garnet, coal slag or plastic
granulates.

b, Sand, Copper Slag or Cadmium shall not be used as abrasive material


for blast cleaning.

c. On a blast cleaned surface, the abrasive shall not leave any dust
embedment greater than Grade 2 of ISO 8502-3. Checks on dust levels shall
be made at last once (1) per 100 m2 of prepared surface and a minimum of
three (3) checks per day during the progress of the work.

d. Abrasive for stainless steel substrate shall be non-metallic materials.

e. For manual blasting, contaminated and / or re-cycled abrasives shall not be


used.

f. The abrasives recycled using automated machines shall be tested for


chlorides & sulphates every eight (B) hours. The records for such tests shall
be maintained by the Contractor.

g. The abrasives shall not contain more than 300 ppm of sulphates.

h. The abrasives shall not contain more than 100 ppm of chlorides,

8.5.3 The selected abrasive material shall be in accordance with SSPC SP COM or
lso 8504-2.
8.5.4 Water Soluble Salts - The abrasive shall not have a conductivity more than 300
gSfcm. The test shall be carried out as follows:

DOC. NO. KOC-P-001 Page 23 of 50 REV.3

. The abrasive is mixed with de-ionized water, conductivity max. 1 lSlcm, in


the proportion 1:2, e.g. 50 cm3 abrasive to 100 cm3 water. The mixture is
shaken for five (5) minutes, allowed to settle for at least one (1) hour and
then shaken again for five (5) minutes.

Some of the water is decanted, the temperature is recorded and the


conductivity measured by a conductivity guge. lf the conductiv$ gauge
does not have any temperature compensation adjustment, the conductivity
should be converted to 20"C or measurement should be canied out at this
ternperature.

lf the conductivity exceeds 300 pSlcm the abrasive shall be rejected.

b. Abrasive material shall be dry and free from oil, grease, dust, salts and any
other impurities or contaminants as per ASTM D7393.

c. Abrasive materials shall be capable of achieving the required surface profile


without contamination of the substrate. To produce the required surface
profile, abrasive particle size shall follow the surface preparation
commentary of SSPC manual as necessary to comply with visual blast
cleaning standards mentioned in clause 8.6 of this Standard.

d. Abrasive material sample along with the test reports shall be provided by the
Contractor to KOC for approval. The Gontractor shall carry out a
demonstration to veriff that the requred cleanliness and profile is achieved
before commencing the work.

e. All abrasive materials shall be kept dry, and covered when not used.

8.5.5 The blasting equipment and technique shall comply wth the following
requirements:

a. The Contracto/s abrasive blast cleaning equipment shall satisfy KOC safety
requirements (See clause 6.0).

b. For field and shop blast cleaning, abrasive shall be carried by a jet of
compressed air through a hand-held nozzle. The compressed air supply and
volume shall meet the work requirement and shall be substantially free from
oil and water contamination. Traps and filters shall be cleaned regularly.

c. For blast cleaning of large horizontal surface areas, like tank roofs, bottoms
etc., a self contained vacuum last unit can be used. Such machines are
usually operated by remote compressed air or hydraulically actuated for
traction.

d. "Deadman handles" shall be fixed to the blast line as close as practical to the
blast nozzle and shall be held by the blast operator alone.

e. Nozzles used shall have a maximum orifice size of 9 mm and shall be of


venturi design. Nozzles shall be discarded once the orifice size increases by
more than two increments.

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8.5.6 Openings in vessels, piping, access fittings, nozzles, etc. shall be properly
protected against entry of abrasive material. All previously painted or galvanized
surfaces shall be adequately protected prior to commencing any blasting
operation.

8.5.7 Blast cleaned rusty surface (due to rain or condensation) and surfaces with
temporary holding primer, shall be re-blasted to the specified surface profile.
8.5.8 Surface blast cleaning to the specified surface profile shall extend a minimum of
150 mm beyond the area to be coated during the same day.

8.5.9 Surface blasting to the specified surface profile shall continue a minimum of 25
mm into adjoining previously coated surface. The edges of the previous coating
shall be feathered,

8.5.10 All prepared surfaces shall be cleaned from any dust / abrasive material
preferably by dry brushing and/or vacuuming with industrial vacuum cleaner.
Pressure air blowing is not permitted. Any surface showing signs of
contamination, after blast cleaning, shall be solvent cleaned and re-blasted.

8.5.11 The mill coating on the external surfaces of pipes coming in the
concrete pit may be removed prior to surface preparation. However, the
first 300 mm of the mill coating from the pit wall shall not be removed.
This area shall be sweep blasted for over coating.

8.6 Blast Cleaninq Standard

8.6.1 The surface profile height shall be in accordance with the requirement of
painting system. The measurement techniques of surface profile testing are
specified in ASTM A4417 or as per ISO 8503-5.

8.6.2 Blast cleaning shall be carried out to a visual standard in accordance with
NACE/SSPC/ISO 8501-1, either as Sa 3, or Sa 2% (lSO 8501-1) subjected to
the requirements of paint Manufacturer's data sheet. Reference shall be made
to these standards for photographs of equivalents to the mentioned qualities.

8.7 Restrictions on4lternatlve Techniques to Blast Cleaninq

Under the following circumstances, alternative surface preparation techniques


(like manual I power tool cleaning) can be canied out subjected to KOC
approval as below:

a. When dry abrasive blast cleaning s unsafe or any of KOC safe$ precautions
requirements cannot be met.

b. When there is a risk of damage to instrumentation, equipment (e.9.,


electrical, rotating, etc.)within the proximity of blasting operations.

c. Where there is a flammable atmosphere or similar condition present,


restrctions may be applied by KOC.

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d. Where blast cleaning is not practcal, e.g. for welds, edges, bolts, nuts,
corners, crevices etc. and for paint defects / damages repair.

B.B Power Tool Cleaninq

8.8.1 Power tool cleaning shall be to a visual standard in accordance with ISO 8501-1
St3/St2 or SSPC-SP3.

8.8.2 Where power tool cleaning is carried out, 100% of the surface shall be covered
using abrasive or wire type power discs. ln some locations which cannot
accommodate a power disk, e.g. welds, power impact tools shall be applied
(vibratory and rotary, needle guns, scrapers) followed up by wire brush cleaning.

8.8.3 Power tool cleaning shall extend a minimum of 25 mm distance into adjoining
coated surfaces.

8,9 Hand Tool Gleaninq

a. Hand tool cleaning may be used for cleaning rusted surfaces in some
circumstances as specified in clause 8.7 of this Standard and for paint
defects / damages repair.

b. Hand toolcleaning shall be to visual standard in accordance with ISO 8503-2


St2) which is equivalent to SSPC-SP2.

8.10 Acid Picklino fEtchino) Preparation

a. This method may be used by Contractors in some crcumstances and


locations as an alternative to blasting, provided that it is compatible with
paint system and approved by KOC.

b. When using this method, the surface shall be etched to a degree suitable for
the specifred coating system. Details on this method are specified in SSPC
sP8.

c, KOC Fire and Safety Regulations shall be adhered to when usng this
method.

8.11 Preparation of Stainless Steels

8.11,1 Stainless steels shall not be painted unless specified by the relevant equipment
data sheet. The surface specified to be painted shall be:

a. Thoroughly degreased using solvent cleaning or suitable emulsifying agent


and washed with fresh water to remove any contamination.

b. Blast cleaned to a surface profile of 25-50 rm (or as recommended by the


coating manufacturer) using chloride free abrasive such as aluminum oxide.
Hand or power tools using P60 grade paper may be used for surface
preparation, when grit blast cleaning is impractcal. (See clause 8.7).

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c. Protected from any further contamination by debrs produced during grit


blasting of adjacent carbon steel because embedded particles could promote
corrosion. Any observed contamination should be referred to KOC for
disposition.

d. Condition to set for coating - Leachable free chloride content in the coating
for SS shall be limited to 30 ppm.

8.11.2 Power tool cleanng equipment shall be canied out by using non-ferrous tools
for stainless steel.

9.0 PAINTING I COATING APPLICATION

9.1 General Requirements

9.1.1 All Painting, Coating or Lining activities shall be canied out only by those whom
are certified after trade test by KOC lnspection & Corrosion Team as per KOC-
P-006. The qualified personnel shall be issued relevant Qualification cards. I I I

9.1.2 Coating works shall be in accordance with the requirements established by this
Standard and the recommendations of the paint/coating manufacturer. Any area
not specifically covered, shall be in accordance with the principles and
guidelines set forth in the SSPC Manual.

9.1.3 The contractor shall provide all materials, tools, equipment and manpower
required for carrying out the works.

9.1.4 Surfaces, to be painted / coated, shall be inspected and approved by KOC


before any paintinglcoating is applied. This shall be after surface preparation
and between each subsequent coating. No primer or paint shall be applied
without KOC approval.

9,1.5 All surfaces, to be painted / coated, shall be dry and dust / contaminants free
before application of the first coat.

9.1.6 Whenever requested by the KOC inspection personnel, chloride / salt test shall
be carried by the Contractor, at the Contractor's cost, on the blast cleaned
surfaces of onshore / offshore facilities.

9.1.7 Precautions shall be taken to prevent painting from being applied to name
plates, couplings, shafts, valve stems, vent openlngs, gauge glasses, pressure
gauges, etc. Masking tape, plastic film or any other suitable material shall be
used, and all shall be removed after completion and acceptance of the painting
application,

9.1.8 All areas prepared for field welds shall be kept free from paint over a distance of
at least 100 mm from the weld centre, except welding/shop primer of 25 pm (1
mil).

9.1.9 A minimum of 100 mm around edges of abrasive blasted area shall be left un-
coated unless adjoining area can't be coated on the same day.

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9,1.10 Crevices created by two surfaces in close contact which cannot be protected by
painting should be mastic sealed on both sides with a sealant that is compatible
with the paint / coatings to be applied over it.

9.1.11 Any surface level pitting, which are accepted by the KOC inspection personnel,
shall be filled with epoxy fillers which are compatible with the coating system.
Such fillers shall be cured to hard prior to the application of further coats,
Minimum / maximum recoat windows published by the Manufacturer of the
epoxy filler must be strictly observed prior to over coating.

9.2 Selection of Painting and Coatinq Svstem

9.2.1 The selection of painting/coating system for particular applications and required
surface preparation shall be as per Appendix 3 of this Standard.

9.2.2 The coating shall be selected only from those Manufacturer's whom are
included in the KOC approved Vendors list.

9.3 Paint Mixinq and Thinninq

9.3.1 Mixing of paint to an even consistency, Manufacturer's mixing instructions,


environmental conditions and maximum pot life shall be strictly adhered,
especially for multi pack paints.

9.3.2 Mixing, by high speed mechanicaf agitators or rotary mixers, with flat blade or
Jiffy mixers and speed control, shall be used for containers larger than five (5)
litres. Hand mixing is permitted only for containers up to five (5) litres.

9.3.3 For painting syslems where pigment separation readily occurs e.g. zinc primers
or aluminium polyurethane top coat, continuous mixing at low speed shall be
carried out during application.

9.3.4 After thorough mixing, whenever requested by the KOC inspection personnel,
the correct viscosity of the paint shall be proved by measuring with an approved
flow cup. Such tests shall be carried out without any cost implications to KOC.

9.3.5 Thinners shall not be added to paint without KOC approval. Only the thinners
recommended by the paint Manufacturer may be used, even for cfeaning,

9.3.6 When thinning is permitted by KOC, paint Manufacturer's instructions shall be


strictly adhered and the accepted procedures mentioned in clause 7.3 of ASTM
D3276 shall be followed.

9.4 Restrictions on Paintinq

9.4.1 Weather Conditions

Painting shall not be conducted in the similar weather conditions of abrasive


blast cleaning as specified in clause 8,2,1 of this Standard and also under the
following condtions:

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a. when the metal surface temperature is above 500C or any such lower /
higher temperature limit recommended by the coating Manufacturer

b. under adverse weather conditions, e.g, rain, fog, sandstorm, high wind
velocity (56 km/hr. or higher), high wave tide or when such conditions are
lkely before the painting / coating has become dry.

9,4.2 Work Conditions

Painting / Coating shall not be conducted in the following work conditions:

a. where the specified surface finish is deteriorated at the time of applying the
first coat.

b. when adjacent areas or equipment are not sufficiently protected from paint
application.

c. outside daylight hours on exterior locations, unless permitted by KOC.


Approved special lighting shall be arranged for night painting,

9.5 Paint Apolication Practice

9.5.1 General

a. The specified surface finish, of all areas to be painted, shall be prepared


before applying the frst coat. lf required, surfaces shall be re-prepared to the
specified finish.

b. The paint shall be applied in a uniform manner and to the prescribed number
of coats and dry film thickness (DFT) given in Painting Schedules without
any runs, sags, marks or other blemishes.

c. Finished application, after all repair works, shall be uniform in color and
texture which shall give proper cosmetic and aesthetic appearance. Any area
which does not meet to this requirement shall be applied with a cosmetic
coat without any cost implication to KOC.

d. lntermediate and finish paintings shall be applied following final assembly of


component parts. For surfaces inaccessible for proper painting and / or
inspection, painting shall be applied prior to final assembly, The Contractor
shalldesignate the inaccessible areas and obtain KOC approval,

e. Where a multi-coat paint system is specified to be used, all intermediate


coats shall be of contrasting color to differentiate between coats. Colors for
intermediate coats shall refer to the Paint Manufacturer's recommendations.

f. Time intervals between coats shall be kept to the minimum recommended by


the Paint Manufacturer in order to prevent contamination between coats. ln
case contamination does occur, it shall be removed by washing with suitable
detergent solution and rinsing with clean fresh water.

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g. Stripe coat shall be applied by brush on all weld joints and irregular surfaces,
prior the spray application

h. To minimize the tme between abrasive blasting and priming, stripe coating
of primer coats may be carried out following spray application of the full
primer coat.

9.5.2 Airless Spray Application

a. Paint application by airless spraying shall be the preferred paint application


process. The use of air spray rnethod shall conform to the requirement of
coating system and shall be subject to KOC's approval.

b. Spraying equipment, guns, nozzle sizes, orifice sizes & shapes and pressure
ranges shall meet the work requirements and the Paint Manufacturer's
recommendations and shall be free from oil and water contamination.

c. All paint spraying lines and pots shall be cleaned and flushed before the
addition of new material. The last rinse or flush shall be done with the solvent
compatible with the paint i coating that will be sprayed after rinsing and
flushing.

d. Large surfaces shall be painted with passes in two directons at right angles
Spray overlap of the previous pass shall be by 50%.

9.5.3 Brush Application

a. Brush application shall be done on areas which cannot be properly sprayed


e.g. for welds, edges, bolts, nuts, corners, crevices etc., and for touch-up
maintenance where spray application is not practical.

b. Strpe coating of sharp edges, corners and welds can be done bqfore
apptication of finish paint to ensure that these areas receive the minimum
specified fi lm thickness.

c. Brushes shall be of a type, size and shape which permits proper application
of paint and meets the Manufacturer's recommendations. Natural bristle
brushes may be used only with solvent based paints / coatings. Synthetic
bristle brushes may be used with water based paints / coatings.

d. Brush application shall be done such that a uniform coat, with no deep or
detrimental brush marks, is obtaned. Runs and sags shall be avoided.

9.5.4 Roller Application

This method of application can be used, subject to KOC approval; for painting
small areas (less than t0m2) of relatvely flat steel surfaces and where high film
build is generally not to be attained. Roller application will ride over hgh spots
and miss edges and shall not be used for painting corners, bolt heads, etc.
Roller shall be chosen only if recornmended by the coating Manufacturer and
also the roller shall have the correct pile length, depending on the type of paint

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and degree of roughness of the surface. Roller shall not leave any residue over
the painted surfaces.

9.6 Priminq

9.6.1 Priming shall be done on the prepared surfaces before rusting occurs or withn
four (4) hours of blast cleaning, whichever is sooner. The only relaxation
allowable to this requirement is where the following three (3) conditions exist.

a. The work to be primed is fully enclosed.

b. The ambient temperature is above 30"C.

c. The relative humidity is below 50%.

9.6.2 All acid / de-scaled steel surfaces shall be primed as soon as the surface is
dried, neutralised and while it is stillwarm.

9.6.3 ln order to facilitate shop or site handling procedure, holding (shop) primer of 25
pm may be applied on steel surface. lf applied, however, this shall not replace
the function or plan of the film thickness specified for the priming coat. Shop or
welding primers shall be compatible wth the specified painting system.

9.6.4 Zinc silicate primers shall be applied to abrasive blasted surfaces only. ln order
to protect the porous primer film from salt or chemical contamination, it shall be
sealed with a tie coat as soon as practcal after complete curing has occurred.
The tie coat shall achieve sound adhesion to the zinc silicate primer and be
compatible with the finishing coat.

9.6.5 The thickness of zinc silicates and silicone coatings shall never be more than as
recommended in the Appendix (3) of this Standard. Any such items where the
coating thckness found outside the lirnits of Appendix (3), shall be re-blasted
and coated as per the specification on the Contractor's cost.

9.7 Shop Pgintins

9.7.1 Shop painting of items may be carried out by the Contractor as below, subject to
KOC approval.

a. The Contractor shall be responsible for paint condtion on arrival of such


items "on-site" and shall carry out any paint damage repair needed.

b. The Contractor shall comply with all aspects of this Standard and related
aspects of KOC Safety regulations.

9.7.2 Completely Fabricated ltems

a. Full surface preparation and painting works shall be done prior to


transportation to Ste,

b. All painted items shall be protected / packed to avoid any coating damage

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during transportation. Care shall be taken in handling and installation to


minimize coating damage.

9.7.3 Partially Fabricated or Non-Fabricated ltems

a. These items may be prepared / primed and further coated before


transportation to Site with the approval of KOC.

b. The painting used shall have enough durability to withstand the "on-site"
construction period before further painting occurs.

9.8 Repair of Damaqes / Defects

9.8.1 New painted surfaces are likely to require repair and maintenance in the
following cases:

a. For painted areas which have been damaged by other adjacent field
activities or during handling / transportation of off-site painted items,

b. For areas which suffer paint defects e.g. disbonding, insufficient film
thickness, blistering, etc.

9.8.2 The gpe of coating materials used for repair and maintenance shall be identical
to, or compatible with the original material.

9.8.3 The selection of suitable surace preparation shall depend on the size of areas
to be painted, the type of repair painting materials to be used and the Safety
regulations involved. The following order of preference shall be adopted and
subject to KOC approval.

a. Dry blast cleaning to the required visual standard (lSO Sa 21t2 or Sa 3) and
surface profile.

b. Powertool cleaning to bare metal standard SSPC-SP11 with a minimum 1


mil anchor profile.

c. Power tool cleaning to ISO standard St3 (only where blast cleaning is not
practical or permitted).

d. Hand tool cleaning to ISO standard St2 (only for minor touch up/repair work)

9.8.4 Surface preparation of defective or damaged areas shall be extended over the
surrounding sound coating for a minimum of 25 mm on all sides and a further 25
mm of sound paint work shall be lightly blasted to etch the surface. The edges of
the existing coating shall be feathered to obtain a uniform finish.

9.8.5 Surfaces to be painted that become contaminated with oil, grease, salts, etc.
shall be cleaned with a proprietary solvent i detergent solution and rinsed with
fresh clean water.

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9.8.6 Repair works shall be in accordance with the specified painting system to
restore the film thickness and shall cover the prepared surface and the etched
paint work. For colour coding and / or cosmetc reasons, it may be necessary to
extend the finish coat over a large surrounding area.

9.8.7 It is mandatory that all defective work shall be corrected to the satisfaction of
KOC representative. Work shall not be deemed complete until the foregoing has
been achieved,

9,8.8 Finished application, after all repair works, shall be uniform in colour and texture
which shall give proper cosmetic and aesthetic appearance. Any area which
does not meet to this requirement shall be applied with a cosmetic coat without
any cost implication to KOC.

10.0 MATNTENANCECOATTNG lel

10.1 Surface Preparation

10.1.1 Pressure wash down overall shall be carried out with detergent solution in water
to remove all traces of rust, oil, greases, salt and other contaminations, followed
by rinsing with fresh water.

10.1,2 Preference for the surface preparation method shall be s per clause 9.8.3 of
this Standard.

10.1.3 Prepared surface shall be free from any contamination. The salt / chloride level
shall be less than 10 pg/cm'.

10.1.4 When surface preparation is carried out by any other method than abrasive blast
cleaning, all the corroded areas and loose paint shall be prepared to Swedsh
Standard St, 3 or SSPC SP 3 ensuring a 50 mm overlap onto sound coating. No
loosely bonded coating shall be left afterthe surface preparation.

10.1,5 Feathering shall be carried out on the edges to have a smooth transition
between old intact coating and new coating,

10.1. lf the spot repair as per ISO 8501-2 shows more rusting i,e. greater than 10%
and a general rust grade of 5-G (ASTM D610), the entire coated area shall be
blast cleaned as per clause 9.8.3 (a) of this Standard.

10.1.7 Where coatng maintenance to stainless steel surfaces is requred, the entire
surface shall be thoroughly sweep blasted to remove flaking and poorly
adherent paint and to provide a surface roughness to any well-adhered paint
surfaces.

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10.2 ication - Maintenance

10.2.1 For any surface where blast cleanng has been carried out, the coating shall be
as for new construction and also applied as per clause 9.0 of this Standard.

10.2.2 The compatibility to the existing coating shall be checked as per ASTM D5064
by applying a small patch with the proposed coating on the existing coating prior
the commencement of actualjob.

10.2.3 Manually / power tool cleaned surface shall be coated as described in the
Appendix 3, system A1-6 of this Standard.

10.2.4 For items to be coated only for cosmetic appearance, the prepared surface shall
be only coated with Acrylic Polyurethane to a minimum thickness as specified by
the Coating Manufacturer.

10,2.5 Finished application, after all repair works, shall be uniform in colour and texture
which shall give proper cosmetic and aesthetic appearance. Any area which
does not meet to this requirement, shall be reinstated with a cosmetic coat
without any cost implication to KOC.

11.0 GALVANIZING IS I

11 .1 Surface Preparation

11.1 .1 Allthe items to be galvanized (internal & external) shall be blast cleaned to SA 2
lz as per ISO 8501-1. The surface profile shall be restricted to a maximum of 30
pm.

11.1.2 Surface preparation method and abrasives used for blast cleaning shall meet all
the requirements as mentioned in above clauses of this Standard.

1 1.1.3 Fasteners such as bolts, nuts and washers to be used for the assembly of
galvanised parts shall be hot dip galvansed in accordance with ISO 10684. The
threading of the bolts and nuts shall be cleared of excessive zinc after
galvanizing to ensure trouble free use.

11.1.4 Pickling: Dilute solutions of either hydrochloric or sulphuric acid (8-15 7o) shall
be used to provide a chemically clean metallic surface.

1 1.1.5 Fluxing: Steel shall be immersed in liquid flux (zinc ammonium chloride solution)
to remove oxides and to prevent oxidation prior to dipping into the bath of
molten zinc. The water used for this purpose shall not be brackish water.

11 .1.6 Painting of new galvanized surfaces shall be only for top coating purpose in
conformity wth system 81, D1-4 of Appendix 3 of this Standard. The surface
preparation method shall be carried out as follows:

a. The greasy film on the new galvanized steel surface and any other oil or
grease contamination shall be removed by using emulsifying agent.

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b. The surface shall be chemically etched for newly galvanized surface


(primed) by using proprietary T'wash solution. (refer to clause 7.5 of this
Standard).

c. Weathered surfaces shall be cleaned using wire brushng or sweep blasted


to remove all corrosion products or deposits and degreased with emulsi7ing
agent.

11.1.7 Other surface preparation methods may be used in accordance with ASTM D
6386 for painting new galvanized surfaces subject to KOC approval.

11.2 Galvanizinq Process

11.2.1 The temperature of the Molten Zinc Bath shall be maintained in the range 440"C
- 460'C and shall be recorded in lne with the process continuously.

11.2.2 The level of the Zinc shall be maintained throughout the process by adding
additional zinc to the bath.

11.2.3 Aluminium added to the bath shallnever be more than 0.150/o

11.2.4 The water used in the whole process shall be de ionized water,

11.2.5 The time to be kept in the hot bath shall be calculated prior to loading the
materials to the bath and recorded in the report format.

11.3 lnspection

11,3.1 A control sample for thickness testng shall be taken randomly from each lot of
all the hot dip galvanized items. When examined by normal corrected vision,
shall be free from nodules, blisters (i.e., raised areas without solid metal
beneath), roughness and sharp points (if they can cause injury) and uncoated
areas.

11.3.2 Cellular pattern of dark grey areas or some surface unevenness shall not be a
cause for rejection; also white or dark corrosion products - primarily basic zinc
oxide - formed during storage in humid conditions after hot dip galvanizing shall
not be cause for rejection, provided the coating thickness remains above the
specified minimum value.

11.3.3 Flux residues, lumps and zinc ash shall not be permitted. ltems that fail visual
inspection shallbe re-galvanized and resubmitted for KOC inspection.

11.3.4 A minimum of five (5) magnetic test readings shall be taken on 1000 mmz of
coated areas. The mean thickness value over the whole of such five (5)
readings shall be minimum 100 pm. However, this mean thickness of any item
shall never be more than 250 pm. Thickness measurements shall not be taken
on cut surfaces or areas less than 10 mm from the edges.

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11,3.5 A cross hatch test shall be carried out on the galvanized surfaces as and when
KOC will request. The galvanized surface shall withstand this test without any
peeling or flaking of the galvanizing.

1 1.3.6 The total uncoated areas for renovation shall not exceed Q.5 o/o of the total
surface area of a component. Each uncoated area for renovation shall not
exceed 10 cm2. lf uncoated areas are larger, the article contaning such areas
shall be re-galvanized. Renovation shall be by zinc thermal spraying as per BS
EN ISO 22063 or by an approved zinc rich paint. The galvanizing procedure
shall include the renovation procedure and the product intended to use for
renovation.

11.3.7 The Contractor shall arrange to provide access with required safety measures
for KOC inspection during at any stage of galvanizing process.

11.4 Repair

11.4.1 Any repair or renovation work canied out to the galvanized item shall be afrer
approval of KOC personnel.

11.4.2 A detailed procedure for the repair shall be submitted to KOC prior to
commencement of the job.

11.4.3 Damages due to welding shall be spot blast cleaned. However, small repairs
due to mechanical damages may be prepared with power tool.

11.4.4 Allowable repair shall be carried out only with high zinc content paints which
have a minimum znc dust content of 92o/o. The product used for this shall be
accepted by KOC,

11.4.s Aluminium paints shall not be used for the repair of galvanizing.

11.4.6 The final shade of the repair area shall have cosmetic match with the existing.
Top coat by acrylic polyurethane may be applied to match with the existing
shade.

12.0 INSPECTION AND TESTING

12.1 General Requirements

12.1.1 lnspection and testing at all stages of surface preparation and painting / coating
application shall be conducted by the Contractor prior to offering to the KOC
lnspection personnel. The Contractor shall provide all necessary inspection
equipment and perform such inspections as necessary to assure that the
paintng / coating complies with the requirements of this Standard.

12.1.2 All the inspectons by the Contractor shall be carried out by their coating
lnspector who is at least Level 2 certified by NACE I B-Gas or an approved
equivalent. ln additon, the coating lnspector shall possess KOC qualification
card after sitting for a written test as specified in KO Standard KOC-P-006.
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12.1.3 Surface preparation and painting / coating application shall be subjected to


inspection and approval at any stage by KOC.

12.1.4 KOC inspector shall have the right to inspect at all times any tools, materials or
equipment used in the performance of surface preparation and paint application
to ensure the compliance with the requirements of this Standard.

12.1.5 Abrasive material shall be inspected to ensure compliance with the


requirements of this Standard. (refer to clause 8.5.2)

12.1.6 Painting / coating materials shall be inspected to ensure compliance with the
requirements of clause 7.0 and the specified painting schedules (Appendx 3) of
this Standard.

12.1.7 KOC have the right at all times to draw samples of coating materials fuom Site /
Contractor stores and subject to laboratory test / analysis to veriff that the
supplied materials meet the minimum requirernent as set in this Standard. lf any
item faled to meet the requirement, all applied materials belonging to the same
batch shall be removed and reapplied with materials as selected by KOC
without any additional cost to KOC, including all costs incurred for the testing
borne by the Contractor.

12.1.8 Equipment for blast cleaning and paint application shall be inspected to ensure
the compliance with the requirements of this Standard (see clauses 6.3, 8.5.5
and 9.5) and paint Manufactureds recommendations.

12.2 lnspection / Testinq Equipment

12.2.1 The Contractor shall have the necessary equipment and tools for inspection and
testing of environmental conditions, surface preparation and painted / coated
surfaces. All this equipment shall be approved by KOC prior to starting any
work. The Contractor shall provide the calibration certificates for all measuring
and testing equipment for KOC review.

12.2.2 Following inspection / testing equipment shall have an EXTERNAL Calibration


Certficates.

a. Surface Profile Gauges

b. Dry Film Thickness Gauges

c. Pinhole / Holiday Detectors


d. Adhesion (pull off) Testers

e. lnstruments to monitor ambient conditions

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12.3 Environmental Conditions Testing

12.3.1 Prior to commencing any blast cleaning / paint application work, ambient
temperature, metal surface temperature and relative humidity (RH) shall be
measured and recorded every two (2) hours during the shift in the respective
formats Readings shall comply with clauses 8.2.1 and 9.4.1 of this Standard.

12.3.2 For works in confined areas, the oxygen deficiency and gas testing shall be
performed.

12.3.3 Other environmental conditions, e.g. wind speed, wave tide and sandy or rainy
weather, shall be checked before the commencement of any work.

12.4 Blasted Surface lnspection I Testinq

12.4.1 Visual lnspection

a. Metal substrate shall be checked to ensure spatter / protrusons removal,


cleanliness etc. prior to blast cleaning.

b. Blast cleaned surfaces shall be visually inspected (surface magnifier may be


used) to ensure the absence of all types of imperfections and contaminants
and for the conformance with the specified visual standard mentioned in the
painting / coating schedules, Appendix 3 of this Standard.

12.4.2 Surface Profile Testing


On dry blast cleaned surfaces the profile height shall be spot checked by means
of replica tape and a calibrated micrometer in accordance with NACE RP 0287
to ensure the compliance with painting schedule requirements.

12.4.3 Contaminants Free Testing

When requested by KOC, the following tests shall be carried out by the
Contractor without any cost impact to KOC.

a, Chloride test shall be carried out as per ISO 8502-6 & 9 on the blast cleaned
surfaces of onshore / offshore facilities. The chloride level shall never be
more than 10 pgm/cm2. The acceptance value shall remain the same unless
a lesser value is recommended by the coating Manufacturer.

b. The blasted surface shall be free of dust and contaminants which shall be
within ISO 8502-3 Grade 2.

12.5 Painted Surface lnspection I Testinq

12.5.1 Visual lnspection

All painted surfaces shall be visually inspected to ensure the absence of skips,
overspray, sags, foreign particles contamination, air pockets, drips, holidays and

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any CIther paint defects. The repair of damaged / defected coating shall be done
in accordance with clause 9.8 of this Standard.

12.5.2 Test for Curing of lnorganic Zinc Silicate Primer

a. Zinc silicate primed substrate shall be tested for adequate curing prior to
over-coating (see clause 9.6.4). The test shall be performed in accordance
with the requirements of ASTM D4752.

b. The zinc silicate surface shall receive 50 double rubs with a cloth wetted in
Methyl Ethyl Ketone (MEK). Traces of zinc deposited on the cloth shall not
exceed Grade 1 ofASTM D 4752.

12.5.3 Paint Film Thickness Test

a. The paint shall conform to the system and to the minimum film thickness as
specified in the painting schedules of this Standard.

b. The wet film thickness (WFT) shall be spot measured as an initial indication
of the expected dry film thickness (DFT). The measurement shall be in
accordance with ASTM D1212.

c. The DFT of individual coats and of the total painting system shall be
measured in accordance with ASTM D7091 or SSPC-PA2. There shall be at
least one (1) area each for horizontal, vertical and curved surfaces. For
internal painting in storage tanks, the film thickness shall be measured at
randomly selected areas.

d. A minimum of five (5) readings shall be taken in each area. Additional


readings shall be taken, if there is any change in personnel, application
equipment, spray nozzle size, thinning of the paint, etc.

e. The (DFT) shall be measured by using an approved coating thickness gauge


suitable for the given type of painting system and thickness rnge.

f. The gauge shall be calibrated prior any measurement. The calibration shall
be repeated at least once an hour if working on the same surface, and
before measuring film thickness on the insides of angles and at points nearer
than 15 mm from an edge.

12.5.4 Paint Adhesion

When requested by KOC, a spot adhesion test may be carried out using a
suitable Adhesion Tester. The paint adhesion recorded must be ai least equal to
the specified adhesion by the paint Manufacturer for the type of paint and or
system. The paint adhesion testing shall be in accordance with ASTM D3359 or
ASTM D4541.

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12.5.5 Holiday Detection (Porosity Check)

All coated metal surfaces shall be subjected to visual inspection for holidays,
pinholes and overspray. For special coatings where pinholes cannot be allowed,
a full scan holday test shall be done, using suitable equipment for each Wpe of
coating as high voltage can cause damage to coatings. The acceptable fevel of
pinholes shall be subjected to KOC approval. Holiday detection test shall be
carried out in accordance with NACE SPO188.

13.0 QUALITY ASSURANCE

13.1 The Contractor / Manufacturer shall operate quality systems to ensure that the
requirements of this Standard are achieved. The quality systems shall be
preferably based on ISO 9000 series of standards and the Contractor /
Manufacturer shall demonstrate complance by providing a copy of the
accredited certficate or the quality manual.

13.2 Verification of a Contractor's / Manufacturer's quality system is normally part of


the pre-qualification procedure and is, therefore, not detailed in the core text of
this Standard.

14.0 DOCUMENTATION

14.1 General

14.'1.1 All correspondence, drawings, instructions, data sheets, design calculations, or


any other written information shall be in English language, ln case of dual
languages, one language shall be English.

14.1.2 All dimensions, units of measurement, physcal constants, etc. shall be in Sl


units, unless otherwise specified.

14.1.3 All documents (texts, specifications, data sheets, etc.) shall be provided with
electronic files in the approved softrare (MS Word, Excel, AutoCAD, etc,).Any
design calculations shall be submitted in the approved and widely used software
agreed by KOC.

14.2 Work Proposal

The Contractor shall submit his proposal for all aspects of work, for the approval
of KOC prior to the commencement of any work. This will include the following:

a. lnformation on work location, materials selection, equipment to be used,


items to be coated, surface preparation, painting schedule to be used, etc.

b, Manufacturer's technical data sheet, material performance certificates and


test approvals shall be provided for each painUcoating product.

c. Material safety data sheets and safety precautions to be taken.


d, lnspection and test plans and procedures, and the equipment to be used

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e. Specific repair proposals to satisfy the requirements of clause 9.8 for both
extensive and minor repair.

14.3 Work Records / Reports

The Contractor shall operate a comprehensive recording / reporting system on


all aspects of the painting work including inspection / testing work. The data
shall be set out on painting work record I data sheet within 24 hours of carrying
out a specific work. Appendix 1 in this Standard shows a sample of this record /
data sheet.

14.4 Final Report

A report shall be submitted on completion of the painting works. The final report
shall include a summary on all aspects covered e.9., surface preparation,
painting systems used and inspection and testing records performed.

15.0 PANTING / COATING SCHEDULES

15.1 The painting / coating schedules (A-E) are attached to this Standard n Appendix
3. The requirements for surce preparation and painting / coating systems are
/
listed for categories of onshore offshore structure, equipment and other
facilities.

The painting / coatng schedules explained in Appendix 3 are:

a. Schedule A - External Painting / Coating Systems For Onshore Above


Ground Storage and Processing Equipment (All Static
Equipment(s), Saddles, Pipng, Valves...etc)

b. -
Schedule B Painting Systems for Onshore Structural SteelWorks.

c. Schedule C - Painting systems for Mechanical, Electrical and


lnstrumentation EquiPment.

d. Schedule D - Painting / Coating systems for Offshore Structure and


Equipment.

r6.0 G9LOR SCHEDULES

The finishing colors to be applied to various equipment and facilities shall be in


accordance with colors mentioned in color schedule of Appendix 2 of this
Standard. Selecting different colors is subject to KOC approval.

17.0 APPENDICES

Appendix 1 : Daily Surface Preparation / Painting Report


Appendix2: ColorSchedule
Appendix3 : PaintinglCoating Schedules

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APPENDIX 1 : DAILY SURFACE PREPARATION / PAINTING REPORT

ffi
DAILY SURFAGE PREPARATION I PAINTING REPORT
COMPANY: KUWAIT OIL COMPANY CONTRACTOR

PROJECT CONTRACT NO,

LOCATION DATE
PROCDURE NO.

ITEM REPORT NO.

Dicriptlon of Work

Wl Time
Dry Bulb Dew Pohl RH016 Steel Temp. lnslrumsnt lnslrum6l Callbratlofl
Bulb, Sltug

Surfac SrlUChlordo Altscft Tslex


Requlfad Achievad AplanCo Tal Surlcs Prolila so
Surfce Stendsrd
P16paration Tm6 Surface
(AMrPtl)
Preparaton

Typr'Grsde Of Abrasv Slza Cleanllness

Coatng Applicatjon Method A/S c/s BRUSH ROLLER OTHER

Coling Appliction i
Hrs. LeflUncoled ;
I rm

Appld Mixing
Prlmer lntcrmcd8le Flnal
Cor Ratio

PiNt Mnufac Thinner o


Color wFT Avg. DFT No.
of Thinner
Used luref Base Curno Aent

Holday / Pinhole lnslrumenl


Test
Vollage Used i
Used
Result i

lnspclon Comments

For Contrector For Koc


Signature
Name

Date

Abbrevialions : Prep - Preparalion Ay'S - Air lss Spray C/S - Convntonal Spray

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DCIC. NO. KOC-P-oo{ Page 42 of 50 REV.3

APPENDIX 2: COLOR SCHEDULES

Item Color Standard Remarks


Tanks, Pressure Vessels, Aluminum color shall be
Exchangers, Heaters Columns, RAL 9006 J RAL 901 O
Aluminum lWhite "Leafng" Grade
Skirts, Saddles and PiPing
Rotating Equipment BS 4800
Eleclrical/Mechanical quipment Grey Shade 10-A-3
lnstrumenttion ouioment
Ref6r to KOC-P-o17 for
Refer to Table 2
Ppe Wrks, Valves and Fittings BS 4800 color coding arrangemnt
KoC-P-017 and application for piping.

All valrcs/devices used for Over BS 381 C


pressure Protection (e.9., Safety Elue
Ref. No. 107
Valves).

BS 4800
Overhead Traveling Crane Yellow - red
Shadc 08-E-51

Struclural Steel Works Aluminum BS 4800

Hazards - Fire./Safety Systems Refer to Table 2 BS 381 C

Gas Cylinders (lndustrial) Refer to Table 3 BS 349

Gas Cylinders (Medical) Refer to Table 4 BS 1319

Safety Signs Refer lo BS 5378 BS 5378

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APPENDIX 3 :
PAINTING / COATING SHEDULES FOR.ONSHOBE AND
OFFSHORE STRUCTURES AND EQUIPMENT
l. External Paintinq /..Goatins Svstems for OJshqre Aove_9tound Storaoe T!ks and
Processinq Equipment (All Static Equipment Saddles, Pipinq. Valves...etcl
A'l: Non Fire Proofed / Uninsulated / Non Concrete Encased
MIn, DFT
9ystem/ Scope Speciflcatlon lMlcronl Remarks
Preparation:
Vsusl standard Sa 2 %, profile 35 - 50
pm
A 1-t I
Priminq:
Carbon Steel Up 70 The equpment which is being coated st
Zinc rich Epoxy
to 120oC.
lntermedats: vendor facility I\llAY propose better equivalent
Two peck High build MIO Epoxy 125 coatng system for KOC review & approval.
Finish:
This is applicable for all systems excpt 41.4.
2 Pack Acrylic PU based on Alphatic 50
lsocyanat CurinE Agont. Total 245
Ercpelelgn: . Primed surfaces to be fe of zinc salts prior to
Visual stsndard Sa 3, profile 5O ym finish coating.
A f-2
Prmina: . Water pressu to remove salts shall b6 usd
lnorganic Zinc Silicate 75 whenever requsted by Koc.
Carbon Steel
t2loC to 200oc
Finish: . Second coat to be appled as a mist prior to
High Temperature Acrylic modified Coat 25X2 succeeding coat.
Silicone. . lnorganic Zinc Silicte primed surface shall be
Total 125 tested for degree of cure prior to ovr cotng
(refer clause 12.5.2)
o The final Acrylic Silicone shall cure in mbient
cnditons.
Pregraton: . Alt6lntive pigments to Al shll be used in
Visuel stndard Sa 3, profile 50 lm zon 1 efees.
Prminq: r Primed surfaces to be free of zinc salts prior to
lnorganic Zinc Silicate 50
finish coaling.
A t-3 .
Finish: Second coat to be applied as a mist prior to
Carbon Steel
Hgh Temperature Silicone Aluminum 2x20 succeeding cot.
200oC to 400oC
Toral 90
. lnorganc Zinc Silicate primed surface shall be
tested for degree of cure prior to over coting
(refer clause 12.5.2)
o Silicone Aluminum finish coat MAY not be fully
cure below 170"C-
Prearation: . Thls type of coating shall be not used on
Visual standard Sa 3, profile 75 pm any service operating ln hazrdous area
Primino: zone 1.
A 1*4 Hot / Cold Al-Metal spray Aluminum Silicone shall be applied s sealer
CS / Low Alloy Finish: (onlv fer l-lot 4l Soraved 170 coat on the metal pores for smooth nd long
Steel 400"C to surfceg) life costing which shall be applied immedately
550'C 2y0 after metl spray.
High Temperature Silcone Alumnum
Totl 210 . Silicone Aluminum finish coat MAY not be tully
cure below 170'C.
Preparation:
Visual slandard Sa 2 %, profile 50 pm
. Follor cluse 8.1 I of KOC-P-001
. Stinless stel shall not be pinted /coatd
Priminc xcopt where speclfled by th relovant dat
Al-5 High build Epoxy - Polyamide adduct / sheet / Contract technical specfctlon.
Slinlss steel amine cured, without metallic 120 . Under no clrcumstancos shall Zinc
up to 120"c. pigmentation containng pants be usd over stanss
Finish: steel surfaces
2 Pack Acrylic Poly urethane basd on 70
Alphatc lsocynte CurinE Aoent, Total 190
P.repar?!iqrll
. Vsul standard St-3
A1-6 o Follow clause 10.0 of KOC-P-001
Mantnance First Coat:
6:oating System Surface tolrant, Two-pack High- Build 1?O
Cerbon Steel Epoxy
up ro 120"c. Finish:
2 Pack Acrylc Poly urethane based on 70
Alphtic lsocvanate Curinq Aoent. Total 190

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DOC. NO. KOC-P-001 Page 44 of 50 REV.3

A. External Painting/Coating Svstems for Onshore Above Ground Storaqe Tanks


and Processinq Equipment (AllStatic Equipment, Saddles. Pipino. Valves...etcl
A2 Fire Proofed / lnsulated / Goncrete Encased
Min. FT
Systen Scopo Speclfication Remarks
{Mlcronl
Prparation: a lntumescent type fre proofing materat
. Visual standard Sa 2 % may be applied aer zinc primer.
A 2-1 . Surface prolle 35-50 micron. However, the primer SHALL be
Carbon Steel Priminq: compatible wth the fre proofing material.
Up to 120"C. Zinc rich Epoxy 70 o Tie coal applied for fire proolng /
Finish: conrete encasing shall be compatible
Two-pack High build MIO Epoxy 1 25 with the existing top coat.
a For Offshore atmospherc zone, follow
Total 1 95 syslem D1-1.
Preparation: r Primed surfaces to be free of zinc salts
. Visual standard S 3 prior to next coat,
. Surface prolle 50 mcron . Second coat to be appled as a mst prior
Priminq: to full coating.
lnorganic Zinc Silioate 75 r lnorganic Zinc Silcate primed surface
Finish: shall be tesled for degree of cure prior to
High temperature Silicone Aluminum 2x25 over coaling.
A2-2 r lntumescent type fre proofing materal
Carbon Steel Total 125
Allemalive; may be applied afrer zinc primer.
120'C to 400"C
However, the primer SHALL be
Cold Spray Aluminum 170 compatbl wth the fire proofing material.
r Te coat applied for fire proofing /
conerete encasing shall be compatible
with the exsting top soat.
r For service below 170"C, the fnal coal
shll b Acrvlic Silcone.
Preoration: a Stalnless steel shall not be coated
. Visual standard Sa 2 % except where specfed by the levanl
. Surface Profile 50 pm data sheet / Contracl technical
A 2-3
. Follou clause 8.11 specilication,
Primino: a Under no circumstancet, Zlnc
Stinless steel 120 containing paintc shall be used for
High build epoxy for stainless steel
Up to 120"C. 70 stainless steel urfaces.
Finsh: 2 Pack Acrylic Poly urethane
based on Alphatc lsocyanale Curing olal 190
Agent

Preparation: a Leachable free chlord content in the


. Visual standard Sa 2 % coating shall nol be more than 30 ppm.
. Surlace Profile 50 lm
A21 . Follow clause 8.11
Stainless steel Coatinq :
> 120'C,
2 Coats of lnorganic Silicone based
2x25
coating without Zinc or aluminum
oiomenttion.

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DOC. NO. KOC-P-001 Page 45 of 50 REV.3

B. ONSHORE STRUCTURAL STEEL ITEMS

l. Grating, Ladders, Handrails, Fencing, Stainarays, Walkway, Stair Treads, Cable


Trays, Ducting and Platforms
2, General Concrete / Non Concrete Encased Structural Steel Work
Mn. DFT
Systm/ Scope Specifcation Remarks
{Mcronl
Hot dip galvanizing and Top coaling a Top coatng of galvanized surface may
. Hot dip galvanizng be required ONLY foTCOLOR CODING
Prepartion:
r Visual standard Sa 2 %
Coatinq:
Hot dip galvanize shall be carried out
n eccordence with ISO 1461 / ASTM
BI A 123
Ladders.
The minimunlcoating weight shall be
Platforms,
610 grams/m'surface.
Handrals, Star
reads, Open
For Color Coding,
Grid Flooring, PJeparaton:
Steel Gratng.
ln acordance with clause 1 'l .Oof this
Standard
First ea!
Surface tolerant, Trl,o-pack High-
Build Epoxy 120
Finish:
2 Pack Acrylic Poly urethane based 70
on Aliphatic lsocyanale Curing Agnt
in the required color. Total 't90

This syslem applicable only if the


Preparationi
followng conditions apply.
r Visual standard S 2 % a When galvanizing is nol specified by
Surface prolile 35 - 50 micron. the Conlract tecinical specification,
a2 Primin$ a On acceptence of Concession
Altemative to Zinc rich Epoxy 70
Request for not doing galvanzing
Galvanizing llen nedates:
due to the complex structure design.
(System) Two pack High build MIO Epoxy 125
70
While coatng for concrete encased
Finish:
slruclures, Top coat wlth Polyurethane
2 Pack Acrylic Polyurethane based
Total 265 shall be avoided.
on Aliphalc lsocyanate Curing Agent

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DOC. NO. KOC-P-001 Page 46 of 50 REV.3

C. PAINTING SYSTEMS FOR I/IECHANICAL. ELECTRICAL AND INSTRUMENTATION


EQUIPMENT

Items: Rotating Equipment (Pumps, Compressors, Motors, etc.), Electrical


Equipment and Equipment Supports

MN. DFT
System/ Scope Specification Remarks
lMicronl
r As for A1-1, A1-2, A1-3 and A2-2 systerhs Total painting system to be shop applied.
o Machinery and drivers, instruments& associated
valves may be finish coated in accordance with
ct Manufaclurr's standard coating system.
Pumps, r Manufactures should provide details of lhe
Compressors, proposed PAINTING.
Motors, Fans, . System for future maintenance and repair.
etc. r The pant system must be cpable of
withstanding the environmenlal condlions for
period of 10 years to Ri3, per BS 3900 H3 scale
of deoree of rustinq.
2 Preoaration: Total painlng system lo be shop applied.
Moving Parts: Msual standard Sa 3
Flywheel Surface prolile 35-50 micon
Shafis, Coatinq Svstern:
Couolinqs elc. Shall be as fur svstem A1-1
c3 I This type of equipment shall be prepared, r Manufacturer's standard shall be subiect
Electrcal primed &linished in accordance wilh lhe to KOC approval.
Equipment Manufacluret's stndard. o All panels must display a smooth fnsh
Motors, o The system must capable of withstandng the apprance, Hammered or stippled etc.
Switchgears, environmental conditions for period ol 10 years are not acceptable
Standard to Ri3, per BS 3900 H3 scale of degree of
Equipment, rusting.
Transformers I
Rectifiers
Control Panels
Prepralion: Housing to be finish coated in sellers
Visual standard Sa 2 % works.
Surface profile 3S50 micron r Sho fabrcated supports shall be pintd
Primino: in workshop.
Cf
Zinc rich Epoxy 70
Housng and
lntermediales:
Equipment
Twpack High- Build MIO Epoxy 125
Supports
Finish:
2 Pack Acrylic Poly urethane based 70
on Aliphatic lsocyanate Curing Agent
Total 265

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DOC. NO. KOC-P-001 Page 47 of 50 REV.3

D. PAINTING/COAnNG SYSTEMS FOR OFFSHORE STRUCTVBE & EqU-lPJltlEiNr


(EfERNAL SURFAcES -ATMosPHERlc zoNE. SPLASH zoNE AND SUBSEA)

Items: Structuralsteel, Tanks, Vessels, Piping, Valves, Plants Equipment

D1: Atmospheric Zone


Mln. DFT
System/ Scope Specification Remark
{Mlcron}
Dl-l Prearation: a Primed surfaces to be free of Zinc salts
CS Uninsulated Visual standard S 3, ptofile 50 pm prior to finish coating.
0'C upto 120'C. Primilo: Inorganic Zinc Silicate primed surface
Atmospheric lnorganic Zinc Silicate 75 shall be tested for degree of cure prior to
Zone lntermediates; over-coating (refer clause 1 2.5.2)
Two-pack High- Build Epoxy (2 coats) 2x125
Finish:
Acrylic 2 pack Aliphatic Polyurethane 50
Total 375
Df -2 Preoaration:
CS Marine Visual standard Ea 2lz
Steel and letlies Surface prolle 50 - 75 micron.
(Below main Primino:
deck level) 2 pack High Build Solvent Free Epoxy
Finish: 750
2 Pack Acrylic Poly urelhane based
on Aliphtic lsocyanate Curing Agent 70

Totat 820
Dr-3 Preparation:
CS Marine Vsual standrd Sa 2 %
Steel and jetties Surface profile 75 - 100 micron.
(Below main First coat:
deck level) Glass Flake Epoxy
Finish; 750
2 Pack Acrylic Poly uthane based 70
on Aliphatic lsocyanate Curing Agent
Total 57O
Dl{ Preparation:
Galvnized ln accordance with clause 8.12
steel slruclure Primnq:
Hndrail Zinc Phosphte Epoxy(2 Pack) 60
Finish; 2 Pad( Acrylic Poly urcthane
based on Aliphatc lsocyanate Curing 2x50
Aoenl 12 coats) Total 160
Dl-5 Preoaration:
Deck - Heavy Visual standard Sa 2 %
Duty Non- Slip $urlace profile 2!35 micron.
Priminq:
Zinc rich 2 pack Epoxy 50
Finish:
Slca sand filed modified Epoxy 3000
cladding covered with non-sparking
aggregate, sl reep away excess
Seal:
2 Pack Acrylic Poly uthane based 50
on Aliphatic lsocyanate Curng Agent,
semi oloss Total 31@
Prparation:
. Visual standard Sa 2'h
. Surface profile 25-35 micron.
D{-6 Prming:
Deck - Light Zinc rich 2 pack Epoxy 50
Duty Non- Slip Fnish:
Two pack epoxy covered with non- 250
sparking aggregate
Total 300

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DOC. NO. KOC-P-001 Page 4t of 50 REV.3

D2: Splash Zone

Min, DFT
Syrtem/ $cope Speciflcation Remarkg
lMicronl
D2-1 Preparation: Splash zone area wll be as defned by the
Carbon steel Visual standard Sa 2 % Gonlracl document.
Above L{T to Surface profile 75 micron.
under main Coatino Svstemi
deck. Rising Three coats of Polyamide Coal far 3x200
main Caissons / Epoxy
conduc{ors Total 600
D2'2 Preparalon: Same as D2-1
(Alternative) Visual standard Sa 2 Yt
Carbon steel Surface profile 50 - 75 micron.
Above LAT to Primino:
lhe spider 2 pack High Build Solvenl Free Epoxy
deck. Rising Finish: 750
main Caissons / 2 Pack Acrylic Poly urethane based
conduclors on Aliphatic lsocyanale Curing Agent 50

Total 800

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DOC. NO. KOC-P-00{ Page 49 of 5 REV.3

cKNowLEpGMNT
This Standard has been approved by the Standards Technical Committee (STC)
consisting of the followng:

Mr. Hamzah Ahmad Standards Team Chairman


Mr- Mahd. Emam lnsp^ & Corr, Tearn {S&E) Deputy Charman
Mr. S. Kumar Standards Team Secretary/Member
Mr. A. Unnkrishnan Standards Team Member
Mr. N. Ramanathan Major Projects lV Team Member
Mr. DanielPino Utilities Team Member
Mr. AbdulR. Al-Shamari lnsp. & on. Team (N&WK) Member
Mr. Haithem Aboughaith Gen, Projects Team Member
Mr. GopalMurti Opns. Tech, $vcs. (WK) Team Member
Mr. Mohd. Aslam lmadi Design Team Member
Mr. G. Unnikrishnan Design eam Member
Mr. Fahad Al-Qattan HSE $ystem Team Member
Mr. Abdulla Al-Yousef Project Mgmt. Team (NK) Member
Mr. Richard Arthur lnfo. System Planning Team Member

The revised draft of this Standard had been circulated to the KOC User Teams for review
and the responses were received from the following:

ENGTNEERINq ROUP H,S,.E*.gRpuP

Team Leader H$E (TS) Team Leader HSE Systems

Team Leader Design Team Leader H&E

Team Leader Construction

MAJOR PROJECTS GROUPS fI&II} t,l.r DIJ_S_TRTAL svcs : G Ro u P

Team Leader Project $upport Team Leader lnsp. & Corr. (N&WK)

AHMADTSERYTCES GROUP oFNS. SUPPORT GBg_UP (S&EKI

Team Leader Utilities Team Leader OTS (S&EK)

eam Leader Project Design Team Leader Gen. Projects

GAS Mc[{T...9Ro-uA EXPORT & MARNE qn{q. GROUP

Team Leader Gas Opns. {S&EK) Team Leader HSE {E&MO)

Team Leader HSE {Gas)

OPERATIONS GROUP {NKI SUPPORT SVCS. GROUF {NK}

Tearn Leader MSR (NK) Team Leader HSE (NK)

2
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DCIC. NO. KOC-P-001 Page 50 of 50 REV.3

suPPoRT SVCSj.GROUP {WK} SECURITY & FIRE GROUP

Team Leader HS (WK) Team Leader Fire

Task Force ,Fesponsible for Revision of this Standard I s I

The revision of this Standard (Rev.3) has been entrusted by the Standards Technical
Committee (STC)to the Task Force No. (TF-C/13) comprising of the following members:

st. Name of Task Force KOC Teams Responsibilities Tel. No.


No. Members
1 Mr. Abdul R. Al- lnsp.& Corr (N&WK) Task Force Tel. No. 66394
Shamari Leader
2. Mr. Mohd Emam lnsp. & Corr (S&EK) Member Tel. No.65254

3. Mr. Hasan Sabri lnsp. & Corr (S&EK) Member Tel. No. 65434

4. Mr. Amer Jaragh lnsp. & Corr (N&WK) Member Tel. No. 65428

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