Employer Doc. No.

NSRP Contractor Doc. No.

Complex Project Nghi Son Refinery and Petrochemical S-000-1274-0004V
Limited Liability Company
Nghi Son, Vietnam Rev. 0 Page 1 of 13

Employer Contract No.: , Contractor JOB Code: 0-6495-20 Date: 23/Apr/2014

Specification for Thermally Sprayed Aluminium

Unit No.: 000

Unit Abbreviation.: Not Applicable

Document Class: Z

Issue Purpose For Construction

Rev Date Page Description Prep'd Chk'd App'd

0 23/Apr/2014 All Issued for Construction J.M T.K T.K

A 30/Oct/2013 All First Issue J.M T.K T.K

Operation Centre JOB Code: Operation Centre Doc. No.:

Responsible Company Prepared by Checked by Approved by
JVD J. Miyashita T. Kiso T. Kiso

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CONTENTS

1. SCOPE .......................................................................................................................................................3
2. REFERENCE ..............................................................................................................................................3
3. DIFINITION .................................................................................................................................................4
4. CONFLICTS, EXCEPTIONS AND SUBSTITUTIONS................................................................................4
5. GENERAL REQUIREMENT .......................................................................................................................4
6. ADDITIONAL REQUIREMENTS TO ISO 2063:2005 .................................................................................5
7. REPAIR.......................................................................................................................................................8
8. HANDLING OF TSA APPLIED ITEMS .....................................................................................................10
9. PRE-QUALIFICATION TESTING FOR APPLICATOR AND OPERATOR ..............................................10
10. DOCUMENTATION ..................................................................................................................................13

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1. SCOPE
1.1 This document is supplemental specification for:

“ISO 2063:2005: Thermal spraying -- Metallic and other inorganic coatings -- Zinc,
aluminium and their alloys”

for the Nghi Son Refinery and Petrochemical (NSRP) Complex Project .

1.2 The additional requirements to ISO 2063:2005 are summarized in chapter 6 of this
specification.

1.3 Pre-qualification testing for Applicator and Operator are specified in chapter 9 of this
specification.

2. REFERENCE
Unless otherwise noted, the latest editions and revisions of the following standards shall be
used to supplement and define the intentions and requirements of this specification.

2.1. International Standard

2.1.1 ISO Standards

 ISO 2063:2005 : Thermal spraying -- Metallic and other inorganic coatings -- Zinc,
aluminium and their alloys

 ISO 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

 ISO 14918:1998 : Thermal spraying -- Approval testing of thermal sprayers

2.2. Project Specification

 S-000-13A0-0001V: Specification for Painting

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3. DIFINITION
3.1. Employer : the limited liability company formed by Vietnam Oil and Gas
Group, Vietnam; Idemitsu Kosan Co., Ltd, Japan; Kuwait
Petroleum Europe B.V., Netherlands; and Mitsui Chemicals,
Inc., Japan, with the purpose of developing and operating an
integrated refinery and petrochemical complex and its
associated infrastructure and utilities and offsites in Nghi Son,
Tinh Gia District, Thanh Hoa Province, Vietnam

3.2. Contractor : the Joint Venture formed by JGC Corporation, Chiyoda

Corporation, GS Engineering & Construction Corporation, SK
Engineering & Construction Co., Ltd., Technip France, and
Technip Geoproduction (M) Sdn. Bhd., for the execution of the
NSRP Complex Project

3.3. Applicator : a party who carried out all or part of TSA application work at
Shop and/or Field

3.4. Operator : a person who employed by Applicator and carried out TSA
application work at Shop and/or Field

3.5. DFT : Dry Film Thickness

3.6. TSA : Thermally Sprayed Aluminium

4. CONFLICTS, EXCEPTIONS AND SUBSTITUTIONS

All conflicting requirements between the Applicator’s procedure and the requirements
contained herein shall be brought to the attention of Contractor for resolution. All
exceptions, deviations and substitutions to the requirements specified herein and
referenced documents shall be submitted in writing to Contractor for Employer approval.

5. GENERAL REQUIREMENT
5.1 This specification defines the minimum requirements for materials, surface preparation,
application, inspection and testing of TSA.

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5.2 Requirements of ISO 2063:2005 and additional requirements specified in this

specification shall be conformed to the activities of TSA.

5.3 Applicator’s supervisor shall be familiar with the requirements of this specification and
all other information pertinent to the work.

5.4 It is not practical to describe requirements for surface preparation application for every
component that may be encountered. Where requirements beyond those described in
this specification emerge, Contractor shall make recommendations and request
Employer approval in a timely manner.

5.5 TSA process and related equipment shall be successfully proven and suitable to
achieve requirements specified in this specification.

5.6 TSA shall only be performed by pre-qualified Applicator and pre-qualified Operator by
Employer in order to demonstrate satisfactory performance prior to TSA application for
production.

5.7 Applicator shall submit Standard TSA Operating Procedure covering all aspects of
surface preparation, TSA application, and inspection and testing to Contractor for
approval and Employer’s pre-qualification

5.8 Unless otherwise specified, Applicator shall furnish all labor, supervision, Employer
approved materials, tools, equipment necessary to perform the surface preparation and
TSA activities specified in this specification.

5.9 Employer’s and Contractor’s inspectors shall have the right to reject any equipment or
work that does not conform to Employer approved specification.

5.10 All work performed by Applicator shall be subject to inspection by Contractor and
Employer or their designated inspector.

6. ADDITIONAL REQUIREMENTS TO ISO 2063:2005

The paragraph number specified in this chapter/section refers to the same paragraph in ISO
2063:2005.

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6.1. Chapter 5, page 3

6.1.1 (ADD)
Al99.5 shall be used as thermal spray material.
6.1.2 (ADD)
Minimum local thickness shall be 250 microns.

6.2. Section 6.1, page 3

(ADD)
Roughness of surface shall comply with Applicator standard.

6.3. Section 6.4, page 4

6.3.1 (ADD)
The sealant shall be heat resistant silicone aluminium which shall tolerate maximum
operating temperature of equipment item or piping subject to TSA.
6.3.2 (ADD)
The sealant shall be thinned, mixed, and applied in accordance with coating
manufacturer’s written instructions.
6.3.3 (ADD)
DFT of coat of the sealant shall be minimum 20 microns.
6.3.4 (ADD)
Metallic shine/gray color of the coating manufacturer standard is acceptable for the
heat resistant silicone aluminium.

6.4. Section 6.5, page 4

(DELETE)

All sentences of section 6.5

6.5. Section 7.1.4, page 6

(ADD)

Applicator shall propose number and locations of thickness test points to Contractor
for review and approval.

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6.6. Chapter 8, page 6

(ADD)

All inspection and testing results shall be recorded in Contractor approved format,
and shall be maintained by Applicator.

6.7. Section 8.1, page 6

(ADD)

Applicator shall carry out DFT measurement of TSA and coat of the sealant by
suitable method specified in sections 8.1.1, 8.1.2 or 8.1.3.

6.8. Section 8.2, page 7

6.8.1 (ADD)

The adhesion test shall be carried out in accordance with section A.2 of Annex A of
ISO 2063:2005.

6.8.2 (ADD)

The adhesion test shall be carried out by “flat sample test panel”. The test panel shall
satisfy the following requirements:

 The test panel shall be prepared for each equipment item or piping subject to TSA.
Such test panel shall be made from similar material as the area subject to TSA,
and shall have a surface area of at least 225cm2(=150 mm x 150mm).

 The test panel shall be blast-cleaned and thermal sprayed at the same time and
manner as the comparison equipment item or piping.

 The sealant shall not be applied on the test panel.

 The test panel shall be labeled in such a way as to permanently identify the test
panel and the comparison equipment item or piping.

 One test panel per one Operator per one day (= 1panel/1Operator/1day) is
acceptable, unless otherwise specified. Extent of actual TSA application shall be

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marked and recorded for each test panel represented on drawing with
identification number, working date and Operator name to ensure inspection
traceability.

 The test panel shall be retained for a period of one year after delivery of the
equipment item or piping, and shall be available for inspection by Contractor as
required.

6.8.3 (ADD)

Three adhesion tests shall be performed on each test panel.

6.8.4 (ADD)

All three adhesion tests shall meet or exceed 7.0MPa.

6.8.5 (ADD)

If any of the adhesion value is less than 7.0MPa, re-adhesion tests shall be made at
random on the actual TSA surface of equipment item or piping.

6.8.6 (ADD)

All random re-adhesion tests shall meet or exceed 7.0MPa; otherwise the failure
area of equipment item or piping shall be repaired in accordance with chapter 7.

7. REPAIR

Applicator shall submit repair procedure which follows the following repair cases to
Contractor for approval.

7.1. Repair Material

7.1.1 Repair shall be carried out by the following materials:
 TSA
 Corrosion resistant coating intended for cyclic temperature service, such as
Intertherm 751 CSA or equivalent.
7.1.2 The corrosion resistant coating shall satisfy the following requirements:
 The coating shall tolerate maximum operating temperature of equipment item or
piping subject to TSA.

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 The coating shall have UV resistance in case the coating is used at un-insulated
condition.
 In case corrosion resistant coating is selected, application of sealant is not
required.
 Color of the coating shall be the coating manufacturer standard metallic shine or
gray.

7.2. Thin Thickness

7.2.1 Area of thin thickness shall be overcoated with additional TSA coating or the corrosion
resistant coating. This coating shall be applied while the surface is clean and dry. In
case corrosion resistant coating is selected, surface preparation method shall follow
the coating manufacturer’s instruction.
7.2.2 For both repair cases, specified thickness in this specification shall be totally
maintained.

7.3. Repair of TSA - Exposed Substrate Surfaces

7.3.1 If damage to coating extends to substrate surface, then the repair area shall be
blasted in accordance with this specification in case repaired by TSA. In case
corrosion resistant coating is selected, surface preparation method shall follow the
coating manufacturer’s instruction.
7.3.2 Care shall be taken not to damage adjustment coating except for a light feathering of
the edges of the coated area over a distance of 50mm.
7.3.3 Application of coating to repair areas shall be in accordance with requirements of this
specification in case repaired by TSA. In case corrosion resistant coating is selected,
application of the coating shall follow the coating manufacturer’s instruction.
7.3.4 The coating shall overlap onto the existing feathered coating edges to ensure that the
specified thickness shall be totally maintained.
7.3.5 If required, the sealant shall be re-applied over the whole area affected by blasting and
coating application.

7.4. Repair of TSA - No Exposed Substrate Surfaces

7.4.1 Areas of visible damage to TSA not exposing the substrate shall have their remaining
coating thickness checked.

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7.4.2 If the measured thickness is lower than the specified minimum, then if needed the
sealant must be removed, and TSA re-applied in accordance with requirements of this
specification. In case corrosion resistant coating is adopted, the coating shall be
applied in accordance with the coating manufacturer’s instruction.
7.4.3 For both repair cases, specified thickness shall be maintained.

7.5. Repair of Coat of Sealant

7.5.1 Repairs to damaged coat of sealant shall require cleaning of the surface with
detergent wash and hard bristle brushes, followed by through drying.
7.5.2 Visible oil or grease shall be removed in accordance with SSPC SP-1.
7.5.3 The affected area shall then be roughened by light hand sanding, without removal of
the TSA coating.
7.5.4 The sealant shall then be applied according to manufacturer’s instruction of the
sealant selected.
7.5.5 Specified thickness of coat of the sealant shall be maintained.

8. HANDLING OF TSA APPLIED ITEMS

To avoid damage when handling TSA applied items, the following special precaution
shall be taken:

 The sealant shall not handle until the coating materials is thoroughly dry.

 TSA and sealant coated surfaces shall be protected against shocks and blows.

 TSA and sealant coated productions shall be properly handled to avoid cracking,
peeling or wrinkling.

 TSA and sealant coated items shall be properly protected during its transportation
and storage.

9. PRE-QUALIFICATION TESTING FOR APPLICATOR AND OPERATOR

9.1. Applicator pre-qualification

9.1.1 Applicator shall submit Standard TSA Operating Procedure that controls application,
inspection and testing to Contractor and Employer approval. The Employer approval
shall be identified as pre-qualified by Employer.

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9.1.2 The Standard TSA Operating Procedure shall include the information of sections A.2,
A.3 and A.4 specified by Annex A of ISO 14918:1998.

9.2. Operator pre-qualification

The requirements for pre-qualification testing of Operator shall conform to ISO

14918:1998 and additional requirements specified in this section.

The paragraph number specified in this section refers to the same paragraph in ISO
14918:1998.

9.2.1 Section 3.1, page 2

(CONDITION)

The word “thermal sprayer” shall be deemed as “Operator”.

9.2.2 Section 3.2, page 2

(CONDITION)

The word “examiner or examining body” shall be deemed as “Employer” or “Contractor”.

9.2.3 Section 4.1, page 2

(ADD)

The pre-qualification testing shall be carried out prior to any work.

9.2.4 Section 5.4, page 4

(DELETE)

The thermal spraying and testing of the test pieces shall be witnessed by the certifying
body.

(REPLACED WITH)

The thermal spraying and testing of the test pieces shall be witnessed by Contractor.

9.2.5 Section 6.1, page 5

(DELETE)
The thermal sprayer shall satisfactorily complete a test covering the appropriate coating

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process, application method and material. The written test should be prepared by the
certifying body. For particular aspects to be tested, see Annex A.
(REPLACED WITH)

The thermal sprayer shall completely understand contents of the Standard TSA
Operating Procedure.

Job knowledge test may be carried out by means of oral examination based on the
Standard TSA Operating Procedure by Employer or Contractor as necessary.

9.2.6 Section 6.2, page 5

9.2.6.1 (DELETE)
The thermal sprayer shall be tested to determine whether he has the practical skills
necessary for the thermal spraying procedure, as detailed in the specific acceptance
criteria (according to Annex A and Annex B)
(REPLACED WITH)
The thermal sprayer shall be tested to determine whether he has the practical skills
necessary for the thermal spraying procedure in accordance with section B.1 of
Annex B.
9.2.6.2 (ADD)

Material specified in section 6.1.1 of this specification shall be used for the practical
test.

9.2.7 Section 9.2, page 6

(ADD)
Test records shall be submitted to Contractor. Template of the certificate shall refer to
Annex C of ISO 14918:1998.

9.2.8 Adhesion test - B.1 of Annex B, page 11

9.2.8.1 (DELETE)
An adhesion test shall be performed in accordance with EN 2063.
(REPLACED WITH)
An adhesion test shall be performed in accordance with requirements of sections
6.8.1, and 6.8.3 of this specification.
9.2.8.2 (ADD)

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Acceptance criteria for the adhesion test shall follow the requirement of section 6.8.4
of this specification.

10. DOCUMENTATION
10.1 Applicator shall submit the following documents to Contractor:

 Standard TSA Operating Procedure (for Contractor approval and Employer

pre-qualification)

 Repair procedure

10.2 Applicator shall submit detailed records to Contractor for review. As a minimum each
record shall be individually and uniquely numbered and shall contain, but not limited to,
the following information:

 Test record of Operator pre-qualified

 Inspection and testing results which cover each equipment item or piping subject to
TSA

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