KOC-P-001 R2 Painting and Coating of Metal Surfaces New Construction

7/21/2019 KOC-P-001 R2 Painting and Coating of Metal Surfaces New Construction

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NO

KOC-P-001

KUWAIT

OIL COMPANY

K.S.C.)

STANDA RDS PUBLICATION

KOC

STANDARD

FOR

PAINTING

AND

COATING OF

METAL SURFACES

-

NEW CONSTRUCTION

DO C. N O. KOC-P-001

STANDARDS lVlSlON



KOC STANDARD

FOR

PAINTING

AND COATING OF

MET L SURFACES NEW CONSTRUCTION

DO C. N O . KOC P 001

ISSUING AUTHORITY:

STANDARDS DIVISION



TABLE OF CONTENTS

FCrcWORD

S OPE

APPLICATION

TERMINOLOGY

REFERENCE CODES AND STANDARDS

ENVIRONMENTAL CONDITION

HEALTH, SAFEN AND ENVIRONMENT

PAINTS COATING MATERIALS

SURFACE PREPARATION

PAINTICOATING APPLICATION

INSPECTION AND TESTING

QUALITY ASSURANCE

DOCUMENTATION

PAINTINGICOATING SCHEDULES

COLOUR SCHEDULE

APPENDICES

APPENDIX

I : Q A I ~ N G

ECORDDATA

SHEET

APPENDIX

2A

COLOUR SCHEDULE Table

1

APPENDIX 8

:

COLOUR JDENTlFlCAlION FORHAZARDS

AND FIREISAFETY Table 2

APPENDIX

2C

COLOUR IDENTlFlCAT ON OF

GAS

CYLINDERS OR INDUSTRIAL GAS

VIDE

BS 349 Table 3

Page No

6

6

6

8

10

11

13

16

22

27

30

3

31

32

35

36

7



DOC O.

KOC-P-001

Page

4

of 55

REV.

2

APPENDIX 2 D

APPENDIX 3 A

APPENDIX

30

APPENDIX 3C

APPENDIX

3D

APPENDIX 3E

COLOUR IDENTIFICATION FOR MED ICAL

GA S VIDE

BS 1319 Table 4

SCHEDULE A EXTERNAL PAINTING1

COATING SYSTEMS FOR ONSHORE

STORAGE A N D PROCESSING EQUIPMENT

SCHEDULE B PAINTING SYSTEM S FOR

ONSHORE STRUCTURAL STEEL WOR KS

SCHEDULE C PAINTING SYSTEMS FOR

MECHANICAL, ELECTRICAL AN D

INSTRUMENT ATION EQUIPMENT

SCHEDULE D PAINTING OATING

SYSTEMS FOR OFFSHORE STRUCTU RE

EQUIPMENT (EXTERNAL SURFACES -

ATMOSPHERIC

ZONE,

SPLASH

ZONE

SUB

SCHEDULE

E

NTERNAL PAINTING

SYSTEMS FOR STORAGE AND

PROCESSING EQUIPMENT

S E A



FOREWORD

This docume nt KOC Standard for Painting and C oating of Me tal Surfaces

-

Ne w

Construction has bee n amended t o incorporate the several changes occurred since

.

its first publication (Rev.1) in 1995 Funher,

it

has been update d in line wrth

Preparation Procedure for Generating KOC Standards Recommended Practices

(KOC-A -001). Thus the docum ent (Rev.1) was superseded and withdrawn .

This revised Standard

(

Rev.2

)

has been approved b y th e Standards Technical

Comm~ttee STC

)

and t he Standards Division for publication wh ich is ult~ ma tely

intended for use throug hout th e corporate engineering and operational fun ct~ on s f

Kuwait Oil Company.

This Standard sets out t o achieve the follow ing objectives:-

6)

To esab ltsh the basic technical requirements for surface preparation, pa int ~n g

maierials, meth ods of application and inspection/testing of protective external

internal coating tpainting of metal surfaces abovegro und in oil, gas and sea

water facilit ies and related utilities under bo th onshore offshore conditions.

b

To provide th e general technical guidance for developing projec t specifications

in order t o achieve reliability, quality and safety in an economical m anner.

C)

T o set our clear requirements t o mon itor compliance in design, material

seiect~ on, pplcation, inspection testing w ith a contract.

d T o maintain the KOC requirements of safety and environmental protectio n

established by UO egulations and procedures.

Feedback as we ll as any c omm ents or suggestions derived fro m the application of th is

Standard

at

any stage of engineering, purchase or field application are invited and

should be directed to:

Supdt. Standards Division

(Chairman, Standards Technical Cornminee)

Engineering G roup,

K.O.C.

P.O.

Box 9758, Ahmad i 610 08

State

of

Kuwait.

The amendment

of

th is Standard is acknowledged t o the Task f o r c e (TF-PC101

comprising of th e follow ing members:-

Mr. S. Kumar - Standards Division

Dr. Muay yad Aj jawi

-

Ex)

Standards Division

-



SCOPE

This Standard specifies the minimum basic requirements for surface

preparation, coating materials, me thod of application and inspection/testing for

pro tecti ve ex tern al a nd wher e applicable, internal paintinglc oating

of

metallrc

surfaces above ground oil, gas and sea water facilrties and related utilities.

This Standard covers the paintinglcoating for b ot h ne wl y constructed onshore

and offshore facilit ies.

It

also covers the repair o f defects or damages t o the

ne w painted i tems.

The internal linings (Gunite Fibreglass) of tanks and vessels are covered in

separate docu men ts KOC-P-002, Pan s respectively.

Th is Standard is no t applicable t o buried pipelines and subsea lines, decorative

parnts for non-metal surfaces areas (concrete, masonry, w ood , etc .), freld t r ~ a l

of n ew ly developed pa ~ntrng /coating ystems.

APPLICATION

The materials and equipm ent for surface preparation, paint and coating

app lcati on and inspectionltesting, shall con form t o th e requirements of this

Standard and the referenced standardsk odes mentioned herein.

Any except ions or deviations fr om this Standard, along w it h their merits

justif ication, shall be brought t o the attention of KOC's Controll ing Department

for their review , consideration and amendm ent by Standards Division (if

required).

Compliance w ith this Standard does not of i tself confer imm unity fro m legal or

statutory obligations.

TERMINOLOGY

Definit ions

For th e purposes of this Standard, t h e following definitions apply:-

Abrasive

Natur al or sy nthetic solid m aterial used

as

a medium

in

abrasive blast-cleaning.

Grit

te rm used

to

describe

the

angular or irregularly shaped particles o f abrasives

used.

<



Shot

te rm used t o describe th e spherically shaped panicles

of

abrasive used for

blast cleaning.

Comparator

A

specimen surface, or surfaces,

of

known average profile, representing a

panicular abrasive blast-cleaning process.

Coat

A

continuous layer

of

a coating material that results fr om a single application.

Cure

The chemical reaction resulting in the fina l polymerized produc t in the

psin1 coa;~ng

system.

Discontinuity

(Holiday

void, crack, thin spot, foreign inclusion or contamination in the coating film

that significantly lowers the dielectric streng th of the coating.

ry Film

Thickness

The

dry

film

thickness of paint is the thickness of p aint wit hou t solvent and is

measured by f i lm thickness gauge expressed in micr on

(10 00 microns

equivalent to 1mm .

Pot life

The elapsed t ime with in which

a

coating can be effectively applied after all

components of coating system have been thoroughly m ixed.

Rust

grade

degree of rusting)

Classification describing t he degree of

rust

formation

on

a

steel surface prior t o

cleaning.

Atmospheric Zone

Th e par t o f an offshore structure above th e splash tone .

Splash Zone

The zone of the structure that is sfternately

in

and out of th e water because of

th e

influence of

the

astronomical tides, w inds an d

sea

waves.



DOC

O.

KOC P 001 of

55

REV

2

Submerged zone

The zone that extends downward from the splash zone and include that

structure below the mudline.

Surface Rofile

he micro-roughnessof a surface, generally expressed as the average height of

ye major peaks relative to the major valleys.

Abbreviations

KOC Kuwait Oil Company K.S.C.)

CS Carbon Steel

DFT

Dry Film Thickness of Paint)

WFT Wet Film Thickness of Paint)

M

0 Micaceous Iron Oxide

RH Relative Humidity

LAT Lowest Astronomical Tide

REFEREN E

CODES AND STANDARDS

Conflicts

In the event of conflict between this Standard and the standardskodes

referenced herein, or other contractual or purchase requirements, the most

stringent requirement shall apply, unless otherwise specified.

List of Standards, Codes

and

Specifications

The latest edition of the following standards, codes and specifications shall

apply

National International Standards

Paintin~Coat ing General

BS 49

Identification of the Contents of Industrial Gas Containers.

BS 381C

Specification for

olour

for Identification, Coding and Special

.

Purposes.



D O C . N O . K O C P 0 0 1

of

REV 2

Specification for Hot-dip Galvanized Coatings on lron

a n d

Steel

Amcles.

Specifcation for Identification of P~ pel lnes nd Servic es.

Specification fo r Bitumen-based Coating s for Cold Appl~c atron,

Suitable for se in Contact with Potable Water.

Sch edu le of Paint Colours for Buildmg Pu rpo ses.

Code of Practice for Protective Coating on lron and Steel

Structures agarnst Corrosion.

Metallic and Other Inorganic Coatings. Therm al Spraying, Zrnc,

Alumrnum and their Alloys.

Surface reparation

--

AS TM

D2092

G u ~ d e fo r Treatment of Zmc-Coated Galv an~z edi Steel

Surfac es for Painting.

ES 7079 -A1

Spe cifc atio n for Rust Grades and Preparation Grades of

I S 3

8521- 1 Uncoated Steel Sub stra te and of Steel Sub stra te After Overall

Removal of Previous Coatin gs

-

Visual Assessment of Surface

Cleanllness.

ES 7079 D2

Preparation of Steel Substr ate Before Application of Paints and

IS0

8504-2

Related Produ cts. Abrasive Blast Clean ing.

SIS 05 59 00 Pictorial Sur fac e P reparation St an da rd s for Painting Steel

Surfaces .

SSPC-SP Steel Structu res Painting Council S ur fac e Preparation

Specifications.

Inspection nes tin g

ASTM Dl

186

Test Method for Nondestructive Measurement

of

Dry Film

Thickness of Nonmagnetic C oating s Applied to a Ferrous Base.

ASTM Dl212 Test Methods for Measurement

of

Wet Film Thickness of

Organic Coatings.

ASTM D2697 Test Method for Volume of Nonvolatile Matter in Clear or

Pigmented Coatings.

ASTM D3276

Guide for Painting Inspectors Metal Sub stra tes) .



AST M D3 35 9 Test Methods for Measuring Adhesion by Tape Test.

ASTM DUl7 Te st M etho ds for Field Measurements of Surface Pro f~le f

Blast Cleaned Steel.

ASTM D4541

Te st M eth od for Pull-Off Streng th of Coatings Using Portable

Adhesion-Testers.

BS

3 9 0 0

H3

Designation of Degree of R usting.

I S 0 9000 Mo del of Quality Assurance in Design, Development,

Production, Installation and Servicing.

NACE

RP 188

Disco ntinuity Holiday) Testing of Protective Coatings.

A C E R23287 Surface Profile Mea surem ents of Abrasive Blast Cleaned Steel

Surface Using a Replica Tape.

SSPC

PA 2 Measurem ent of Dry Paint Thickness w it h Mag netic Gauges.

Health and Safety

API 2217

Guidelines for Confined Space Work in the Petroleum Industry.

BS

1 3 1 9 Specification for Med ical Gas Cylinders, Valves and Yoke

Connections.

BS 5378

Safety Signs and Colours.

NFPA 231 Standard for General Storage

OSHA 29 CFR 191 Regulation, Penaining Wor k

in

Confin ed Areas.

KOC Standards

KOC Fire and Safety Regulations.

KOC-GO02

KOC Standard for Hazardous Area C lassification.

KOC-G-007

KOC Standard for Basic Des ign

Data

ENVIRONMENT L CONDITION

T h e e n v i r o n m e ~ tof Kuwait, is severe

o

all plant and equipment and must be

considered carefully before selection/approval o f paint s an d coating materials.



The ambient temperature range is - 3°C t o 55°C. The expose d black body

metal temperature d ue t o solar radiation is 85T

Humidi ty can pose a serious problem with long periods of relat ive h u m ~ d ~ t y

(RH)

level of

100

being p a n of normal weather pattern.

other environmen tal conditions in Ku wa it, refer t o KOC Standard for Basic

3esiyn Data, KOC-G-007, w hich provides the detailed design inform at~ on

,.?garding the environm ental, site and util ity supply conditions prevailing

i rough out

the KOC facilities.

HEALTH, SAFETY AND ENVIRONMENT

General

The contractor shall employ all necessary health and safety procedgres to

pro;ect pe rso me and surrounding environment during on-site f~ e ld orks .

Ali r ~ i e v a n ts ~ f e t y equirements of the KOC Fire and Safety Regulations shall

be conformed, in part icular the requirements for blast ing and power tool

cleaning, for scaffolding and access platforms, for compressors and

compressed air equipment for ve ntilation and ventilation equipm ent in confined.

areas and for personnel protection, p rotectiv e equipment and clo thing.

The contractor shall com ply wi th the KOC Fire

&

Safety Regulations and the

Health & Hygiene Procedures while performing the works within KOC areas.

Where there 1s

a

risk of flammable atmosphere being present in a particular

vbiork area, KOC may, wi th relevant safety authority, impose restr~ ct ions n

methods

of surface preparation. Flame heating equipm ent shall no t be used in

hazardous areas. KOC-G-002 describes area class if~cation or faci l~ttes nd

eq i l~pment .

For internal paint ingkoating of drinking water facilities (tanks, vessels, etc.),

the contractor shall submit evidence

(

Kuw ait heath authority approval) tha t

the pa int system wi l l not in any w ay contaminate the w ater.

Storage, Hand ling and M ixing Safety Precautions

Safe Storage

a

All

paints, coatings and thinne rs shall be stored

in

enclosed storage

ereas

or structures that re well-ventilated nd protected f rom

temperatures exceeding manufacturer's recommendations, open flames,

electrical discharge an d direc t sunlight. A ir con ditioned storage areas

shalt be considered where excessive ambient temperatures are expected .



b )

The storage area shall be secluded and no other materials shall be stored

in the enclosed place. The enclosure shall be demarcated

as O

SMOKING

area strict ly.

C)

Al l paints, coatings, solven ts, o il and equipm ent cleaners shall be s;ored

in closed labelled original containers.

d

Portable fire extinguishers of suitable quality and appropriate.quantlty

shall be prov ided at the storage areas and such extingu ishers shall be

inspected and approved b y Fire & Safety Depanment.

Manufacturer's HealthISafety Precautions

Manufacturer's hea lthha fety precautions and procedures for m ixing, handlrng,

storage and application of paints and coating materials shall be strictly

adhered. Safety precautions shall be clearly described on the technical data

sheet of pamt and coatrng materials supplied as well as on the containers.

Safety Precautions for Blasting Painting Equipment

Blast cleaning and spray painting guns shall be earthed (spark proofm g) t o

prevent building up of an electros tatic charge, especially whe n the application

is in confined w ork places.

All blasting equipment shall be inspected and certified b y an authorised

com peten t thir d pa rty. Pressurised hoses shall be tes ted and certified for

ma xlm um safe work ing pressure. Hoses and other pressure items shall be

checked period~ cally o m ake sure that any damage or loss of electrical

cond uctivity will no t lead t o a safety hazard.

Pressurised hose and blasting gun shall compulsorily be equipped w ~ t h

'Deadman Sw itch'.

Suitable fire extinguishers shall be p rovided near the air compressor.

Enclosures shall be provided all around the area, wh ere shot / grit blasting will

be carried out.

4

Clean sir-mask PPE shall

be

worn b y th e technicians while blasting or spray

painting.

Safety Precautions i n F bm mab le Atmos@wres

KOC

will

advise o n the area classification for b o t h plant design and

construction / maintenance projects. Ce nain paint compo sitions shall no t be

use d i n some plant design area classification

e.g.

zon I , s t can ignite with

explosive force at certain conditions.(see clause 7 1

5

of this Standard).



The contra ctor shall provide KOC w it h all necessary material safety data sheet

for the proposed paint systems, solvents and painting procedure In order t o

determine area clas sifcation for the duration of painting work .

Safety

Precautions

in

Confined

Space

All tank

/

vessel interiors shall be gas-free. Approval under entry permit

procedure

is

required before the tanklvessel can be entered.

A I elecrrical equipment used including lighting equip men t, v en tila t~o n

equipment, high voltage holiday testing equipment, etc., shall be grounded and

suitable for the hazardous area classifca tion of the wor king areas as advised

b y

KOC.

All other equipm ent includin g ladders, tools, etc., shall be spark-

proof.

The procedures for perform ing safe wor k in confined spaces shall be in

2 -cordance

~ w t h S H A 29 CFR

9

r API 2217

Site Clearance

&

Environmental Protection

On com pletion of painting works, facilities shall be arranged b y contractor for

effective

and safe removal of spillage collection and disposal of pain tsko atin g

materials, brushes, scaffolding, waste, equipment, etc. All necessary

p r e c a i l t ~ o wshall be taken t o safeguard the surrounding enviro nme nt.

PAINTS

OATING

MATERIALS

General

All palnts oating materials shall

be chemically pure, and free fr om foreign

contaminants. The age of coating material components shall no t exceed the

recomm ended pot-life as limited by the m anufacturers.

All paints coating materials shall be delivered t o th e site

in

original sealed

manufacturer's containers w ith batc hk od e numbers and date of manufacture

clearly marked thereon.

pprovals

Al l paints and coating materials, including thinners and equipm ent cleaners, i n

any one sys tem shall originate fr om one manufacturer.

The KOC approved schemes are

only

those used

in

the paintinglcoating

schedules

A E (Appendix

3

end as defined

in c lauses 7.3 7.14 of

this

Standard. The us e of alternative schemes shall be approved i n writin g b y KOC.



The contractor s subm ittal for paintingkoating materials shall include details of

generalized composition, service temperature and technical specifica t~ons of

the products to be used for KOC review and approval.

The selected composition of painting / coating materials shall comply with the

relevant clauses penaining t o the materials given be low.

inc-Rich Epoxy Rimer

his primer based on polyamide cured 2 pack epoxy. Minimum volume of

solids shall be 63 as per

ASTM

D2697.

Inorganic Zinc Silicate Primer

Sased on ethy l silicate media. Minim um volume of solids shall be at least

589

s per ASTM D2 697 . Capable of withs tanding continuous high temperature

u p t o 403 C) and have excellent abrasion and chemical resistance.

Zinc Phosphate Primer

Based on long oil alkyd and urethane alkyd media. Minimum volume of solrds

shall be 48 as per

ASTM

D2697.

Mordent S olution (1-w ash ) Pre-treatment Primer

Used for preparation

of galvanized surfaces.

t

is a tw o components etch

primer, based on phosphoric acid solution incorporating copper salts and

corrosion inh~b itive igments in

a

solventlwater solution.

High Build Epoxy Intermediate

Based on polyamide cured tw o pack high build epoxy binder. Pigmented with

M~ caceous ron Oxide

(MIO).

Min imum volume solids shall be 55 per

ASTM

D2697.

Coal Tar Epoxy Rimer/lntermediate/Finish

The formulation of the tw o pack incorporate:

Pack

1.

Epoxy resin and suitable pigments.

Pack 2. Polyamide or amine curing agent and coal tar.

The

Epoxy tesin shall comprise at

(east 35

by weight

in

the resin/coal

t a r

blend as per

ASTM

02697

For contrasting of intermediate coats, a luminium or red oxide may be used.



Two Pack Polyurethane Finish

B2sed on acrylic modif ied t w o pack al iphatic polyurethane wit h t i taqium

dioxide or M I 0 pigment.

Minimum volume of solids shall be 45 per

ASTM

D2697.

se vi-g los s and colour retention f inish is required.

;mine Adduct Epoxy Paint

4 t w o pack epoxy amine adduct cured paint wh ich cures to a coating wi th

excellent resistance to chemicals.

Mm imum volume of sol ids shall be

48

as per

ASTM

D2697.

IT shail be approved by the N I Y C (Na tional Wa ter Counc il) and Kuiv ait heal:?

a ~ t h o r i t y .

Solvent Free

High

Build

Epoxy

Paint

f32sed

on

polyamide cured t w o pack epoxy wit h a coat ing w i th good

resistance t o fresh water and t o abrasion.

Minimum volume of solids shall be

100

per ASTM

D2697

(solvent free).

It shall e approved b y the NWC (National Water Counc il) and health au thority.

Zinc

Free

Inorganic Silicate Finish

Air curing zinc free inorganic sil~ ca te ased on eth yl sil icate media; capable of

wrthstandmg continuous

high

temperature (up t o 400'C) and have excellent

abrasion and chem ical resistance.

High Temperature Alum inum Silicone

Finish

Based o n si l icone alkyd or modif ied sil icone alkyd media

e.g.

ecrylic sil icone).

M ~ n i m u m o lu me of sohds sha ll be 49 as per ASTM 02697.

Ptgmtrnted w ith leafing aluminium pigment.

Heat resistant, capable t o withstand continuous high temperature up t o

400°C.

M us t be capable

of

curing t o handle at ambient temperature.



Me tal Spray Coatings

a) Based o n mo lten Alum inium me tal sprayed o n surfaces prepared in

accordance w ith BS

EN

22063.

b ) Aluminium me tal spray coating is suitable fo r high temperature (up to

550°C) surfaces with restriction (see clause 7 15) . The sprayed

aluminium may be silicon sealed and for temperatures up to 250'C silrcon

sealed sprayed aluminium can provide more protection and longer I~ f e .

Restriction

on

Using

Aluminium

Pigments and M eta l Spray

Due t o the susceptibil i ty of metall ic aluminium to ignite wi th explosive force,

Alum inium metallic pigments and Aluminium metal spray shall no t be used on

any

surface operating above

1 2 0 T

in area tolie

1

as specified in KOC

Standard for "Hazardous Area Classification"

(KOC-G-002)

or

KOC

Hazardous

Area draw ings.

SURFACE PREPARATION

General

All fabrication wo rks including cutting and drilling of holes shall be completed

prior t o surface preparation. In special areas, how eve r, preparation and

priming

of s tructured steel members and piping ma y be approved

b y KOC

prior

to f inal assembly.

Surface preparation shall preferably, for optim um c oating performance, be

carried ou

by

dry abrasive blast cleaning. Alternative techniques shall only be

applied in some circum stances as described in clause

8 7

The surface preparation requirements for p ainting system s are indicated in the

painting schedules

A-E

(Appendix

3)

and detailed in the clauses as follows:

Working Restrictions

Weather Conditions

All surface preparation shall not be condu cted

in

the following conditions:

a)

W hen th e steel surface temperature is less tha n 3 above de w point .

0

W he n the air temperature

is

below

5°C

C)

Wh en the relative hum idity

RH)

s 85

r

higher.

d

Under adverse weather conditions, e.g. rain,

fog,

sandstorm, high wind

velocity (56 K m h r. or higher) , high wave t ide or whe n such conditions

are l ikely prior to completion of the work i e abrasive blast cleaning

1



8.2.2

Work Cond~t ions

F~ el d urface preparation shall not be conducted in the following co nd ~ t~ on s:

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

Approved special lighting shall be arranged for night blast cleaning.

W he n the initial primer coe? cannot be completed w ith in 4 hours of

prepara:ion. Surfaces wh ich remain unco ated for longer th an this period

shall be reblasted prior to priming.

When

adjacent

areas

or equipment are insufficiently protected from

damage or contamination b y abrasive dust or debris.

In areas close to painting operations, t o prevent damage or contam ination

of we t palnt films b y abrasive material.

8 3 Surface Imperfections Removal

Surface impe rfections or irregularities shall be removed completely (made flush

or sm oo th) prior t o blast cleaning. Imperfections shall be considered as

fol lows:

LVel

spatter and slivers shall be removed. Sharp or rough welds shall be

rounded and contoured. Any other observed defects in welds and

material should be referred to KOC for dispos it~on.

Po ro s~ ty (w eld voids) shall be cleaned and fil led w it h acceptable fil ler

mz?erial or closed over b y a suitable mechanical meth od approved by

KOC.

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

Such impe rfections tha t appear after blast cleaning or acid pickling shall

be similarly removed.

If

grinding is needed, check ing of the remaining

wa ll thicknes s and KOC s approval are required.

8 4

Surface Contaminants Removal

8 4 1

The me tal surface shall be cleaned t o remove any

oil

grease,

din

etc. using

solvent andlor suitable emulsifying alkaline cleaners fol low ed by washing wi th

clean water

or

w et steam r insing.

SSPC SP7

outlines these m ethods.

8 4 2

Degreasing by wiping the surface with solvent only is not recommended in

heav ily oillgrease surfac e contamination, because thi s invariably leads t o the



DOC. NO. KOC P 001 of 55

I REV.

2

spreading of a th in film of oil over wide area. The solvent/emulsifying agent

cleaned surface shall be allowed t o dry before proceedmg w ith further

preparation or painting.

Soluble salts on steel surface exposed t o a salt laden atmosphere shall be

removed by washing or

by any other suitable techn ique. See clause

10.5.3

for iron salts contaminant free testing.

Dry Abrasive B last Cleaning Practice

Dry abrasive blast cleaning shall be used t o remove all rust and mill scale and

t o achieve th e required visual standard and surface pro file defined in the

approved painting'coating schedules (Appendix

3).

Ab:ssive material shali satisfy the follow ing requirements:-

Abrasive material for mild

/

carbon steel preparation shall be indu str~ al

grade metal angular grit or shot (generally iron or steel). Contaminated or

re-cyc led grit or s hot shall no t be used. Abrasives for stainless steel

substrate shall be non-metallic materials. New less-dust generating

abrasive media suc h as Garnet plastic granulates and alike, capable of

produc ing the required surface profile, m ay be used for blast cleaning.

Sand m ay be used as abrasive material for field blast cleaning, subjec ted

t o KOC's approval. Sand material shall be graded

30

6 0 mesh), hard,

version, si lca or olivine sand w ith less tha n a 10 percent breakdown. No

sand shall be used more tha n once.

The selected abrasive material shall be in accordance w ith SSPC-SP-COM

or BS 7079 R IS0 8504-2 .

Abrasive material shall be dry and free fro m oil, grease, dust, salts and

any other impurities or contaminants.

Abrasive materials shall be capable of achieving th e required surface

profile with out contamination of the substrate. T o produce th e required

surface profile, abrasive particle size shall fol low th e surface preparation

commentary of SSPC manual as necessary t o comply w ith visual blast

cleaning standards mentioned in clause 8.6 of this Standard.

All abrasive materials shall be

kept

dry,

nd

covered wh en no t used.

Abrasive material sample shall e provided

by

th e contractor, for KOC's

testing a nd approval before wo rk comm encement.

Th e blasting equipment and technique shall comply wit h the fol lowing

requirements:



The con trac tor's abrasive blast cleaning equipm ent shall sat isfy KOC's

safety requirements (See clause 6.3 .

For field and shop blast cleaning, abrasive shall be carried by a jet of

compressed air through a hand-held nozzle. The compressed air s u ~ p l y

and

volum e shall meet wo rk requirement and shall be substantially free

fr om oil and wa:er contam ination. Traps and filters shall be cleaned

regularly.

For blast cleaning of large horizontal surface areas,

like tank roofs ,:

bottoms etc.,

a

self contained v acuum blast unit can be used. Sirch

machines are usually operated by remote compressed air or hydraulica ly

actuated for tractio n.

'Deadman handles' shall be fixe d t o th e blast line as close as practicable

to t h ~last nszzle and shall be held b y the blast operator alone.

Nrjzzles used shall have a ma xim um oriflce size of

9

m m and shall be of

ventur l des~g n.

Openings in vessels, piping, access fitting s, nozzles, et c. shall be properly

protecte d against entry of abrasive material. All previously painted or

ga ~,anisedsurfaces shall be adequately protec ted prior t o comm encine any

blasting operation.

Giast cleaned rus ty surface (due t o rain or condensation) and surfaces w ith

temp orary holding primer, shall be re-blasted t o the specified surface profile.

Surface blast cleaning t o the specified surface profile shall exte nd

a

min imum

of 1 5 0 eyond the area to be coated during the same day.

Surface blasting t o the specifled surface profile shall continu e a minim um of

25 m m into adjoining previously coated surface. Th e edges of the previous

coating shall be feathered.

All prepared surfaces shall

be

cleaned from any dust / abrasive material

preferably by dry brushing andlor vacuuming wi th industrial vacuu m cleaner.

Pressure air blowin g is no t permitted. A ny surface sho win g signs of

contamination, after blast cleaning, shall be solvent cleaned and re-blasted.

Blast Cleaning Standard

The surface profi le height shall be

in

accordance w it h th e requirement of

painting system. The measurement techniques

of

surface profile testing are

specified in

ASTM

D4417



DOC.NO.KOC P 001

P a ~ e

0

of 55

REV 2

Blast cleaqing shall be carried out t o a visual standard in accordance

w t h S S

05 59 00 e~ther

s Sa

2,

Sa

2 /1

or Sa

3

(identical

to BS 7079

Part

A1

or IS0

8501-1) subjected to the requirements of paint manufacturer's data sheet.

Reference shall be made t o th es e standards for photographs of equivalents to

th e mentioned qualities.

Gestrictions on Atterna tive Techniques t o Blast Cleaning

so me circu mst ance s, blast cleaning shall not be done and alternative surfac e

.reparation techniques like manual power tool cleaning shall be applied.

Th ese alternative techn ique s are subjected to KOC's approval and restricted a s

iollows:

a

When

dry

abrasive blast cleaning

is

unsafe

or

any of KOC's safety

precautions / requirements cannot be met.

b

When there

is

a

risk

of dam age t o instrumentation, equipment (e .g .,

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

c) Where there is a flammable a tm osp her e or similar condition present,

restrictions may be applred by KOC.

d ) Where blast cleaning is not practical, e .g . for welds, ed ges , bolts, nuts,

corne rs, crevices et c. and for paint d efe cts tda ma ges repair.

Power Tool Cleaning

Power tool cleaning shall be to

a

visual standard in accordance with SIS 05

59

00 St3

or

BS 7079 Part A1 S t 3 (equivalent t o U.S. Standard SSPC-Sp 3).

Where power tool cieaning is carried out, 100 of the surfac e shall be

covered using abrasive or wire typ e power discs. In so m e locations which can

not accommodate a power disk, e.g. welds, pow er impact tool s shall be

applied (vibratory a n d rotary, needle gun s, scrape rs) followed u p by wire brush

cleaning.

Pow er tool cleaning shall exte nd a minimum

of 25

mm distance into adjoining

coated surfaces.

Hand

Tool

Cleaning

Hand tool cleaning ma y be used for cleaning rusted surfac es n s o m e

circumstances s specified

n

clause 8.7 an d for paint d efect sJdam ages repair.

Hand tool cleaning shall be

to

visual stan dard in accordan ce with S IS

05 59 00

S t 2 (BS

079

St2 ) which is equivalent to SSPC-SPZ..



Acid

Pickling (Etching) Prepara tion

This method may be used by contractors, in so me circumstances and locattons

a s a n alternative to blasting provided tha t

it is

compatible

with

palnt sys tem

and approved

b y

KOC

When using t h i s

method,

the

surface shall be etch ed t o a d egre e suitable for

th e specified coating syst em . Details on this method are specified in SSPC-

SPB.

KOC

Flre and Saf ety Regulations shall

be

adhered t o when using

this

method

Preparation of Stainless Stee ls

Sramless stee ls shall not b e painted unles s specifled by th e relevant equipm ent

d : ~

7 e e t . he s urfs ce specifled t o be painted shall

be:

th0:oughly deg re ase d using solvent cleaning or suitable emu lsif y~n g ae nt

and washed with fresh water t o remove a ny contamination.

blast cleaned to a surface profile

of 25-50

micron using chlorlde

free

abrasive su ch a s alumina. Copper slag abrasiv es shall not

be

used . Hand

or

power tools using

P6

grade paper may

be

used for surface

preparmon, when grit blast cleaning is impractical. (s ee clause

8.7).

protecte d from an y fu nhe r contamination by debris produce d during grit

blas?ing of adja cent carb on steel because embedded panicles could

promote corrosion. Any observed contamination should

be

referred to

KOC

for disposition.

Blast

/

Power tool cleaning equipment used for carbon steel

shall not

be

subsequently used on stainless steel.

Preparation of Galvanized urfaces

Painting of new galvanized surfaces shall be only for top coating purpose in

conformity with systems

B1

Dl -1

0

l 11 of Appendix 3 of th i s Standard.

The

surf ace preparation metho d shall

be

carried out as follows:

a)

The g reasy

film on t h e ne w galvanized steel surface and a ny other

oil

or

grease contamination shall

be

removed using emulsifying agent:

b

The surface

shall be

chemically e tc he d (primed) by using proprietary

T

wash solution.

see

clause

7.6

C

Weathe red surf aces shall be cleaned using wire brushing or s w e e p

blasted

to

rem ove all corrosion produ cts

or

deposi ts and degreased wrth

emulsifying agent.



8 . 1 2 . 2

Other su rfa ce preparation me tho ds may be used in acc ord anc e with ASTM

D 2 92

for painting ne w galvanized sur fac es subject t o KOC s approval.

PAINT/COATING APPLICATION

General Requirements

Paintingkoating works shall be in accordance with

the r quir m nts

established by t h i s Standard and t h e recommenda tions of th e paintlcoatlng

manuf acture r. Any are a not specifically cove red, shall be in accord anc e wrth

th e principles and guidelines set fonh in the SSPC Manual.

Th e c ontrac tor shall provide all materials, tools, equipmen t and manp ower

required for carrying out the works.

Surfaces , to

be

painted /c o at ed , shall be inspected and approved

b y KOC

before any pa~n tlng oatmg

is

applred. Thrs shall be after surface preparation

and between each subsequent coating. No primer or paint shall be applled

v,~~thoutOC s approval.

All

sur fac es, t o be painted coated , shall be d ry and dust contaminants free

before applcatlon of th e first coat.

Precautions

shall be taken t o prevent painting from being ap pl ~e d o name

plates, cou pl~ ngs , hafts, valve stems , vent openings, gauge glasses, pressure

ga dg es , et c. Masking ta pe , plastic film or any other suitable material shall be

used, and all shall be removed after completion and acceptance of the palntlng

apphcatron.

All

area s prepared for field welds shall be kept free from paint over a drstance

of at least

1

mm from th e weld cen tre, ex cept welding sho p primer of 25

mrcrons.

A

minimum

of

1 mm around ed ge s

of

abrasive blasting shall

be

left unless

adjoining

a

recently prepared a nd coated other surfac e.

Crevices created

y

t w o surfaces in close contact which cannot

be

protected

by

painting should

be

mastic sealed on both sides.

Selection of

paint in^

Coating ystem

The selection

of

painting coating sy st em for particular applications and

required su rf ac e preparation Shall be as given

in

t h e approved painting

Schedules A

B,

C

D,

and (Appendix

3

of

this Standard.



DOC. NO KOCP 001

REV. 2

Paint Mixing and Thinning

Mlxin g of paint t o an even consistency, manufacturer s mixing instruc t~ons ,

environme ntal conditions and ma ximu m pot l ife shall be strictly adhered,

special ly for T w o pack paints.

Mixing,

by h h speed mech anical agitators or rotary mixe rs, w it h flat blade

?nd speed control, shall

be

used for containers larger th an

5

I~ t res . and

71xrng is perm rned o nly for containers

u

to l i tres.

t o r paintin g systems where pigment separation readily occur e.g . zinc sil icate

~ ri m e r s , ontinuous mixing shall be carried out during appl ication.

After tho rou gh mixing, the correct viscosity of th e paint shall be proved by

measuring with an approved f l ow cup.

Thinners shall not be added to p aint witho ut KOC s approval, only the thlnners

recommended b y the palnt manufacturer may be used, even for cleanrng.

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 fol lowe d.

Restrictions

on

Painting

Weather

Conditions

Palnting shall no t be cond ucte d in the similar weather conditions of abrasive

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

fo l lowing c ond i t~ons:

a

Wh en the metal surface temperature above

50°C

b) Under adverse weather condit ions, e.g. rain, fog, sandstorm, high win d

velocity

(56

Kmlhr. or h igher), h igh wave t ide or whe n such cond i t~ons

are l ike ly before the paintk oat ing has become dry.

Work Condit ions

Painting Coating shall not be conducted in the fo l lowing work condit ions:

a)

Whe re t h e specif ied surface f inish is not existed t th e t ime of apply ing

th e fi rst coat.

b

W he n adjacent areas or e quipment are no t suff iciently protected fr om

paint appl ication.



DOC NO .

KOC-P-001

of 55 REV. 2

C )

Outside daylight hours on exterior locations, unles s permitted

by

KOC

Approved special lighting shall be arranged for night painting.

9 5 Paint Application Practice

9.5.1 General

The specified surface fmisfi, of all areas t o

be

painted, shall be prepared

before applying th e first co a t ff required, su rfa ce s shall be re-prepared t o

the specifled fmish.

The paint shall be applied in a uniform manner a nd to the prescribed

number of coa ts and

dry

film thicknes s DfT)given in Painting Schedules

without any .runs, sags ,

marks or other blemishes. Finished application

shall be uniform

in

colour, texture and appearance.

Intermedia te and finish paintings shall be applied following final assembly

of component pans. For surfaces inaccessible

for

proper painting and / or

inspection, painting shall be applied prior t o final asse mbly . The

contractor and KOC will designate inaccessible areas.

Where a multi-coat paint sy stem is specified to

be

us ed , all intermediate

co at s shall be of contrasting colour t o differentiate betw een coat s.

Colours for intermed~atecoats shall refer t o th e paint manufacturer s

recommendations.

T m e intervals between coat s shall be kept t o

t h e

minimum recommended

by pamt manufacturer in order to prevent contamination between coat s.

In case

contamination does occur, it shall be removed by washing w~tti

suitable dete rge nt solution and rinsing with clean

fresh

water.

9.5.2 Airless Spray Application

a)

Paint application by airless spraying shall be the preferred paint

application process. The use of air spra y method shall conform to t h e

requirement

of

coating sys tem and shall

be

subject

to

K Cts

approval.

b)

Spraying equipment, guns, nozzle size s, orifice sizes shape s and

pres sure range s sP.ali me et t h e work requirement s an d t h e paint

manufacture r s recornmendations an d shall

be

free from

oil

and water

contamination.

C

All

paint spraying lines and pots

shall

be cleaned a nd flushed before the

addition o new material.

d

Large surfaces shall be painted with passes

in

t w o directions a t right

angles. Spray overlap of th e previous pa ss shall

be

by 50 . .



9 5 3 Brush Application

Brush applicat ion shall be done on areas which cannot be properly

sprayed

e.g. for welds, edges, bolts, nuts, corners, crevices etc., and for

tou ch -up maintenance where spray application is no t pract ical.

Stripe coating of sharp edges, corners and welds ca n be done before

application of f lnish paint t o ensure that these areas receive the mln lmJm

specifred fi lm thickne ss.

Brushes shall be of a type, size and shape which permits proper

application of paint and meets manufacturer s recommendations.

Brush application shall be done such that a uniform coat, w ith no deep or

de tr~m en tal rush marks, is obtained. Runs and sags shall be avo ~d ed .

T h ~ s method of applcat ion can be used, subject to KOC s approval, for

painting large areas of relatively flat steel surfaces a nd w here high fi lm build is

generally no t t o be attained. Roller application wil l ride over high spots and

mlss edges and shall not

be used for pa inting corners, bolt heads, etc . Care

mi ls?

e

taken

t o choos e the correct roller pile length, depending o n the ty pe

of paint and degree of roughness of the surface.

9.6

PI

iming

9 6 1 Priming shall be done on prepared surfaces before rusting occ urs or wit hin

4

hours of blast cleaning, whichev er is sooner. The only relaxation allowable t o

this requirement is where the following three 3)conditions are existing.

a)

The wor k t o be primed is ful ly enclosed.

b )

The ambient temperature

is

above

1

I°C

C

The relat ive hum idi ty is be low 75 .

9.6.2

All acid descaled steel surfaces shall be primed as so on as the surface is dry

and w hi le it is still warm.

9.6.3

In order t o faci l i tate shop or site handling procedure, holding (shop) primer of

25 microns may e applied on stee l surface.

f

pplied, however, this shall not

replace the funct ion

or

pan of the f i lm thickness specif ied for th e priming coat.

Shop or we lding primers shall

be

compatible with the specif ied paint ing

system.



DOC

NO.

KOC-P-001 P a ~ e

6 of

55

REV.

Zmc silicate primers shall be applied to abrasive blasted surfaces on ly. In order

t o protect the porous primer fi lm fro m salt or chemical contamination,

rt

shall

be sealed

w ith a tie coat as soon as practicable after complete curing has

occurred. The tie coat shall achieve sound adhesion t o the zinc siicate primer

and be compatible w ith the finishing co at.

hop

Painting

3 0 p painting of i tems may be carried out b y the contractor as below, subject

KOC's approval.

3

The contractor shall be responsible for paint condition on arrival of such

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

b

The contractor shall com ply with all aspects of this Standard and related

aspects of KOC's safety regulations.

Completely Fabricated Items

a Full surface preparation and painting wo rks shall be done prior t o

transportation t o site.

b

All painted items shall be protected packed t o avoid any coating damage

during transpo rtation. Care shall be taken in handling and insta llat~ono

minimize coa ting damage.

Partially Fabricated or Non-Fabricated ltems

a These items ma y be prepared / primed and further coated before

transportation to sire wi th the approval of KOC.

b

The painting used shall have enough durability t o withsta nd the 'on-site'

constru ction period before further painting occurs.

Repair

of

Darnages'Defects

New painted surfaces are likely to require repair and maintenance in the

following cases:

a

f o r painted areas wh ich have been damaged b y other adjacent f ield

activities or during handlingltransportation of off-site painted items.

b

For areas wh ich suffer pain t defe cts

e.g.

disbonding, insufficient fi lm

thickness, blisterin& etc.

The t yp e of coating materials used for repair and maintenance shall be identical

to, r compatible w it h the original material.



The selection of suitable surfac e prsparation shall dep end on the size of areas

t o be painted, th e type of repair painting materials t o be

used

and the Safety

regulations involved. Th e following order of pre fere nce shall be adopted.

a )

Dry blast cleaning t o t h e required visual standard

(

S a 2 or Sa 3 and

su rf ac e profile.

2

Power tool cleaning ro standard

St3

(only wh er e blast cleaning

is

not

practical or permitted).

Hand tool cleaning t o standard

St2

(only for minor touch up repair

work)

Surf ace preparation of defective or dam aged ar eas shall be extende d over the

surroun ding so un d coating for a minimum of 25 m m on all

sides

and a further

25 mm

of sound paint

work

shall be lightly blasted t o et ch t h e surface.

Surfaces to be painted that beco me contaminated with oil, grea se, salts , et c.

sh ll

be cleaned with a proprietary solvent ideterg ent solution and

rinsed ~ ~ 2 1 t h

fres h clean water .

Repair works shall be in acc orda nce with t he specified painting sys tem t o

res tore the f~ lmhicknes s and shall cover the prepared surf ace and the etched

p a n t work For colour codmg and /or cosmetic reas ons it may

be

necessary to

extend th e f ~ n ~ s hoat over a large surrounding area .

It

is

mandatory thai all defective work

be

corrected to

the

sat isfa ctio n of

KOC s

represen tative. Work shall not

be

dee me d comple te until the foregoing

bas been achieved.

INSPECTION ND

TESTING

General Requirements

lnspectlon and testing at all sta ges of surfac e preparation and paintingkoating

a p p l c a t ~ o nshall be conducted

by

the contractor. T he contrac tor shall provide

all nece ssar y inspection equipme nt and perform su ch inspections as necessary

t o assu re th at th e painting coating complies with the requirements of this

Standard.

Surface preparation and painting /coa ting application m a y be subjected to

inspection an d approval at any s tag e by KOC.

KO

inspector shall have th e right to inspect at all times an y tools, materials or

equipment used in the performance

of

surface preparation

nd

paint

application

to

ensure

t h e

compliance with th e requirements

of

this Standard.



Materials an d Equipment lnspection

Abrasive m aterial shall be inspected t o ensure compliance wi th the

requirements of this Standard. (see clause 8.5.2)

Painting / coating materials shall be inspected t o ensure compliance wi th the

requirements of clause 7 0 and the specified p ainting schedules (Appendix 3

of

this Standard.

Equipment for blast cleaning and paint application shall be inspected to ensure

the com pl~an ce i t h the requirements

of

this Standard (see clauses

6.3,

8 .5 .3

and 9 .5 ) and paint m anufacturer s recommendations.

lnspe ctionrres ting Equipment

The contractor shall heve the necessary equipment and tools for inspection

and testing of environm ental conditions, surface preparation and

painted. coated surfaces. All this equipment shall be approved by KOC prior to

starting any wo rk. The contractor shall provide calibration certificates for all

measurement and test equipment fo r KOC s revie w.

Environm ental Conditions Te sting

Prior to com men cing any blast cleaning paint application work, ambient

temperature, m etal surface temperature and relative hu mid ity

RH)

shall be

measured. Readings shall comp ly w it h clauses 8.2.1 and 9.4.1. For works in

confme d areas, the ox yge n deficiency and gas testing shall be performed.

Other environmental conditions, e .g , wind speed, wave tide and sandy or rainy

weather, shall be checked before the comm encement of any w ork.

Blasted Surface InspectionRest ing

Visual lnspection

a

Me tal substrate shall

be

checked t o ensure spatter

/

protrusions removal,

cleanliness e tc. prior t o blas t cleaning.

b

Blast cleaned surfaces shall be visually inspected (surface mag nifier m ay

be used) t o ensure the absence of al l types of imperfect ions and

contam inants and for the conformance w ith the specified visual standard

mentioned in th e paint ing / coating schedules (Appendix 3).

Surface Profile Testing

O n dr y blast cleaned surfaces the prof ile he igh t shal l b e spot checked

y

means o f surface profile comp arator or y replica tape and a calibrated



micrometer in accordance w ith ASTM D44 7 or NACE RP0287 o ensure the

compl~ancewi th p a m n g schedule requirements.

Contammants Free Testing

W hen requested b y KOC, a Potassium Ferrocyanide paper test shall be carried

out t o con firm the absence of contamination of the blast cleaned surface by

soluble iron salts. This shall be done in accordance w it h

BS 5493

Appendix

G

Painted Surface lnspectionrresting

Visual Inspection

All painted surfaces shall be visually inspected t o ensure th e absence of skips,

overspray, sags, foreign panicles contamina tion, air poc kets, drips, holiaays

and

s y

other palnt defects. The repair of damage dldefected c oating shall be

d o n e In accordance wtlh clause 9 .8

of

this Standard.

Curing o f Inorganic Zinc Srlicate Primer Tes t

a ) Z ~ n csilicate primed substrate shall be tested for adequate curing prior to

0vercoa:ing (see clause 9.6.4). The test shall be perform ed as fol lows:-

Rub the applred c oating w it h a clean tissue or piece of cloth. There

should be no t race of paint on the cloth. The cloth should then be soaked

In cleaners

s

recommended b y the paint manufacturer; and again rubbed

on the coatrng. After about thirty seconds there should be no trace of

zinc on th e cloth. If the re is any greyness, the n th e zinc sil icate IS not

ully

cured and sh l l

not

be overcoated.

b The manufacturer s recommendations instruct ions shall be ful ly adhered

when performing this test .

Paint Fi lm Thickne ss Test

a

The paint shal l conform t o the system and t o the min im um film thickness

as specified

in

th e pa inting schedules.

b

he w e t ilm thickness

WTT

shall be spot measured as

an

initial

indicat ion of the expected dry

ilm

thickness

IDFT .

Th e measurement

shall be in accordance with

ASTM

D1212.

C)

The DFT of individual coats end

of the

tota l paint ing sys tem shall be

measured

in

accordance with

ASTM

D l 18 6 o r SSPC-PA2. There shall be

at least one area ea ch for horizontal, vertical and curv ed surfaces. For

internal paint ing in storage tanks, t he

film

thickness shall

be

measured at

te n (10 ) random ly selected areas.



l

A minimum of f ive

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 range.

f )

The gauae shall be calibrated prior any measurem ent. The

calibration

shall be repeated at least once an hour if work ing on the same surface,

and before measuring fi lm thickness on th e insides of angles and at

points nearer than

5

m m from an edge.

Paint Adhesion

When requested by KOC, a spot adhesion tes t may be carried out using a

suitable Adhesion Tester. The paint adhesion recorded mu st be at least eqilal

t o the specifled adhesion b y the paint manufacturer fo r th e typ e of paint

and or sys tem .

The paint adhesion testing shall be in accordance wlth ASTM

D3359 or ASTM D4541.

Hohday Detection (Porosity Check)

All coated me tal surfaces shall be subjected t o visual inspec tion for holidays,

pinholes and overspray. For special coatings where pinholes cannot be

allov,~ed, a ful l scan holiday test shall be done, using suitable equipment for

each typ e of coating as high voltage can cause damage t o coatings. The

acceptable level of pinholes shall be subjected t o KOC 's approval. Holiday

detection test shall be carried out in accordance with

NACE RPO188

QU LITY ASSURANCE

The Contractor / Manufacturer shall operate quality system s to ensure that the

requirements of this Standard are achieved. The quality system s shall be

preferably based o n IS 9000 series of standards and the contractor

manufacturer shall demonstrate compliance b y providing a copy of the

accredited certificate or th e quality manual. Verification of

a

contractor's

manufacturer's quality system is normally part of th e pre-qualification

procedure and is, therefore, no t detailed in th e core te xt of th is Standard.

DOCUMENTATION

General

All correspondence, drawings, instructions, data sheets, design calculations, or

any other written information shall be in English language. I n case of dual

languages, one language shall be English.

All dimensions, units

of

measurement, physical constants, etc. shall be in

SI

units, unless otherw ise specified.

All docu me nts (texts, spec ifimtions, data sheets, etc.) shall e provided with

electronic files in the approved software MSWord, Excel, AutoCAD, etc.).



A n y design calculations shall be submitted

in

the approved and widely

used

software agreed

by KOC.

Work

Proposal

The

contractor shall submit his proposal for all aspects of

work, for the

approval of

KOC

prlor t o th e com mencement of any w ork. This will include

t h e

following:

a) Information on work location, materials selection, equipment to be u se d,

items t o be coated, surface preparation, painting schedule to be used,

etc.

b

Manufacturer's technical data she et, material performance ce ni fc at es

and te st a pprovals shall b e provided for ea ch paint coating product.

C

f d ~ t e r ~ a iafety dsta she ets and safety precautions to be taken

d

lnspect~on

n d tes;

plans and procedures, and the equipment to be u sed.

e

S p e c ~ f c epair proposals t o satisfy the requirements of clause

9.8

for

both extensive and minor repair.

Work Records~Reports

The cont ractor shall operate a comprehensive recording reponing sy st em on all

ss pe ct s of th e painting work includmg inspection/testing work. The dat a shall

be se t out on painting work reco rdlda ta sh ee t within 24 hours of carrying out

a

sp ec ~f ic ork. Appendrx

1

shows

a

sample of this recordjdata s he et .

Final

Report

A report shall be s u b m ~ n e don completion

o

th e painting works. The fmal

repon shall include a summary on all aspects covered e.g . , surface

preparation, painting s ys te ms u sed and inspection and testing records

performed.

PAlNTlNGlCOATlNG SCHEDULES

The

painting coating sche dule s

A-E)

are a t tached to

t h i s

Standard in

Appendix 3 T he requirements f or su rfac e preparation an d paintinglcoating

systems are listed for categories

of

onshore offshore structure, equipment

and other facilities.

The paintinglcoaring sch edu les explained

in

Appendix

3

are:

Schedule A External PaintingICoating Sy st em s for Onshore Storage

Processing Equipment.



Schedule Painting System s for Onshore Structura l Steel wo rks .

Schedule C Painting Systems for Mec hanical, Electrical and Instrumentation

Equipment

.-

Schedule D ?ainting.lCoating Systems for Offshore Structure and

Equipment.

chedule

E

Internal Painting System s fo r Storage and Processing

Equipment.

14 0

OLOUR S HEDULE

The f in ishing colours t o be applied t o various equipm ent and faci li ties

sh ll

be

n

accordance wirh colours mentioned in colour schedule

of

Append~x

.

S~ e::~ng

di f fe rent

co lmrs

is

subject to KOC's approval.



7 5 0 APPENDIX

PAINTING RECORD DATA SHEET

........

roposed by

.................

......

Checked by Date: .

...........................................

tem being painted. ............... ....................Location.

Substrate Material. .

........................................................................

A. Surfact Preparation

.......................

urface Cleanliness

(Visual Standard i

Surface Condition

.......................

S;* ~:E Prc li~

He ;?

. . . . . . . . . . . . . . . . . . . . . . .

cf,:,c:c-l

Ambient Temperature ( 'C)

. . . . . . . . . . . . . . . . . . . . . . .

C o v a m ~ n a n t s ree T e s t

. . . . . . . . . . . . . . . . . . . . . . .

.......................

e.0.

Point

( T I

.......................

~ i i i d € umidity C/o)

SLI:~B:E Temperature ( 'C)

.......................

Cleaning Method(s)

.....................

......................

brasive type

Abrasive S ~ e v e ~ t e .....................

B. Paint

Application Equipment

Primer 2 n d Coat 3rd Coat 4t h Coat

Brush Roller /Con. Sp ra y' A~ rle ss

.............................. ..............................

Conventiona Gun

....................................................................

A~r l es s IP S z e Angle ( thou'deg'

....................................

Pump Ratio

................._.........................,,.......................

....................................................................

upply

Air

Pressure (psi)

C. Painting Con ditions

Relative Humidity

( I

Surface Te mpe rature t°Cl

Ambient Temperature PC

Dew P oin t ( " a

....................................................................

ther weather Condit ions



P INTING

RECORD

/

DATA SHEET

Contd...

0 Paint Coating Materials

...............................anufacturer

TypeXode Bstch No. Product No No of

t o m

Cur~ng er~od

Primer ............. . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . .

Intermediate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Finish

. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .

Colour Codmg

Over Coa?~ng

T ~ m e

nterval ......................................................................

T o ~ a l V ......................................................................

To?al

D R

......................................................................

Adhesion Test ......................................................................

P~nhole est

......................................................................

Material Safety

Data

Sheet

(

for

information

DOC. NO KOC P 001

Remarks



APPENDIX

A

.

OLOUR SCHEDULE table

1

Item

Stora

e

8

Processing Equipment:

&Pressure Vessels, Exchangers, Heaters

Columns, Skirts, Saddles and Piping

Rotating Equipment

ElectricallMechanicaI Equipment

Instrumentation Equipment

Control Panels/Equipment Support

Pipe

Works, Valves and Fittings

All valves/devices used for over pressure

protection e.g., Safety valves).

Overhead Travelling Crane

Structural Steel Works

Hazards Firelsafety systems

Gas Cylinders (Industrial)

Gas Cylinders

(Medical)

Safety Signs

Grey

Refer to Table

2

KOC-P-017

Blue

Yellow red

Aluminium

Rritish

Standard

No.

-....

- P

S

4800

Remarks

Alirminium colour shall

be

Non

Leafing grade.

BS

381 C

Ref.

No.

107

BS 4800

Shade

08-E-51

BS 4800

Refer to KOC-P-017 for colour

coding arrangement and

application for piping.

Refer to

Table

2

BS 381

Refer to

Table 3

DS 349

Refer to Table 4

RS 1 3 1 9

Refer to

BS 5378 RS 5378



. -

[DOC

NO. KOC P 001 1

of I REV. 2

APPENDIX 2C

cOLOUR IDENTIFICATION OF G AS CYLINDERS FOR INDUSTRIAL GAS VIDE

BS 349

Table3 Contd...)

Methyl Ctrlotrde C H L I

Neon

Ne

N~tro~en

. .

N

Oxygen

- . .

r

Phosyerre I -

ropane Comrnerc l l

- - .

-.

Sulphur

0:oxldtt

SO

Cheen

~gnal

ed

- - - *

b ~ h t runsw~ck

GIeen

41

1 Black

I - bss

630 a k

.

Gbss

None

.

P ~ L O C ~ ue 103

Note

For

dour+

White

and E I k k u)reference number is

quoted

inBS 381C.



IEV.

APPENDIX

COLOUR IWNflFlC TION

FOR MEDICAL

GAS-VlD+RS

1319

Table 4

Vl)ua

End

Oxvaen

I

0 2

Nitrous Oxide

_.

N70

Cyctopropm

.

C3Hn

arbon Dioxide C02

Ethylene

C7H4

Helium

He

Nitroaen NZ

Oxygen Carbon Dioxide (mixtures) 0 7 C07

Oxygen

nd

Helium M i m e s

0 2

He

Air Media l )

AIR

Oxygen ndNitrous Oxide mixlures 0 2 N 7 0

W h l t ~

French nlue

-

-

ig ht Orange

-~r en ch rey

Dark Violet

-

~ddle rown

--

R i x

--

White and

BS

381C

I ...

Illack Gloss

-

166rnnch Rlue GlossIMatt

~

.1ghtOrange

7

GlosslMatt

rrench Grey

-

630

Gloss

Dark Violet 796 Gloss

Middle Drown 41 1 Gloss

French Grey

-- -

63 Gloss

Black Gloss

Rlack

I

Gloss

French Grey

.

63 Gloss

.

French

Wue 166

Gloss

French Rlue

I

166

I

I

I

NOTE

For

White

and

81ack.

no referencenumber

k quoted in

BS

381C.



OOC

NO. KOC P 002

I

of

55

I Rev 2

. -

APPENDIX

--8

SCHEDULE : PAlNTlNG SYSTEMS FOR ONSHORE

TRUCTURAL- - . TEEL WORKS

I 1

G, Q.

Lbddcn

Nmdrdl.

Fmclng, Stdrwavs. Wdkwnv

Stdr

t reads, Cable trays, Du ctinn rmd Platforms.

2 ~encrd oncrete I ot Concrete Encased Structrmd Steel Work.

SCOPE

Ladders. platforms.

handrails, sta ir treads.

open

grid flooring sted

grating.

SPECIFICATION

Hot dtr, galvantnnq anti Top

cnattnq

Hot

dip

galvani~ing

Plqarat

on

- Vtwal standard Sa

2

BS 729 rr,qrrtr~rncnts

Coating-

Hot dtp ~alvan17c hall

b~

car r t4

OII~

In accordancr, wvth RS 729

The mtntmum coattnq wo qht

shall be 610 ~rarnslrn' urface

Top coating

Top coatvnq of galva nrwd

surface maybe rrq r~ t r dor

colour c d mg

r

for rnaintmanc~

of smrral weathered tt m s

&qal;rtio

In accordance wi th clarrse

8.12

of this Standard.

Interm(H1~ale

Two-pack High-build Epoxy

FAjsk

Recoatable Acrylic Polyurathane

in

the reqtrirmf colorrr.

REMARKS

Wh~rc?ot galvanlsed. rnc system 'R2' for all

axccpt handrails which shall be A 1

1.



SCHEDULE

C: PAINTING

SYSTEMS FOR

MECHANICAL

.

LECTRICAL

- - ND

NSTRUMENTAllON QUIPMENT

Item: RotatingEqulpmcnt lhmps,

Compressors. Motors. etc.), Elr?ctrical Eq tt i pmn t m Equipment's

Supparts

SCOPE

Pumps, Compressors. Motors. Fans

etc.

- -

.-.- .. -- .

SPECIFICATION

MIN. THICKNESS

DFT IMICRONI

-

. - -

. .

- A s f o r A l - 1 , A l - 3 ,A1 4 a n d A l - Bsys t cm s

Machinery and drivms. instrrtrnents

Pi

ass ocia l4 valves may

he fin ish coated tn accordance wcth man~rIactttrc?r's taridard

coatinn syslmns.

Manttfactrtrcs shotrld provide d~tails

f

the p r o m s d

PAINTING

systems for fttttrre maintcmance and fopair.

The pa nt system mttst bc? capable of wtthstanding the

c?nvtronrncntal cnndt ttons for pcrrtod nf

5

vcnrs to Ri3 pm BS

3900 H scale of drylrw of ntstinq.

Movi

Parts:

FF~~SZ~ I TXP~~ouplings etc.

Electrical Equipment

Motors, Switchmars, Standard

quipment

ransformers

Rectifiers

Preprat on-

VI~II~Itandard Sa3

S ~ ~ r f a c orollle 25-35 micron

Coattng Syz1c.m-

Shail i)(?a ~or system A 1-1

This type of eq ~ripment hall be prc?pard, prim&

t

finished

in accordance with the man~tlact~rrcr 'standartl.

The system mttst

be

canahle of wtthstanding th e

environmcnfal cnncfitions for

period of 5

ycars to Ri3,

per

BS

3 9 0 0 H3 scale o f d q r w 01 rusttnq.

Housings and

Equipment Supports.

Pr9arjat;bni

~tsr~aTstandarda 2

Surlace proltle

25-35

micron

Pnmitnt :

coc rtch Epoxy

Intr?rrndiale:

' f w d

High

buitd

MI0

F w x v

Ftnrsh:

Ar.iviZ ModifidPolyurethane

Control Pands

As lor C3 Svstem

REMARKS

Total patnting system to be shop appl id.

Total painting system to be shoo applied

Manufacturer's standard shall be sttbiect to

KOC approval.

Housings to be finish coated in sdlers

works.

Shop fabricated supports shan he

patntcd in workshop.



APPENDIX 3

NGtCOATING SYSTEMS FOR OFFSHORE STRUCTURE

8

EQUIPMENT

EXTERNALSUR_FACES ATMOSPHERIC

ZONE,

SPLASH

ZONE

AND SUBSEA

hems: Structural Steel Tanks. Vessels.

Piping,

Valves Plant Equipment.

Dl:

Atmospheric

Zone

Pn md surface

to

be

tree

of zinc

salts

prlw

to

1 coatrru.

Inorganrc Ztnc Srbcatepruned surfacesh ll

be

rested lor w r e e of cure pror

to

over

coarmq. SM clause 10.6.2)

Prtriwd surfaces to be f rw of

rm

salts prmr to

funsh coalmy.

Inorgmrc Zmc Sllrcate pr~nwd urface shall be

leslt?d oc dqru e of cure p r w to

ovw

coarmg.

l s w clausel0.6.2J

econd

ccktt to ba

ppked

as

a

trust prior to lull

Cwlrn().

S m o

s 01-1

Allerndi~ve lyruents to

Al shall

be used

m

zone

1

;vws lscw clause 6.5 .1 7.1

5).

Slllcorl Alu~nrwnl~nrslr oal

nwy

no1 tully cure

ur l l~lqurpmcrbl In servce.



APPENDIX

SCHEDULE O 1Contd..

S OPE

CS

ow alloy

s t d sttrfaces.

Uninsrrlated

Up to

55 °C

Stainless steels AlSl 300

and

400 series and duplex

t y m

Up to

120ec

---- Ad..

SPECIFICAT ON

Propara1nn:

~ l s ~ r n itindard Sa 3

S~rrfacc roltlc 50 nvcrons

First coat:

AI~Meini pray

Finlsh:

t;?mperatrrre

A l

Silicone

hcparatlo?

IT1stcai st ~r ~c fa rda

3

Prrrn~rig-

/6orclawc Zinc Silicate

Tle coat-

Two-pack Epoxy

Fincsh:

Two gack hiqh bttild MI 0 Epoxy

f2 coats1

Fqariyio":

Vlsr~a l tandard Sa 3

Srr rlxe profrle 5 0 micron

Prirningi

hi%<antc Zinc Sil icate

~intsh:

Twollack Epoxy tie coat

~ryara t ron :

V ~ w a itandard Sa 2

In

accordance wl th clattse

8 11

Prrmtng

li q11 I~celd poxy for stainless

stclcls

Ftnl5hl

Rrcoa tahlr Acrylic Polyr trclthanc

iO

70

Total 17 0

7

5

25

7x75

Total

250

75

25

Total

1

0 0

Total 700

REMARKS

ShRH not be

used

far services opetatkg

hr

wea

zone

1.

- Primcd srtrface to be f r w of 7inc salts prior to

f ncsh coatinn.

Inorqanrc Zinc Silicate primed swfacc? shall b e

t ~ d dor dcqrcv of cure prior to over

coating. l sce clartse

10.6.2

As above

Dl -5'

remarks.

Under

no

drcumlPtrnces

shall 7inc conlain inn paints

hr?

rt s 4 on starnl~ss lael s~trfaccs



SCHEDULE

D

lcontd

I

CS

slruclures

and

Jelt~es.

Galva~wtnl tccl structure

Harldrall

Galva~~lredteel structure

Gra1111y

. . .

. .

SPECIFICATION

Pre@fmon.

Vtsual st~~rdard

a 2%

In accordawe w11lr clause 8 .11

1

I~US

Sldllddrd

Coatmc_l

Two

coals ol Foster Allas hual

reusidrlcu 57 73 r approvcd

F

I

Coal Tar

Epoxy 13

coals)

wN 7HICKNESS

OFT IMICRQNI

Same

as 0

7'

above

Galvarured

surlaces

must

be as

per

BS

729.



APOENOIX 3

SCHEDULE Contd.1

Deck Heavy Duty Non -sl ~p

Deck

Light Duty Non-slip

Preparation;

- VISBI~I?aridardSa 2

St l r l ac~~r ~ l t l o

5

35 micron

Priming;

Ztnc r~ c h pack Epoxy

Finish:

-- .

S ~ k aand fill4m o d i f i d q m xy

ckd d ~ n g

overed

wtth non spark ng

aggregate,

sweep away ex c~ ss

SF ;

Two pack epoxy

P_rpa""

V~su al tandard Sa

2%

Surface profda 25-35micron

Priming:

zn:

r~ ch pack poxy

Finish:

Two pack Epoxy co ve r~

with

non-

sparking aggrcgalc?

5 0

Total 3100 3.1 mm)

50

250

Total 300

.



DOC. NO. ROC-P-001

I

Page

5 of

--

--- -

.

REV.

2

APPENDlX

E

SCHEDULE

E:

lNTERNAL PAINTING S Y S W M S. OR TORAGE

A

AND

PROCESSING

- FOUlPMENT

It-:

Tanks k strlrJIB~~tlSlopIt)rmln.IBrbckish

ater. Desalter wash water and Fire water tanks. Wetldr y crude tm ks

nd

Test tmks.

Gmerdf f resh

wster

Services. SeparMors. Drains sump vessel. Drains flash vessel nd Desdters.

Wet crude storefln and Test

tanks (fixed or floating

roof) inclrrding int ma l

structures and piping inside

and or~tside.

I

Wet crude starm e snd Test

tanks (fixed or floating roof1

incldin l Interns1 structures

and piping inside and

outside.

IndustrisflBaflastl

SloplDemin. /Brackish

water, Desalter wash water

(md fire water tanks

(inckrdmg nternal

structures and piping inside

nd outside).

Dry crude tanks

f_opara Ion-

Vlzr~al tandard Sa 2

s~~rfacerof~lc

5

mtcron

Pr~m~_ng In_tfrmc.dtat~lFtn~sh:

fi;rw coats ol Coai f m Epoxy (Amme

cur~ d )

P'eparation:

Vt sr d SiSndard Sa 2

surface profile 7 5 mlcron.

Priming:

m m t d e Epoxy primer

Finish:

Twocoa ts o f high build Coal Tar Epoxy

Reparat oz

31CuXStandardSa 2

surface proftle

7 5

micron.

Rimingl~nyrmediateIF~nis~

-

oats

Cod

f i r

Ei)oxv IAmine

cured)

The

shell plates may be sr thwt to

coating as per systc?m

€2.

if rcquird

bv

KOC-MV-007,Data Sheet.

MIN. THICKNESS

or

T MICRON)

-

-

3x150

Total

4

50

Total 350

3x150

Total

F~hrc t ss ining

in

~ccnrdance ~t h

OC-P-

0 0 2 Part 2.

Entire floor plt~ s mcters of the loww shd l

corssc or mar. expw,ted water I e v ~ l

0.5

mc.tc.rs) whichcvcr is gredtcr.

Rdnr to KOC-MV-007 or information on

arms to he coated I ot coated bv coal tar

m x v .

Same as E 1 1 above.

Fibre glass lining in accordance with

KOC-P-

0 0 2 Part 2.

Entire floor plus 0.5 meters of the loww shell

course.

Fibre glass lining in accordmw w~th OC P-

002

Fnt~rc.loor plr~s

5

meters ol ttic 1owc.r shell

cot~rsc.

. . .



ACKNOWLEDGEMENT

This S tandard has been approved

by

th e S tandards Technica l Commi t tee STC

consist ing of t he following

:-

,:. Ali ti

Babe

( Sta nda rds Div.)

Chairman

M I

ohd. Ernam

( Ins?.

Corr. Div.) De put y Chai rman

Mr. S. Kumar

(

Stan dard s Div.) Secretary1 Member

Dr. Moham mad l lyas

( Sta nda rds Div.) Memb er

Mr. Khalid S. AI-Ali (

Maint. Proj. Div.) Me mb er

Mr.

Henry

S,

Hill (

Maint. Ping. Div.) Mem be r

Mr. Jassem Al- Ouraini

( PMD-

North

)

Member

The dre9

c

thls Standard h a s been ci rculated t o the KOC User De pa nm en ts for thelr

rEvli . i*i E 1s

c c r n m e x s werE r rzeived f rom the fol lowing

:-

ENGIKEERING GROUP PROD. EXPORT OPERATIONS GROUP

Gen . Supdt . Engg. Services

Gen. Sup dt . Prod. Services

Gen .

S ~ p 3 t . roj.

M g m t

N W 1

Gen. Supdt . P rod. Opns

(

N&W

Gen .

S ~ i p d r .

roj

Mgmt ( S

) Gen . S u p d t . P ro d. O p n s

( S

MAJOR PROJECTS GROUP INDUSTR IAL

SERVICES

GROUP

Ge7

S,>31

Engg Projects

N&E 1

Gen. Sup dt . Ahmadi Services

MAINTENANCE GROUP

Gen. Supdt . Main t . Sv cs .

Gen. Supd t . Maint .

(

N W

)

LOSS PREVENTION GROUP

Gen. Supd t . Consv. Insp.

Gen . S u p d t . Fire S a f e t y

DWIDED

ZONE

GROUP

Su pd t. Proj. Engg. Facilities

Div.

his KOC Stand ard

for

Painting an d Coating of Meta l Sur fa ces - New Construct ion

has

b e e n a m e n d e d

by the Task

Force

( TF-PC101

) compris ing

of the

following

m e m b e r s

:

KOC-P-001 R2 Painting and Coating of Metal Surfaces New Construction

Documents

Transcript of KOC-P-001 R2 Painting and Coating of Metal Surfaces New Construction