Yibal Khuff Project (YKP) Specification for External Coating Ac co un tab le/ Ap pr ov al ( ATA/IFA) ATA /IFA) Dis tr ib ut io n L is t:
Name
Function
Signatur e / Date Date
Responsi Responsi ble/Reviewer ble/Reviewer / Checker (RTA/I (RTA/IFR) FR) Distribut ion List:
Name
Function
Signatur e / Date Date
Function
Signatur e / Date Date
Informed (IFI) (IFI) Distribu tion Li st:
Name
KHF-00-104133-RA-7754-00001-0000 / Rev 02
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Yibal Khuff Project (YKP) Specification for External Coating Revision History Revision No. 01 02
Date 09-Sept-15 14-Jan-15
Autho r TAA MM
Scope / Remarks Issued for Review Issued for Approval
Holds List S.No
Reference Clause
KHF-00-104133-RA-7754-00001-0000 / Rev 02
Remarks
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Yibal Khuff Project (YKP) Specification for External Coating Table of Contents 1.0 Int ro du ct io n .............................................................................................................................. 6 1.1 Proj ect Descr ip ti on .................................................................................................................. 6 2.0 Purpose .................................................................................................................................... 7 3.0 Scope ........................................................................................................................................ 8 3.1 Excl us io ns ................................................................................................................................ 8 4.0 References ............................................................................................................................... 9 5.0 Abb rev iat io ns ......................................................................................................................... 11 6.0 Defin it io ns .............................................................................................................................. 11 7.0 Ord er of Preced ence ............................................................................................................. 12 8.0 Coati ng Materi als ................................................................................................................... 13 8.1 Recom men ded Materi als ...................................................................................................... 13 8.2 Therm al Spr ay Coati ng s ....................................................................................................... 14 9.0 Equi pm ent .............................................................................................................................. 14 10.0 Surf ace Prepar atio n ............................................................................................................ 14 11.0 Coati ng App li cat io n ............................................................................................................. 14 12.0 Con tr ol and Insp ecti on ....................................................................................................... 15 13.0 Safety .................................................................................................................................... 15 14.0 Paint in g & Coati ng Sch edul es (PCS) ................................................................................ 15 Notes: ............................................................................................................................................ 17 15.0 Coati ng Syst ems ................................................................................................................. 17 16.0 Painting and Coating Schedules (PCS) Datasheets ........................................................ 18 SCHEDULE: PCS-13 .................................................................................................................... 19 SCHEDULE: PCS-14 .................................................................................................................... 21 SCHEDULE: PCS-15 .................................................................................................................... 22 17.0 Painting and Coating System Evaluation ......................................................................... 23 17.1 Intro ducti on .......................................................................................................................... 23 17.2 Perfo rm anc e Tests .............................................................................................................. 23 17.2.1 Perfo rm ance Tests ........................................................................................................... 23 17.2.2 Test Meth od s .................................................................................................................... 23 17.2.3 Acc eptan ce Cri ter ia .......................................................................................................... 23 17.2.4 Evalu ati on Meth od Post Test .......................................................................................... 23 17.2.5 Application and Technical Application .......................................................................... 23 18. App ro ved Coat in g Sy st ems and Vendo rs ........................................................................... 29 PCS-1 Extern al Coati ng fo r Abov e Grou nd Struc tur es up to 100 °C ..................................... 29 PCS-3 External Coating f or Above Ground Structur es between 100 to 400 °C either in su lat ed or no t in su lat ed. .......................................................................................................... 29 PCS-4 External Coating fo r Steel Str uct ures Under In sul ation up to 100 °C ........................ 30
KHF-00-104133-RA-7754-00001-0000 / Rev 02
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Yibal Khuff Project (YKP) Specification for External Coating PCS-5 Extern al Co ati ng fo r St eel St ru ct ur es >400 °C .............................................................. 30 PCS-6 External Abo ve Ground Coating fo r Galvanised Steel and Stainless Steel Struc tures up to 100 °C .................................................................................................................................. 31 PCS-15 Exter nal co atin g fo r carb on st eel pip eli nes (3LPP) ................................................... 31 PCS-15 Exter nal co atin g fo r carb on st eel pip eli nes (3LPE) ................................................... 32 Appen di x - 1 FORM TO B E APPENDED WITH EVERY PA INT PROCEDURE ......................... 33
KHF-00-104133-RA-7754-00001-0000 / Rev 02
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Yibal Khuff Project (YKP) Specification for External Coating 1.
Introduction
1.1 Project Description The Yibal field is located approximately 300 km southwest of Muscat and 50 km southwest of the Fahud field. The Yibal Khuff project involves the integrated development of the Upper Khuff, Lower Khuff and Sudair reservoirs located below the currently producing reservoirs in the Yibal field.
The project includes development of wellheads, RMSs, flow lines/trunklines, a Central Process Facility (CPF) and a Power Plant. The CPF includes: Inlet facilities, Liquid handling (Oil and Water Processing), Gas Treatment, Sulphur Recovery and Blocking, Utilities Complex.
High level block diagram of the facilities is shown in the following Figure.
Figure 1 Yibal Khuff Project High Level Block Diagram
High level description of the Off-plot facilities:
•
47 well sites.
•
Each well site is tied back to one of three Remote Manifold Stations (RMS) through 6 inch buried flow lines.
•
The West and South RMSs are connected to the CPF through single CS trunklines each, while the East RMS is connected through dual CS trunklines.
•
Fuel gas lines from the CPF to each RMS
•
Gas export pipeline from CPF to the GGS downstream of GGP
•
Oil export pipeline from CPF to MOL downstream of Yibal A
KHF-00-104133-RA-7754-00001-0000 / Rev 02
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Yibal Khuff Project (YKP) Specification for External Coating • •
Water export pipeline from CPF to Yibal A skim tanks Raw water import pipeline to the CPF
High level description of the CPF facilities: •
2-phase inlet separator to receive and separate liquid and gas.
•
Acid Gas Removal Unit (AGRU) using Shell Sulfinol-X where deep removal of H2S, CO2, RSH and COS is accomplished.
•
Gas dehydration and molecular sieve unit for water and trace RSH removal to meet 5 ppm mol total sulphur specifications.
•
Hydrocarbon Dew Pointing Unit (HDPU) using direct R134a refrigerant to meet cricondentherm specifications of export gas.
•
Gas export compressor comprising 2 x 50% single stage fixed speed, centrifugal machines.
•
Acid Gas Enrichment Unit (AGEU) using MDEA to concentrate the acid gas from the AGRU for processing in the Sulphur Recovery Unit (SRU).
•
Sulphur Recovery comprising 2 x 65% SRU, sulphur degassing and incinerator and CANSOLV SO2 scrubbing to meet sulphur recovery e fficiency and SO2 emissions regulations.
•
Sulphur handling comprising liquid sulphur storage and sulphur blocking facility.
•
Oil handling system comprising 3-phase separation, flash gas compression, oil dehydration & desalting, wet stabilization, storage and export
•
Water handling system comprising 2 x 100% sour water stripping using steam, water storage and disposal pumps.
•
A power plant using a Frame 6B gas turbine and HRSG, utilizing steam to supplement the steam being generated from waste heat recovered in the sulphur recovery process. A back- pressure steam turbine generator will let MP steam down to the LP steam system.
•
Steam generation and distribution for MP and LP steam with 2 MP auxiliary boilers.
•
A closed loop chilled water cooling medium system with mechanical refrigeration unit using R-134a as refrigerant.
•
A utility complex including raw water treatment facilities to produce boiler feed water, steam condensate polishing, instrument and breathing air systems, fire water, chemical injection system and nitrogen generation.
•
Flare system (AP & LP) including AP flare gas recovery compressor.
•
Drain Systems (closed, continuously contaminated and accidentally contaminated).
•
Provisions for future depletion compression, including plot space and process tie-ins.
•
Waste handling and effluent treatment facility
2.0 Purpo se The purpose of this document is to provide the minimum requirements for protective painting and coating systems, materials and application methods for the external surface of steel structures, piping, buried and above ground pipelines, equipment, and their associated components for the Yibal K huff Facilities.
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Yibal Khuff Project (YKP) Specification for External Coating 3.0 Scope The specification covers the requirements of surface preparation, coating procedure, coating pre-qualified test methods, qualification requirements for paint/metal spray, and associated acceptance criteria, inspection, environmental control, service color coding identification and documentation for the Yibal Khuff Project Facilities.
This specification is based on SP 1246 parts 1-5. All vendors shall provide compliance to SP 1246 parts 1-5 and this specification for external painting/coating.
For pipelines, this specification is based on ISO 21809-1 and DEP 31.40.30.31-Gen. Vendor shall provide compliance to ISO 21809-2 and DEP 31.40.30.31-Gen.
The scope of this specification is limited to: •
Above ground Structures and equipment including onshore tanks, vessels, structural steel, and surface electrical and mechanical equipment made of Carbon Steel and Stainless Steel.
• • •
In-plant above ground piping including valves, flanges, etc. made of carbon steel and stainless steel. Areas beneath insulation Pipelines constructed of Carbon Steel.
3.1 Exclusio ns The following materials do not require external painting unless otherwise specified by the Company: I.
Stainless Steel surfaces operating below 60°C*
II.
Duplex Stainless Steel surfaces operating below 100°C*
III.
Super Duplex Stainless Steel surfaces operating below 120°C*
IV.
Nickel based alloys e.g. Incolloy 825, Inconel 625, etc.
V.
Non-ferrous alloys
VI.
Concrete structures and foundations
VII.
Plastic and plastic coated materials
VIII.
Instruments and other glass gauges, valve stems, grease fittings, light fittings.
IX.
Cathodic protection anodes
X.
Power cables including buried cables
XI.
Identification tags, nameplates and fabrication markings
XII.
Drilling facilities
XIII.
Temporary construction items that are to be removed during the installation phase and to which only a primer s hall be applied.
* These temperatures are based on COMPANY response to technical deviation KHF-00-104133-RA-720500002. This specification is not applicable to: a.
Internal coating of pressure vessels and storage tanks (covered under KHF-00-104133RA-7754-00002-0000).
b.
Buried piping and structures other than tank base plate.
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Yibal Khuff Project (YKP) Specification for External Coating
4.0 References Standard SP-1246 Part 1 – Apr.
Title Technical Requirements for Coating Systems
2010 SP-1246 Part 2 – Apr.
New Construction Coating Systems
2010 SP-1246 Part 3 – Apr.
Maintenance of Coating Systems
2010 SP-1246 Part 4 – Apr.
Surface Preparation, Application and Inspection of Coating Systems
2010 SP-1246 Part 5 – Apr.
Approved Coating Systems
2010 SP-1257
Work at Heights & Access
SP-1279
Specification for Civil & Building Construction Painting and Decorating
SSPC SP-1
Solvent Cleaning
GU-368
Guidelines For The Protection Of Buried Sections Of Surface Laid Pipelines/Flowlines
GU363
Guidelines for use of Scaffolding
DEP 30.48.00.31 – Jan.
Protective Coatings for Onshore Facilities
2009 DEP 30.48.40.31 – Feb.
Thermal Spray Coatings of Aluminum
2012 DEP 31.40.30.31-Gen
External polyethylene and polypropylene coating for line pipe
Feb 2011
(amendments/supplements to ISO/DIS 21809-1:2009)
ASTM D4417
Standard Test Methods for Field Measurement of Surface Profile of Blast Cleaned Steel
ASTM D 3359 ISO 1461
Standard Test Methods for Measuring Adhesion by Tape Hot dip galvanized coatings on fabricated iron and steel articles — Specifications and test methods
ISO 4624
Paints and varnishes – Pull-off test for adhesion
ISO 11997-2
Paints and varnishes – Determination of the resistance to cyclic corrosion conditions – Part 2: Wet (salt fog)/dry/humidity/UV light
ISO 12994-all parts
Paints and Varnishes- Corrosion protection of steel structures by protective paint systems
ISO 4628-2
Paints and varnishes – Evaluation of degradation of paint coatings –
Designation
of intensity, quantity and size of common types of defect – Part 2: Designation of degree of blistering
KHF-00-104133-RA-7754-00001-0000 / Rev 02
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Yibal Khuff Project (YKP) Specification for External Coating Standard ISO 4628-3
Title Paints and varnishes – Evaluation of degradation of paint coatings – Designation of intensity, quantity and size of common types of defect – Part 3: Designation of degree of rusting
ISO 4628-4
Paints and varnishes – Evaluation of degradation of paint coatings – Designation of intensity, quantity and size of common types o f defect – Part 4: Designation of degree of cracking
ISO 4628-5
Paints and varnishes – Evaluation of degradation of paint coatings – Designation of intensity, quantity and size of common types o f defect – Part 5: Designation of degree of flaking
ISO 4628-6
Paints and varnishes – Evaluation of degradation of paint coatings – Designation of intensity, quantity and size of common types o f defect – Part 6: Rating of degree of chalking by tape method
ISO 2815
Paints or varnishes – Hardness testing
ISO 7253
Paints and varnishes – Determination of the resistance to neutral salt spray
ISO 3248
Paints and varnishes – Determination of the effect of heat
ISO 3233
Paints and varnishes - Determination of percentage volume of non-volatile matter by measuring the density of a dried coating
ISO 3549
Zinc Dust Pigments for Paints- Specification and Test Methods
ISO 2808
Paints and varnishes – Determination of film thickness
ISO 11125-2
Preparation of steel substrates before application of paints and related products — Test methods for metallic blast-cleaning abrasives — Pa rt 2: Determination of particle size distribution
ISO 2431
Paints and varnishes - Determination of flow time by use of flow cups
ISO 8504-2
Preparation of steel substrates before application of paints and related products – Surface preparation methods – Part 2: Abrasive blast-cleaning
ISO 8501-1
Preparation of steel substrates before application of paints and related products – Visual assessment of surface cleanliness.
ISO 8502-4
Preparation of steel substrates before application of paints and related products – Tests for the assessment of surface c leanliness – Part 4: Guidance on the estimation of probability of condensation prior to paint application
ISO 8502-3
Preparation of steel substrates before application of paints and related products – Tests for the assessment of surface cleanliness – Part 3: Assessment of dust on steel substrates prior to paint application
ISO 8502-6
Preparation of steel substrates before application of paints and related products – Tests for the assessment of surface c leanliness – Part 6: The Bresle method
ISO 2409
Paints and varnishes – Cross-cut test
ISO 21809-1
Petroleum and natural gas industries — External coatings for buried or submerged pipelines used in pipeline transportation systems Part 1: Polyolefin coatings (3-layer PE and 3- layer PP) (ISO 21809-1:2011)
KHF-00-104133-RA-7754-00001-0000 / Rev 02
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Yibal Khuff Project (YKP) Specification for External Coating Standard NACE RP0188
Title Recommended Practice. Discontinuity (Holiday) Testing of New Protective Coatings on Conductive Substrates
5.0 Abbreviations ABBREVIATIONS
Description
ASTM
American Society for Testing and Materials
BS
British Standard
CFDH
Corporate Functional Discipline Head
CRA
Corrosion Resistant Alloy
CS
Carbon Steel
CUI
Corrosion Under Insulation
DEP
Design and Engineering Practice
DFT
Dry Film Thickness
ISO
International Organization for Standardization
MOTCC
MIXING OF TWO-COMPONENT COATINGS
NACE
National Association of Corrosion Engineers
TA
Technical Authority
TPI
Third Party Inspector
UER
CFDH Materials and Corrosion
VOC
Volatile Organic Compound
WFT
Wet Film Thickness
YK
Yibal Khuff
YKP
Yibal Khuff Project
6.0 Defini tions COMPANY
Petroleum Development Oman LLC of Muscat, Sultanate of Oman.
CONTRACTOR (EP)/
Petrofac E&C Oman LLC i.e. The p arty to the contract with the COMPANY
PURCHASER
who is responsible for providing the Design, Engineering, Purchasing and support for Construction/Commissioning
CONTRACTOR (C)
The party to the contact with the COMPANY who is responsible for Construction, Commissioning and other work under the c ontract.
VENDOR
The party that manufactures or supplies equipment and services to perform the duties sp ecified by the COMPANY or CONTRACTOR (EP).
SUB-VENDOR
A party appointed by the VENDOR for supply of equipment, materials or product-related services in accordance with Specification and its referenced standards and data sheets.
Inspector
Any person/party whom the PURCHASER certifies as acting for and on behalf of the Company to inspect items to be purchased and/or the work done by the VENDOR/SUB-VENDOR.
KHF-00-104133-RA-7754-00001-0000 / Rev 02
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Yibal Khuff Project (YKP) Specification for External Coating Shall
The word ‘Shall’ indicate a mandatory action, not optional, a “must do”
SHALL [PS]
The capitalized term SHALL [PS] indicates a process safety requirement
Should
The word ‘should’ indicate an action that is not mandatory but is expected or recommended, ought to
May
The word ‘may’ is to be understood as indicating a possible course of action
Include,
If the word “include” or “includes” or “including” is used in any document and
Includes,
this report, it shall be taken as h aving the meaning “including but not limited to”
Including
and shall not be considered as creating or inferring any limitation on the description that follows if other components/equipment required
7.0 Order of Precedence The Design and Construction shall comply with all relevant COMPANY standards listed above and International Codes & standards and specifications as applicable to the respective equipment / package.
In the event of any conflict among the documents or sections relating equipment specifications and other technical document requirements, clarifications shall be sought from the CONTRACTOR (EP)/ COMPANY. All deviations to applicable standards and design codes shall be agreed in writing by the VENDOR and the PURCHASER. Where the Company technical specifications refer to or amend international standards and codes, these shall be deemed to b e part of the specification.
All deviations to applicable standards and design codes shall be agreed in writing by the VENDOR and the PURCHASER. Where the Company technical specifications refer to or amend international standards and codes, these shall be deemed to b e part of the specification.
For any equipment & packages the VENDOR shall notify any apparent conflict between Project Specifications, the related data sheets, the codes and standards and any other specifications. Resolution and/or interpretation of precedence shall be obtained from the CONTRACTOR (EP)/COMPANY in writing before VENDOR proceeds with the design/manufacture. In any case the most stringent requirement shall prevail. However CONTRACTOR (EP)/COMPANY interpretation shall be final.
Any changes or variation to the PDO/Shell/International Codes and standards shall be forwarded to the relevant CFDH through the project team of PDO for review and approval (PDO Variance Tracking tool) in line with Project Change Control and Standards V ariance Procedure PR-1247.
The order of priority of design/specification documents shall be as follows: First priority
:
Local laws, decrees and statutory instruments
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Yibal Khuff Project (YKP) Specification for External Coating Second priority
:
COMPANY Policies (PL)
Third priority
:
COMPANY Codes of Practice (COP)
Fourth priority
:
Project Specific Procedures, Instructions, Requisition etc
Fifth priority
:
COMPANY Engineering Specifications (SP) & procedures (PR)
Sixth priority
:
Group standards (Shell DEPs Version 35)+
Seventh priority
:
COMPANY Guidelines (GU)
Eighth priority
:
National Standards
Ninth priority
:
International Standards
While deciding on the order of priority, due consideration shall be given to safety and ease of operation and maintenance in this order of precedence.
Where the Company technical specifications refer to or amend international codes and standards or other specification, these shall be deemed to be part of the specifications.
8.0 Coating Materials 8.1 Recommended Materials Recommended generic materials are detailed in the relevant section for each system in Section 14 of this Specification which is in line with SP-1246 may only be used if they meet the performance criteria defined in Section 17 of this Specification. Demonstration of performance criteria to the requirements of Section 17 is necessary before any paint/coating system can b e used.
The materials specified in Section 14 of this Specification are those appropriate to large scale application. For local treatment brushable grades of these materials ma y be found to be necessa ry and the number of coats may need adjusting to achieve the necessary dry film thickness (DFT). The use of brushable grades of the materials specified in Section 14 will not require any additional testing in accordance with Section 17.
Metallic coatings (such as Hot Dip Galvanizing), paint vendor responsibilities, paint colours, VOC requirements, uniformity of supply, packaging, labeling and shelf life shall be as per section 3 of SP-1246, part 1.
The colour coding of the final coat of a coating system shall be in accordance with section 3.3 of SP -1246 Part 1.
•
Primary and secondary structural items in carbon and low alloy steels shall be coated with the PCS-1 system up to 100degC.
•
Lifting lugs, reinforcement pads and other structural components directly welded to the equipment/piping shall be coated with the same system as the equipment/piping.
•
Tertiary structural items, such as platforms and ladders specified in carbon and low alloy steels shall be hot dip galvanized. If tertiary steel requires color coding (e.g., safety yellow for ladders), then it shall be coated with PCS-6 system on top of galvanizing as per KHF-00-104133-RA-7754-
KHF-00-104133-RA-7754-00001-0000 / Rev 02
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Yibal Khuff Project (YKP) Specification for External Coating 00001-0000. The structural nuts / bolts shall also be galvanized. It shall be ensured that If hot work is performed on galvanized items situated in the vicinity of stainless steel components, they SHALL [PS] be shielded (e.g. with fire blankets) to avoid contamination.
8.2 Thermal Spray Coatings All Austenitic Stainless Steel items operating above 60°C, Duplex Stainless Steel items operating above 100°C & Super Duplex Stainless Steel items operating above 120°C shall be externally coated with Thermally Sprayed Aluminum (TSA) and shall comply with DEP 30.48.40.31. DFT requirements shall be as per DEP 30.48.40.31.
9.0 Equipment The following shall be as per sec tion 4 of SP-1246, Part 4. •
Compressors
•
Blast cleaning equipment
•
Abrasives, spraying equipments
•
Scaffolding
•
Standing and accessibility
10.0 Surface Preparation Surface preparation shall be carried out in general accordance with the following Standards ISO-8501, ISO 8502, ISO-8503 and ISO-8504 which have been developed to cover all aspects of surface preparation.
Surface preparation shall not be undertaken when: •
Surface temperatures below 5°C
•
Surface temperature is less than 3°C above dew point of the surrounding air
•
The relative humidity of the air is greater than 85%
•
Outside day light hours on external surfaces.
COMPANY may authorize surface preparation outside daylight hours, but the SUBCONTRACTOR must receive written approval before proceeding.
Prior to blast cleaning, power tool cleaning, blast cleaning s hall be done as per section 5 of SP-1246, part 4.
For pipelines, surface preparation shall be done in accordance with Section 10.1 of ISO 21809-1 as amended by DEP 31.40.30.31-Gen.
11.0 Coating Applicatio n The following shall be as per sec tion 6 of SP-1246, part 4. •
Coating application,
•
Environmental conditions during coating
•
Application techniques
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Yibal Khuff Project (YKP) Specification for External Coating
For pipelines, coating application shall be done in accordance with Section 10.2 of ISO 21809-1 as amended by DEP 31.40.30.31-Gen.
12.0 Contr ol and Inspecti on The following shall be as per sec tion 7 of SP-1246, part 4. •
Control and Inspection
•
Project Co-ordination and Technique Service
•
Inspection and Testing
•
Reporting
For pipelines, inspection shall be done in accordance with Section 11 of ISO 21809-1 as amended by DEP 31.40.30.31-Gen.
13.0 Safety The following shall be as per sec tion 8 of SP-1246, part 4. •
Safety
•
Fire and Explosion Hazards
•
Toxic Hazards
•
Safe Working Conditions
•
Scaffolding and Ladders
•
Safety Reporting
14.0 Painting & Coating Schedules (PCS) Painting and coating selection schedules shall be as per section 3 of SP-1246 part 2. Painting and coating selection shall be carried out at operating temperature.
Area o f Ap pl ic ati on
Coat in g
Reference Nos.
External coating for un-insulated carbon and low alloy steel at up to o
100 C
Epoxy system comprising:
Primary and Secondary Structural o
Steel (up to 100 C) - Note-1
External coating of above ground un-
Primer Intermediate coat PU Top coat
PCS-1
Min DFT 200 microns
insulated fuel gas pipeline up to o
100 C.
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Yibal Khuff Project (YKP) Specification for External Coating
Area o f Ap pl ic ati on
Reference
Coat in g
External Coating for carbon and low alloy steel– insulated or uninsulated o
101-400 C
Nos.
Ambient curing system Inorganic zinc silicate Heat resistant aluminum silicone
PCS-3
Min. DFT 100 microns
External Coating for carbon and low alloy steel beneath Insulation - Below
Aluminum mastic to min. DFT 125 microns
PCS-4
o
ambient to 100 C External Coating for carbon and low
Silicone system or thermal sprayed aluminum
PCS-5
Min. DFT 100 microns
(Note 3)
Silicone system or thermal sprayed aluminum
PCS-5
Min. DFT 100 microns
(Note 4)
External Coating for Galvanized
Epoxy Intermediate and PU top c oat
PCS-6
Carbon Steel and Stainless steel items
Min. DFT 100 microns
(Note 3)
o
alloy steel, > 400 C Stainless steels, Duplex SS, Super Duplex SS Alloy 825 (Insulated)
Thermally Sprayed Aluminum External Coating for Insulated or Uninsulated Stainless Steel piping and equipment >60°C operating temperature for Austenitic Stainless Steel >100°C operating temperature for Duplex Stainless Steel >120°C operating temperature for Super Duplex Stainless Steel
Min. DFT 250 (+40 + 40) microns (Total system minimum thickness). 40 microns each is for topcoat and sealer, as applicable).
Max 500 microns.
PCS-13 (Note 5)
TSA coatings shall also comply with Shell DEP 30.48.40.31-Gen. In case of conflict between this
specification
and
Shell
DEP,
CONTRACTOR shall be contacted for further guidance.
External coating for carbon, low alloy steel and stainless steel stud bolts and nuts
up
to
maximum
temperature of 200°C.
operating
Zn-Ni electroplating PTFE top coat
PCS-14
(Note-2)
Structural Nuts/Bolts
Galvanised
-
Tertiary Structural Steel
Galvanised
(Note-1)
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Yibal Khuff Project (YKP) Specification for External Coating
Area o f Ap pl ic ati on
Coat in g
Reference Nos.
External coating for buried carbon
3LPE for the temperatures up to 80 deg. C
PCS-15
steel pipelines
3LPP for the temperature up to 110 deg. C
(Note 6)
Notes: 1.
Tertiary structural items, such as platforms and ladders specified in carbon and low alloy steels shall be hot dip galvanized. However, if in the vicinity of SS equipment, these items shall be c oated with PCS-1. If tertiary steel requires colour coding (e.g., safety yellow for ladders), then it shall be coated with PCS-6 system on top of galvanizing. It shall be ensured that If hot work is performed on galvanized items situated in the vicinity of these components, they SHALL [PS] be shielded (e.g. with fire blankets) to avoid contamination.
2.
Though DEP 39.01.10.12-Gen, version 35 is contractually applicable to this project, however, version 39 allows the use of Zn-Ni electroplating + PTFE topcoat on stainless steel nuts/bolts. DEP 39.01.10.12-Gen, version 39 states that “Contact of zinc with safety critical stainless steel equipment SHALL [PS] be prevented. Contact includes zinc containing coatings and contamination by zinc in fire scenarios from other equipment but not electroplated zinc or zinc-nickel fasteners.” COMPANY has allowed this clause from version 39.
3.
PCS-6 system can be used for un-insulated stainless steels in place of PCS-5 system up to 100°C after qualification of the PCS-6 system for the relevant conditions. This is not applicable for insulated items. Prior COMPANY approval shall be required for such a case.
4.
Insulated corrosion resistant alloys shall be coated with PCS-5 system.
5.
These temperatures are based on COMPANY res ponse to technical deviation KHF-00-104133-RA7205-00002.
6.
3LPP shall not be used for design temperatures below 0°C. Low temperature limits on 3LPE and 3LPP shall be as per DEP 31.40.30.31-Gen.
15.0 Coating Systems The following shall be as per sec tion 4 of SP-1246, part 2. •
System Compatibility
•
Painting and Coating Schedules
•
Protective Coating for Stainless Steel
•
Health and Environmental Restrictions
•
Colour Finishes
For pipelines, all the details including compatibility, coating materials, requirements for coating system etc. shall be as per ISO 21809-1 as amended by DEP 31.40.30.31-Gen.
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Yibal Khuff Project (YKP) Specification for External Coating Sections 10, 11, 12 and 13 of this Specification give information on the surface preparation, coating application, inspection requirements and HSE respectively referred to in the data sheets.
Section 18 of this specification gives the approved list of coating systems that contractors need to follow.
16.0 Painting and Coating Schedules (PCS) Datasheets The following shall be as per sec tion 5 of SP-1246, part 2. 1.
PCS-1
External coating for above ground carbon and low alloy steel structures up to 100ºC
2.
PCS-3
External coating for above ground carbon and low alloy steel structures at temperatures between 100 – 400ºC (insulated or non-insulated)
3.
PCS-4
External coating for above ground carbon and low alloy steel structure beneath insulation
up to 100ºC 4.
PCS-5
External coating for carbon and low alloy steel structure >400ºC
5.
PCS-6
External coating for galvanized carbon steel and above ground stainless steel structures
6.
PCS-13 External coating for above ground stainless steel (Insulated or uninsulated)
7.
PCS-14 External coating for carbon and low alloy steel BOLTS & NUTS
8.
PCS-15 External coating for carbon steel pipelines
Systems PCS 13,PCS 14 and PCS-15 are not detailed in SP 1246 and hence these shall be as follows.
KHF-00-104133-RA-7754-00001-0000 / Rev 02
Page 18 of 34
Yibal Khuff Project (YKP) Specification for External Coating SCHEDULE: PCS-13
External coating for above ground stainless steel (Insulated or uninsulated)
DESIGNATED USE External coating for above ground austenitic stainless steel, duplex stainless steel & super duplex stainless steel structures in onshore locations above operating temperatures 60°C, 100°C & 120°C respectively.
APPLICA BL E STRUCTURES Tanks, vessels, separators, flare stack piping, exchanger shells, columns, associated pipework and fittings (insulated or uninsulated) in stainless steel.
TESTING AND ACCEPTANCE CRITERIA As shown in Section 17.2 of this Specification SURFACE PREPARATION Surface preparation shall comply with Section 10 of this Specification. Blast cleaning standard:
ISO-8501-2001 Sa 2½
Surface profile:
75-100 microns
COATING SYSTEM Primer Type:
Not Required
Application method: DFT microns:
Intermediate Coat Type: Application method: DFT microns, minimum:
Thermal Spray Aluminum Arc or Flame Spray 250
Sealer Coat (Note 3) Type:
Epoxy to a temperature of 120°C Silicone to a temperature of 450°C
Application method: DFT microns, maximum:
Airless spray 40
Top Coat (Note 2) Type: Application method: DFT microns, maximum:
KHF-00-104133-RA-7754-00001-0000 / Rev 02
Aliphatic Polyurethane Airless spray 40
Page 19 of 34
Yibal Khuff Project (YKP) Specification for External Coating Total system min DFT microns:
250 + 40 + 40 (max system thickness shall be 500 microns)
COATING REPAIR Remove all dirt, oil and grease by detergent or solvent washing. Rinse with fresh water. Dry thoroughly, lightly abrade or sweep blast to remove gloss and feather edges up to 1 inch around the defect site and then grit blast to Sa 2½. The coating used for repair shall be the same as the original and shall have the same DFT.
NOTES 1.
Operating temperature criteria shall be considered for the application of TSA coatings.
2.
Top coat (Aliphatic Polyurethane) is not required in case of insulated service. Topcoat of Aliphatic Polyurethane shall only be required if a certain topcoat colour is required and shall be limited to 120°C.
3.
Sealer coat shall not be app lied under insulation.
3.
Specifications for coating system for Painting and Coating Schedule PCS-13 have been derived from DEP 30.48.40.31
KHF-00-104133-RA-7754-00001-0000 / Rev 02
Page 20 of 34
Yibal Khuff Project (YKP) Specification for External Coating SCHEDULE: PCS-14
External coating for BOLTS & NUTS
DESIGNATED USE External coating for carbon and low alloy steel stud bolts and nuts in onshore locations up to maximum operating temperature of 200°C.
As per DEP 39.01.10.12-Gen., PTFE coating over electroplated nickel/zinc has been found to be effective. PTFE coating may be used up to an operating temperature of 200°C (392°F). Epoxy filled PTFE coatings shall not be used. Quality control procedures shall be developed to cover PTFE handling during transportation, storage and installation to avoid coating damage. Other acceptable alternatives are: •
Ceramic-Al filled coatings
•
zinc/nickel electroplating
•
Hot dip or mechanical galvanising
Cadmium plated bolts shall not be used. PTFE alone coated bolts shall not be employed owing to the potential risk of CP shielding. PCS-14 can be used for carbon and low alloy steel bolts of SS equipment and piping.
INTERMEDIATE COAT Intermediate coat shall be as per Part II of MESC SPE 81/007 (Ver. 13A)
TOP COAT Top coat shall be as per Part III of MESC SPE 81/007 (Ver. 13A)
NOTES 1.
Specifications for coating system for Painting and Coating Schedule PCS-14 have been derived from DEP 30.48.00.32 Feb 2012 and MESC SPE 81/007
KHF-00-104133-RA-7754-00001-0000 / Rev 02
Page 21 of 34
Yibal Khuff Project (YKP) Specification for External Coating SCHEDULE: PCS-15
External coating for Carbon Steel Pipelines
DESIGNATED USE External coating for carbon steel pipeline buried onshore locations up to maximum temperature of 110°C.
Three-layer polyethylene coating (3LPE) can be used up to the maximum temperature of 80 deg. C Three-layer polypropylene coating (3LPP) can be used up to the maximum temperature of 110 deg. C
APPLICA BL E STRUCTURES Underground buried carbon steel pipelines.
SURFACE PREPARATION Surface preparation of the pipeline prior to coating shall be as per Section 10.1 of ISO 21809-1 as amended by DEP 31.40.30.31-Gen.
Epoxy Coating st
1 layer shall be of epoxy material with the properties as defined in Table 3 of ISO 21809-1 as amended by DEP 31.40.30.31-Gen and coating application shall be as per Section 10.2.2 of the cited standards.
Adhes ive Co ating nd
2 layer shall be of adhesive material with the properties as defined in Table 4 of ISO 21809-1 as amended by DEP 31.40.30.31-Gen and coating application shall be as per Section 10.2.3 of the cited standards.
PE/PP Coating rd
3 layer shall be of adhesive material with the properties as defined in Table 5 of ISO 21809-1 as amended by DEP 31.40.30.31-Gen and coating application shall be as per Section 10.2.4 of the cited standards.
NOTES 1.
Qualification, Inspection and testing of the 3LPE/3LPP coating system shall be as per ISO 21809-1 as amended by DEP 31.40.30.31-Gen.
KHF-00-104133-RA-7754-00001-0000 / Rev 02
Page 22 of 34
Yibal Khuff Project (YKP) Specification for External Coating 17.0 Paintin g and Coating System Evaluation 17.1 Introduction Coating systems proposed by the Paint Vendors are to comply with the generic painting systems as specified in Section 14 and may only be used if they can be demonstrated, by testing performed by an independent test house, to satisfy the performance criteria defined in tables 4, 5, 6 & 7 below. Each coating system must pass each of the criteria detailed in the tables 4, 5, 6 & 7 below. In general the assessment guidelines used in ISO12944 and ISO 4628 have been used and the systems proposed should meet the requirements of medium durability with a life of 5 -15 years before maintenance is required.
The performance tests shall be carried out on samples coated from paint manufactured in a regular production batch and not from specially prepared laboratory samples. Test data shall be provided that verifies the composition of the coatings as detailed on the technical data sheets.
For status of existing approved c oatings refer to tables in Section 18. Systems with performance significantly in excess of that required by this Specification may be used, provided any additional capital expenditure associated with the enhanced performance can be justified on the basis of a lifecycle cos t assessment.
17.2 Performance Tests 17.2.1 Performance Tests The required tests for each system are defined in Tables 4, 5, 6 & 7 below.
17.2.2 Test Methods The test methods for each of the tests listed in Tables 4, 5, 6 & 7 below
17.2.3 Acceptance Cri teria The acceptance criteria for each test are defined in Tables 4, 5, 6 & 7 below. To pass the coating system must pass all the acceptance criteria.
17.2.4 Evaluation Method Post Test After performing the tests the samples shall be evaluated by the methods shown in Tables 4, 5, 6 & 7 below.
17.2.5 Application and Technical Application Under the local prevailing site conditions, the coating systems shall be capable of being applied at the specified thickness using application equipment recommended by the Vendor. The coating so applied shall be of uniform thickness, free of runs, sags, blemishes, inclusions and holidays.
The Vendor shall supply technical data relating to the following: All product data and all test data shall be supplied electronically in a read only format such as pdf. File. As part of qualification the Vendor shall provide test data that verifies the solids content and zinc content (if required) as detailed on the technical data sheets. The testing shall be done in accordance with ISO 3233 and ISO 3549.
KHF-00-104133-RA-7754-00001-0000 / Rev 02
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Yibal Khuff Project (YKP) Specification for External Coating •
Solids content
•
Specific gravity
•
Flash point
•
Pot life
•
Mixing method and ratio
•
Recommended wet and dry film thickness
•
Identification of thinners and cleaners
•
Theoretical/practical spreading rates (m2/litre)
•
Application data, including spray pressure, nozzle tip sizes, hose lengths and diameter
•
Health and Safety data
Table -4 Required Tests and Acceptance Criteria – External Onshore Above Ground Structures Tests and Parameters Measured
Holiday Testing
Method
NACE RP0188-99 Adh esi on (dr y) at 23 C Pneumatic pullISO 4624 off (MPa min) Cyclic ISO 11997-2 Exposure Disbonding from ISO 12944-6 X- cut3 ( mm max) Rusting, ISO 4628 cracking, blistering, Chalking (% ISO 4628 max) Hardness ISO 2815 Buchholz Adhesion( MPa ISO 4624 min) Overcoatability ISO 4624 Adhesion (of repair) MPa min Salt Spray ISO 7253 Disbonding (mm ISO 12944-6 max) Rusting ISO 4628 Heat Resistance ISO 3248 (dry) Adhesion ISO 4624 pneumatic pulloff (MPa min)
PCS-1 External A/G <100°C
PCS-3 External A/G 100400°C
PCS-4 Insulated up to 100°C
PCS-5 External >400°C
PCS-6 Galvanised C.Steel o <100 C
PCS-6 Stainless Steel o <100 C
Acceptance Criteria No defects No defects
No defects
No defects
No defects
No defects
5
5
5
3
5
5
RQD
N/R
RQD
RQD
5
5
5
0
0
0
2
2
N/R
90% of as new 5
90% of as new 5
90% of as new 5
5
5
5
RQD 5
RQD 5
RQD 5
RQD 5
RQD 5
RQD 5
0 N/R
0 400°C
0 100°C
0 400°C
0 N/R
0 N/R
> 90% of as new
> 90% of as new
> 90% of as new
KHF-00-104133-RA-7754-00001-0000 / Rev 02
Page 24 of 34
Yibal Khuff Project (YKP) Specification for External Coating
Tests and Parameters Measured
Method
Hardness Buchholz Indenter Chemical Analysis Part Solids Zinc content
PCS-1 External A/G <100°C
ISO 2815
ISO 3233 ISO 3549
RQD RQD
PCS-3 External A/G 100400°C
PCS-4 Insulated up to 100°C
PCS-5 External >400°C
Within ±10% of original
Within ±10% of original
Within ±10% of original
RQD N/A
RQD
RQD
PCS-6 Galvanised C.Steel o <100 C
PCS-6 Stainless Steel o <100 C
RQD N/A
RQD 0
NOTES 1.
The required tests and acceptance criteria for PCS-1, PCS-3 and PCS-6 have been taken from Table B1 of SP1246-1.
2.
The required tests and acceptance criteria for PCS-4 and PCS-5 have been taken from Table B7 of SP1246-1.
Table -5 Summary of Performance Tests Test/Method Holiday Test NACE RP0188 Adh esi on (dr y) ISO 4624
Adh esi on (Shear ) ASTM D1002 Cyclic Exposure ISO 11997-2
Test Type
Basic Test Requirements
DC spark
5 - 6V/1µDFT
Pneumatic pull-off
Test at 23 C and maximum recommended design temperature
Lap shear strength
Test at 70 C
o
Tests at design temperature where appropriate for heat resistance qualification.
14 days
For buried structures
20 cycles over 3000hrs
Specimen preparation to ISO 1513 Test time may be reduced for external onshore aboveground coatings Systems to be tested at low DFT (i.e. 75% of the Paint Vendors recommended nominal DFT). Alternative acceptance criteria may be proposed for systems tested at the Paint Vendor's recommended nominal DFT.
salt spray
70hrs
dry in ambient air ‘Weatherometer’ exposure -
16hrs 80 hrs.
KHF-00-104133-RA-7754-00001-0000 / Rev 02
Notes
Periodic checks
o
Accelerated weathering
UV light exposure
Duration
Alternative light source – carbon arc to ASTM D822
Page 25 of 34
Yibal Khuff Project (YKP) Specification for External Coating Test/Method
Test Type
Performance Observations ISO-4628-2 ISO-4628-3 ISO-4628-4 ISO-12944-6 annex-A ISO-4624 ISO-2815 Salt Spray
Duration
Notes
Degree of blistering Degree of rusting Degree of cracking Level of disbondment Adhesion Hardness Corrosion testing
ISO 7253
Basic Test Requirements
Inspection of X-cut test panels
min. 3000 hrs.
Specimen preparation to ISO 1513 System DFT and criteria comments, as for cyclic test
Quantitative assessment to ISO 4628-2/3/4 ISO-12944-6 annex-A Hardness ISO 2815
Surface hardness
Check change in hardness using Buchholz Indenter
Heat Resistance (dry) ISO 3248 (modified for test temperature) ISO 4624
Pneumatic pull-off Hardness
ISO 2815 Chemical Analysis ISO 3233
Test at manufacturers recommended maximum design temperature. Adhesion Test
200hrs
Condition in accordance with ISO 3248 and inspect for coating deterioration using tests below.
Change in Buchholz value Check for solids content. Check for zinc content
ISO 3549
Result to be in accordance with technical data sheets Result to be in accordance with technical data sheets
NOTES 1.
The summary of performance test has been taken from Table B8 of SP1246-1.
Table -6 Required Tests and Acceptance Criteria for TSA coating (PCS-13) Property Coating Appearanc e
Coating Thickness
Test Method Visual Inspectio n
Measuremen ts 100% of surface
ISO 2808
Spot checks on all Surfaces
Acc eptanc e Criteria Uniform appearance, no blisters, bare patches, defects or non-adhering coating 250-500 µm
KHF-00-104133-RA-7754-00001-0000 / Rev 02
Notes
For flat surfaces, the average value of five readings taken in a line at 25 mm intervals shall be determined. For complex geometries, a spot measurement shall be taken. Thickness
Page 26 of 34
Yibal Khuff Project (YKP) Specification for External Coating Property
Coating Adhesion
Test Method
Measuremen ts
Acc eptanc e Criteria
ISO 4624
At least 3, at random
> 7 MPa (1000 psi) on test plate > 8.4 MPa (1200 psi) on work piece
Overall quality
Bend Test
At least 3
Coating Thickness
Water Spray Test
100% of surface
Minor cracks, with no coating lifting or spalling No discoloration, rusting or bleed thru
Notes is determined by the average value of five readings taken on a local area of approximately 10 cm2 (1.6 in2). If thermal spray coating local thickness is less than 90% of the specified minimum value, the thermal sprayer shall apply additional layers to meet the thickness requirement. On Test Plate - If any one value is less than 6.3 MPa (900 psi) or if two or more readings are below 7 MPa (1000 psi) the thermal sprayed surface shall be blasted off and a new coating applied, starting from the location where the last acceptance pull-off strength was measured. On Work Piece – At least once per 100 m2 of prepared surface, with a minimum of three measurements per sprayer per shift. The adhesion shall be minimum 8.4 MPa. The adhesion test shall be stopped when the value of 8.4MPa is reached, so no damage to the work piece takes place. Bend three steel coupons (150 mm x 150 mm, thickness 1.8 mm) through 180° on a 13 mm diameter steel mandrel The TSA coated surfaces shall be wetted with potable water. After 24 hours, continuous wetting the surface shall be re-examined for any signs of rusting or bleed thru. If present, the coating thickness in these areas shall be measure. If the coating thickness is below 250 microns, the section needs to be repaired. A low pressure sweep blast on this area should be performed and additional TSA shall be applied.
NOTES 1.
The required tests and acceptance criteria for PCS-13 have been taken from Table 3 of DEP 30.48.40.31.
KHF-00-104133-RA-7754-00001-0000 / Rev 02
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Yibal Khuff Project (YKP) Specification for External Coating Table 7 Minimum requirements during Qualification and Coating Production of 3LPE/3LPP coatings (PCS-15) Property
Test frequency Qualification
Test frequency Production
once 5 pipes
once per shift each pipe
10.1.2 10.1.3 10.1.2
5 pipes
each pipe
5 pipes
10.1.4
5 pipes
11.1.3
Once
10.2.1
Continuous
first 5 pipes and one of 20 pipes first 5 pipes and one of 100 pipes once per shift or according to (11.1.3) Continuous
9.4.1 9.4.2 9.4.3 9.4.4
5 pipes 5 pipes 5 pipes 5 pipes
Impact
9.4.5
5 pipes
Indentation
9.4.6
5 pipes
Elongation
9.4.7
5 pipes
Hot water resistance
9.4.10
2 pipes
Cathodic disbonding
9.4.11
2 pipes
Degree of cure of FBE
9.4.12
2 pipes
Thermal ageing UV ageing
9.4.8 9.4.9
once once
Ambient conditions Surface condition before blasting Cleanliness of blast cleaned surface Surface profile Surface cleanliness Chlorides Blast cleaning materials and process Coating application temperature Appearance Coating thickness Holiday detection Adhesion
Testing Method and Acceptance [1] Criteria 11.1.1 10.1.1
each pipe each pipe each pipe one of 100 pipes (minimum one pipe per shift) one of 100 pipes (minimum one pipe per shift) one of 100 pipes (minimum one pipe per shift) one of 100 pipes (minimum one pipe per shift) One of 200 pipes (minimum one pipe per shift) one of 200 pipes (minimum one pipe per shift) one of 200 pipes (minimum one pipe per shift) -
NOTES
1.
All the references of Section no. are from DEP 31.40.30.31-Gen
KHF-00-104133-RA-7754-00001-0000 / Rev 02
Page 28 of 34
Yibal Khuff Project (YKP) Specification for External Coating 18. Approv ed Coating Systems and Vendors PCS-1 External Coating for Above Ground Stru ctur es up to 100 °C Manufacturer Hempel
Jotun*
Sigma
Carboline
SIPCO
Berger
Primer Coat Hempadur Primer 1530 (Min DFT 50 microns) Penguard Primer (Min DFT 50 microns) Sigmacap primer EP 7680 (Min DFT 50 microns) Carboguard 893 (Min DFT 50 microns) Siprime 215 (Min DFT 50 microns ) Epilux 78 (Min DFT 50 microns)
Berger
Jotun
Hempel
International
Hampadur Mastic 45881 (Min DFT 170 microns) Interzinc 52 (Min DFT 50 microns)
Intermediate Coat Hempadur Hibuild 4520 (Min DFT 100 microns) Penguard HB (Min DFT100microns) Sigmacap Coating EP 7682 (Min DFT 100 microns) Carboguard 190HB (Min DFT 100 microns) Sipoxy Sheld 240 (Min DFT 100 Microns) Epilux 218 Hb (Min DFT 100 Microns) Epimastic 7200 (Min DFT 150 micron) Penguard express (Min DFT 150 micron)
Intergard 475HS (Min DFT 180 microns)
Top Coat
Comments
Hempathane Topcoat 55210 (Min DFT 50 microns) Durathane (Min DFT 50 microns) Sigmacap finish PU 7690 (Min DFT 50 microns) Carbothane 134 (Min DFT 50 microns)
Sipthane 360 (Min DFT 50 Microne) Luxethane 5000 (Min DFT 50 Microns) Luxathane 5000 (Min DFT 50 micron) Hard top XP (Min DFT50 micron) Hempathane HS 55610 (Min DFT 60 Microns) Internthane 990 (Min DFT 60 microns)
* Water borne epoxies
PCS-3 External Coating f or Above Ground Structur es between 100 to 400 °C either insulated or not insulated. Manufacturer Hempel
Jotun
Sigma
Carboline
Primer Coat Gavosil 15700 Min DFT 75 microns Resist 78 Min DFT 75 microns Sigma Zinc 158 Min DFT 75 microns Carbozinc 11
Intermediate Coat
Top Coat
Comments
Silicone Aluminum 56910 Min DFT 25 microns Solvalitt Aluminum Min DFT 25 microns Sigma therm 540 Min DFT 25 microns Carboline 4674
KHF-00-104133-RA-7754-00001-0000 / Rev 02
Page 29 of 34
Yibal Khuff Project (YKP) Specification for External Coating
SIPCO
Berger
International
Min DFT 75 microns SIPZINK 130 MIN DFT 50 microns Zincanode 330 Min DFT 50 microns Interzinc 22 (Min DFT 50 microns)
Min DFT 25 microns SIPTHERM 520 MIN DFT 25 microns Luxatherm 5600 Min DFT 25 microns Intertherm 50 (Min DFT 25 microns)
SIPTHERM 520 MIN DFT 25 microns Luxatherm 5600 Min DFT 25 microns Intertherm 50 (Min DFT 25 microns)
Note: Manufacturer has to confirm the curing of this coating at temperature up to 50°C maximum. If the curing temperature is higher than this then c oating shall not be used.
PCS-4 External Coating f or Steel Structu res Under Insulatio n up to 100 °C Manufacturer Hempel
Primer Coat
Intermediate Coat
Comments
One coat Hempadur Mastic 45881 Min DFT 125 microns One coat Primastic Aluminum Min DFT 125 microns Jota mestic 80,Aluminium, (125 micron) One coat Sigma Multimastic 7430 Min DFT 125 microns One Coat Sipoxy Shield 285 Min DFT 125 One Coat Epimastic 5100 Min DFT 125 microns
Jotun
Jotun
Sigma
Sipco Berger
PCS-5 External Coating for Steel Structures >400 °C Manufacturer Sipco
Berger
Jotun
Hampel
Primer Coat Siptherm 520 Min DFT 25 microns Luxatherm 1600 Min DFT 25 microns Solvalit Min DFT 25 microns Hempel silicone Aluminum 56910 Min DFT 25 micron
Intermediate Coat
Top Coat
Comments
Siptherm 520 Min DFT 25 microns Luxatherm 5600 Min DFT 50 microns Solvalitt Min DFT 25 microns Hempel silicone Aluminum 56910 Min DFT 25 micron
Note: Manufacturer has to confirm the curing of this coating at temperature up to 50°C maximum. If the curing temperature is higher than this then c oating shall not be used.
KHF-00-104133-RA-7754-00001-0000 / Rev 02
Page 30 of 34
Yibal Khuff Project (YKP) Specification for External Coating
PCS-6 External Above Groun d Coating for Galvanised Steel and Stainless Steel Structures u p to 100 °C Manufacturer Hempel
Jotun
Sigma
Sipco
Primer Coat
Intermediate Coat
Hempadur mastic 45881 Min DFT 75 microns Penguard special Min DFT 75 microns Sigmacover (280)Min DFT 75 microns Siprime 21o Min DFT 50 microns
Berger
Epiflex 1000 Min DFT 75 microns
International
Interseal 670HS (Min DFT 150 Microns)
Top Coat
Comments
Hempathane topcoat 55210 Min DFT 50 microns Durathane Min DFT 50 microns Sigmacap Finish PU Min DFT 50 microns Sipthane 360 Min DFT 50 Microns Luxathane 5000 Min DFT 50 Microns Interthame 990 (Min DFT 50 microns)
PCS-15 External coating fo r carbon st eel pip elines (3LPP) Company Name
Locatio n
Appro ved Systems System 1 Primer: KCC Karumel EX4700 (High Temp.); Adhesive: MPB- Prosive RG.10 Outerlayer: MPB-Procoat H.08.HT
Al Qhatani Pipe Coating
Dammam, Saudi Arabia
Arabian Pipe Coating,
Jubail, Saudi Arabia
Rhenania
Netherlands
Socotherm,
Italy
Bredero Shaw (Middle East) Limited
KHF-00-104133-RA-7754-00001-0000 / Rev 02
System 2 Primer: Akzo Nobel RT9000 R5 (500105) (High Temp.); Adhesive: MPB-Prosive RG.10; Outer layer: MPB-Procoat H.08.HT Primer: 3M SCOTCHKOTE 226N+ SLOW Adhesive: BORELIS BB 127E Outerlayer: BORELIS BB 08E 1199 Primer: Eurokote 799 Adhesive: BB127E-03 Outerlayer: BB108E-1199 Primer: Corro-coat EP-F 2004 from Jotun 2004 Adhesive: Basell Hifax EPR 60 Outerlayer: Basell PP Moplen EP 60 bianco Primer: 3M SCOTCHKOTE 226*N 11G Adhesive: Borealis Borcoat BB127E Outerlayer: Borealis Borcoat BB10SE-1199
Page 31 of 34
Yibal Khuff Project (YKP) Specification for External Coating
Company Name
Locatio n
Appro ved Systems System 1 Primer: HJF-18R; Adhesive: SN104; Outerlayer: SN103
Hilong
China System 2 Primer: PFG 80307; Adhesive: SN-104; Outer layer: SN-103 H.08.HT
PCS-15 External coating fo r carbon st eel pip elines (3LPE) Company Name
Locatio n
Psl
India
Saw Pipes
Mundra India
Al Qhatani Pipe Coating
Arabian Pipe Coating
Dammam Saudi Arabia
System 2 Primer: EX4413-F103 from KCC; Adhesive: CoesiveL8.92; Outer layer: HDPE2050 System 1 Primer: 3M SCOTCHKOTE 226N+ Adhesive: Borealis Borcoat ME 0433; Outerlayer: Borealis Borcoat HE 3450
Jubail Saudi Arabia
Bredero Shaw (Middle East) Limited Hilong (DSS Material)
Appro ved Systems Primer: 3M SCOTCHKOTE 226N+; Adhesive: Borealis Adhesive (ME0420); Outerlayer:Borouge HE3450 Primer: 3M Scotchkote 226N; Adhesive: Borealis Adhesive (ME0420); Outerlayer:Borouge HE3450 System 1 Primer: EX4413-F103 from KCC; Adhesive: ME0420 from Borealis Outerlayer: Borealis Borcoat HE 3450
China
KHF-00-104133-RA-7754-00001-0000 / Rev 02
System 2 Primer: Jotun Corro Coat EP-F1003HW; Adhesive: Borealis Borcoat ME 0433 Outer layer: Borealis Borcoat HE 3450 Primer: 3M Scotchkote 226N+11G; Adhesive: Borealis Borcoat ME0433 Outerlayer:Borouge Poly Ethyelene P>E (HE34500) Primer: 3M 226N; Adhesive: SN-102; Outerlayer: SN-102
Page 32 of 34
Yibal Khuff Project (YKP) Specification for External Coating Ap pen di x - 1 FORM TO B E APPENDED WITH EVERY PA INT PROCEDURE
TO BE FILL ED BY THE PAINT CONTRACTOR: __________________________
Project Paint Specification Number Vendor’s Paint Procedure Number Sr. #
DESCRIPTION
PROJECT REQUIREMENT
CONTRACTOR's REMARKS
Environmental Conditions Temperature
1
Wind Speed Humidity Item to be painted Tag Number Material of Construction
2
Service Temperature Insulated/Un-Insulated Minimum Surface Preparation (Sa/SSPC) 3
Initial Touchup
4
Abrasive Material Compressed Air Quality
5
Oil Level Moisture Content
6
Paint System Reference as per project spec Coat - 1 Type of Paint Manufacturer
7
Shelf Life Application Method Number of Coats Dry Film Thickness Coat - 2 Type of Paint
8
Manufacturer Shelf Life Application Method Number of Coats
KHF-00-104133-RA-7754-00001-0000 / Rev 02
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