PETRONAS TECHNICAL STANDARD

Protective Coatings and Linings

PTS 15.20.03
February 2016

2016 PETROLIAM NASIONAL BERHAD (PETRONAS)

All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form
or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright
owner. PETRONAS Technical Standards are Companys internal standards and meant for authorized users only.
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FOREWORD

PETRONAS Technical Standards (PTS) has been developed based on the accumulated knowledge,
experience and best practises of the PETRONAS group supplementing National and International
standards where appropriate. The key objective of PTS is to ensure standard technical practice across the
PETRONAS group.

Compliance to PTS is compulsory for PETRONAS-operated facilities and Joint Ventures (JVs) where
PETRONAS has more than fifty percent (50%) shareholding and/or operational control, and includes all
phases of work activities.

Contractors/ Manufacturers/ Suppliers who use PTS are solely responsible in ensuring the quality of work,
goods and services meet the required design and engineering standards. In the case where specific
requirements are not covered in the PTS, it is the responsibility of the Contractors/ Manufacturers/

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Suppliers to propose other proven or internationally established standards or practices of the same level

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of quality and integrity as reflected in the PTS.

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In issuing and making the PTS available, PETRONAS is not making any warranty on the accuracy or
completeness of the information contained in PTS. The Contractors/ Manufacturers/ Suppliers shall
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ensure accuracy and completeness of the PTS used for the intended design and engineering requirement
and shall inform the Owner for any conflicting requirement with other international codes and technical
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standards before start of any work.

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PETRONAS is the sole copyright holder of PTS. No part of this document may be reproduced, stored, in a
retrieval system or transmitted in any form or by any means (electronic, mechanical, recording or
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otherwise) or be disclosed by users to any company or person whomsoever, without the prior written
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consent of PETRONAS.
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The PTS shall be used exclusively for the authorised purpose. The users shall arrange for PTS to be kept in
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safe custody and shall ensure its secrecy is maintained and provide satisfactory information to PETRONAS
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that this requirement is met.

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ANNOUNCEMENT

Please be informed that the entire PTS inventory is currently undergoing transformation exercise from
2013 2015 which includes revision to numbering system, format and content. As part of this change, the
PTS numbering system has been revised to 6-digit numbers and drawings, forms and requisition to 7-digit
numbers. All newly revised PTS will adopt this new numbering system, and where required make
reference to other PTS in its revised numbering to ensure consistency. Users are requested to refer PTS
00.01.01 (Index to PTS) for mapping between old and revised PTS numbers for clarity. For further inquiries,
contact PTS administrator at ptshelpdesk@petronas.com.my

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Table of Contents
1.0 INTRODUCTION .......................................................................................................... 7
SCOPE .................................................................................................................................. 7
GLOSSARY OF TERM ............................................................................................................ 7
1.3 SUMMARY OF CHANGES ................................................................................................... 11
2.0 WARRANTY .............................................................................................................. 12
GENERAL ............................................................................................................................ 12
3.0 COATING AND COATING SYSTEMS ............................................................................ 14
COATING SYSTEMS SELECTION .......................................................................................... 14

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NEW CONSTRUCTION COATING SPECIFICATIONS ............................................................. 15

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MAINTENANCE COATING SPECIFICATIONS ....................................................................... 21

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COATING SYSTEM PRODUCT APPROVAL REQUIREMENT .................................................. 25
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PRODUCT QA/QC REPORT ................................................................................................. 25
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COATING QUALITY CONTROL BATCH CERTIFICATE ........................................................... 25

4.0 COATING CONTRACTORS RESPONSIBILITIES .............................................................. 27
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GENERAL ............................................................................................................................ 27
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HSE ..................................................................................................................................... 27
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HAZARDOUS COATING COMPONENTS .............................................................................. 28

PERSONNEL ........................................................................................................................ 28
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PROTECTION OF EQUIPMENT AND STRUCTURAL MEMBERS ........................................... 28

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BLASTING AND SPRAYING EQUIPMENT............................................................................. 29

ACCESS ............................................................................................................................... 29
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HANDLING OF COATED PARTS/COMPONENTS ................................................................. 29

STORAGE PROTECTION ...................................................................................................... 30
SHELF-LIFE.......................................................................................................................... 30
5.0 SURFACE PREPARATION ........................................................................................... 31
SURFACE PROFILE .............................................................................................................. 31
GRADES OF SURFACE FINISH ............................................................................................. 32
SURFACE PREPARATION BY HAND AND POWER TOOL CLEANING .................................... 32
SURFACE PREPARATION METHOD- STAINLESS STEEL, GALVANIZED STEEL, NICKEL ALLOY
AND NON-FERROUS ALLOY ............................................................................................................ 33
6.0 APPLICATION ........................................................................................................... 34
PRE-APPLICATION PROCEDURES ....................................................................................... 34
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APPLICATION CONDITION.................................................................................................. 35
APPLICATION METHODS .................................................................................................... 36
REPAIRS AND TOUCH UP COATING ................................................................................... 38
7.0 QUALITY CONTROL (QC) ........................................................................................... 40
GENERAL ............................................................................................................................ 40
QUALITY REQUIREMENTS .................................................................................................. 40
INSPECTION AND TESTING................................................................................................. 41
PROCEDURE AND REPORT ................................................................................................. 41
8.0 RESOURCE REQUIREMENT ........................................................................................ 43

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COATING CONTRACTOR .................................................................................................... 43

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INSPECTION EQUIPMENT .................................................................................................. 46

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9.0 HEALTH, SAFETY AND ENVIRONMENT (HSE).............................................................. 47
SAFETY AND HEALTH REGULATIONS ................................................................................. 47
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ENVIRONMENTAL REGULATIONS ...................................................................................... 48
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10.0 COLOUR SCHEMES .................................................................................................... 49

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STRUCTURAL COLOUR SCHEMES....................................................................................... 49

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PIPING COLOUR SCHEMES AND IDENTIFICATION SYSTEM ............................................... 49

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EQUIPMENT COLOUR SCHEME.......................................................................................... 49

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PIPELINE/RISER IDENTIFICATION SYSTEM ......................................................................... 49

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SAFETY COLOUR SCHEME .................................................................................................. 50

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11.0 BIBLIOGRAPHY ......................................................................................................... 51

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APPENDIX 1: COATING SYSTEM PRODUCT APPROVAL REQUIREMENT .................................. 57

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APPENDIX 2: COATING FINGERPRINT CERTIFICATE FOR 2-COMPONENT INTERMEDIATE

MATERIALS OF POLYMERIC COATINGS ................................................................................. 59
APPENDIX 3: APPROVED VENDOR COATINGS LIST ................................................................ 62
APPENDIX 4: GLASS FLAKE POLYESTER GENERIC SPECIFICATION ........................................... 78
APPENDIX 6: STORAGE TANK IDENTIFICATION SYSTEM ........................................................ 82
APPENDIX 7: PIPING IDENTIFICATION SYSTEM ..................................................................... 83
APPENDIX 8: PIPING COLOUR IDENTIFICATION LEGEND ....................................................... 84
APPENDIX 9: COLOUR SCHEME FOR ONSHORE/OFFSHORE INSTALLATION AND EQUIPMENT 86
APPENDIX 10: ESCAPE ROUTE .............................................................................................. 91
APPENDIX 11: INSPECTION AND TESTING REQUIREMENTS ................................................... 92
APPENDIX 12: RISK MATRIX ................................................................................................. 94
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APPENDIX 13: TYPICAL COATING QUALITY INSPECTION AND TEST PLAN CHECKLIST ............. 95
APPENDIX 13: COATING DAILY INSPECTION REPORT TEMPLATE ........................................... 97
APPENDIX 15: ITEMS TO BE EXCLUDED FROM PTS 15.20.03 .................................................. 98
APPENDIX 16: MAINTENANCE COATING ............................................................................ 100
APPENDIX 17: SURFACE PREPARATION BY BLAST CLEANING ............................................ 102
APPENDIX 18: RECOMMENDED ORGANISATION CHART FOR COATING WORK EXECUTION . 110
APPENDIX 19: REGULATIONS ON ABRASIVES, COATING PRODUCTS, WASTE PRODUCTION,
PRODUCT STORAGE AND LEACHING OF COATINGS ............................................................ 111

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1.0 INTRODUCTION
This PTS provides the minimum technical requirement for surface preparations, application
procedures, selection of coating and coating systems, enhanced quality control measures,
personnel qualifications and updated colour schemes to be used on metallic substrates requiring
corrosion protection for new construction and maintenance.

SCOPE

1.1.1 The PTS covers both external and internal coating for onshore and offshore facilities on metallic
substrates for domestic and international projects. It shall also include initial and maintenance
coating.

1.1.2 This standard is only applicable to the following listed environments:

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i. Atmospheric (Insulated and Non-Insulated)

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ii. High Temperature

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iii. Immersed lU
iv. Splash Zone
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v. Spray Zone
vi. Sweating
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1.1.3 Services which are not covered under this PTS and required to be coated shall be referred to the
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Owner to advise the appropriate coating system.

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1.1.4 Specialised equipment supplied by vendors such as valves, pumps, compressors, etc. shall be
coated in accordance to specific coating systems as dictated by the environment in Section 3.0 of
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this PTS.
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1.1.5 Other items excluded from this PTS as listed in Appendix 15.
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GLOSSARY OF TERM

1.2.1 General Definition of Terms & Abbreviations

Refer to PTS Requirements, General Definition of Terms, Abbreviations & Reading Guide PTS
00.01.03 for General Definition of Terms & Abbreviations.

1.2.2 Specific Definition of Terms

No Term Definition

1 Chalking The appearance of a loosely adherent fine

powder on the surface of a coating coating,
arising from the degradation of one or more of
its constituents.
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No Term Definition

2 Coat One layer of a coating applied to a substrate in

a single, continuous application to form a
uniform film when dry.

3 Coating System The complete number and types of coats

applied to a substrate in a predetermined order.
The system includes surface preparation,
procedures and materials, coating materials,
sealants, application method, and
environmental controls including special

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procedures e.g. stripe coat application.

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4 Cracking The splitting of a dry coating film that reaches

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the substrate, usually as the result of ageing and
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stresses in the coating system.
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5 Epoxy Type of resin formed by the reaction of aliphatic

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or aromatic polyols (e.g. bisphenol) with

epichlorohydrin and characterised by the
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presence of reactive oxirane end groups.

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6 Equipment The equipment to be coated is listed in

Appendix 1 and includes piping, vessels,
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columns, exchangers, reactors, structural steel,

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fire-fighting systems, tanks, LPG storage vessels,

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furnaces, stacks, flare stacks, flue ducts,

offshore structures and topside facilities.
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7 Fingerprint Method of identifying a coating material

through laboratory analyses of coating density,
solids content, pigment content, etc. (Infrared
Spectroscopy is often used).

8 Flaking The detachment of pieces of the coating film

itself either from its substrate or from coating
previously applied. Flaking is usually preceded
by cracking or blistering.

9 Grit Particles that are predominantly angular, have

fractured faces and sharp edges and are less
than half round in shape.
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No Term Definition

10 Holiday A discontinuity in a protective coating that

exposes unprotected surface to the
environment.

11 Inorganic Zinc-Rich Coating Coating containing a metallic zinc pigment

(typically 75% or more in the dry film) in an
inorganic vehicle.

12 Organic Zinc-Rich Coating Coating containing a metallic zinc pigment

(typically 75% or more in the dry film) in an

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organic resin.

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13 Coating A pigmented coating material in liquid or paste

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or powder form, which when applied to a
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substrate, forms an opaque film having
protective, decorative or other specific
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properties.
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14 Pot Life The elapsed time within which a coating can be

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effectively applied after all components of the

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coating have been thoroughly mixed.

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15 Pre-fabrication Primer A thin and fast drying coating that is applied to

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a blast cleaned steel to provide temporary

protection during fabrication while still allowing
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welding and cutting. This is also known as shop

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primer.
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16 Primer A coating material intended to be applied as a

first coat on an uncoated surface. The coating is
specifically formulated to adhere to and to
protect the surface as well as to produce a
suitable surface for subsequent coats.

17 Shelf Life The maximum length of time packaged

materials e.g. coating materials can be stored at
specific conditions and remain in usable
condition.

18 Shot Particles that are predominantly round, that

have a length of less than twice the maximum
particle width and that do not have edges,
broken faces or other sharp surface defects.
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No Term Definition

19 Stripe Coat A coat applied only to edges or to welds on steel

structures before a full coat is applied to the
entire surface. The stripe coat is intended to
give those areas sufficient film build to resist
corrosion.

20 Surface Profile The irregular peak and valley profile on the

surface of bare metal that results from abrasive
blast cleaning or power tool cleaning.

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21 Zinc-Rich Primer A general term used for inorganic zinc-rich

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coatings and organic zinc-rich coatings used as

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a primer.

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Table 1: Specific Definition of Terms
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1.2.3 Specific Abbreviations
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No Abbreviation Description
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1 CDBM Corrosion Design Basis Memorandum

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2 CORAL 2.0 Cost Reduction Alliance

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3 CSDS Chemical Safety Data Sheets

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4 DFT Dry Film Thickness; the thickness of the

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dried/cured coating or coating film.

5 GRP Glass fibre Reinforced Plastic

6 ITP Inspection Test Plan

7 JHA Job Hazard Analysis

8 JSA Job Safety Analysis

9 LCC Life Cycle Costing

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No Abbreviation Description

10 MCI Materials, Corrosion and Inspection

11 MEL Maximum Exposure Limit

12 MOC Management Of Change

13 MSDS Material Safety Data Sheets

14 OEL Occupational Hazardous Limit

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15 PPE Personal Protective Equipment

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16 QA Quality Assurance

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17 QC
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Quality Control
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18 QP Quality Plan
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19 TDFT Total Dry Film Thickness; the thickness of the

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total number of coatings specified.

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20 TPI Third Party Inspector

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21 PSC Production Sharing Contractors

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22 WFT Wet Film Thickness; the thickness of the

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uncured or wet coating or coating film.

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Table 2: Specific Abbreviations

1.3 SUMMARY OF CHANGES

This PTS 15.20.03 replaces PTS 30.48.00.31 (October, 2012) and PTS 70.48.10.10 (November, 2012).
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2.0 WARRANTY

GENERAL

2.1.1 Contractors, undertaking coating works in accordance with this PTS, shall guarantee the quality
of their coating work. Prior to start of coating works, warranty period shall be agreed with the
Owner.

2.1.2 A minimum warranty period of seven (7) years for all coatings and ten (10) years for TSA inclusive
of maintenance coatings. This requirement shall be incorporated in the coatings contract
document. For shorter design life the warranty period can be reduced to meet project
requirement based on owners agreement.

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2.1.3 The severity of corrosion shall not exceed a Ri 3 scale based on ISO 4628-3 Assignment of Degree

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of Rusting during the warranty period.

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2.1.4 The warranty shall be based on the reference area within the structure or facility involved.

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Reference area shall be selected at a location with typical corrosive stresses for the structure.
Surface preparation, coating application and the quality of work at the selected reference area
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shall be agreed and witnessed by the Owner, the Contractors representative together with TPI.
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Clear documentation and marking on the structure showing the reference area shall be made
available for the reference of the Owner, Contractor and TPI. Refer Error! Reference source not
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found.le 3 for further details on reference area.

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Recommended
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Recommended minimum total

Size of Coated Area,
minimum number area of reference
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m2
of reference areas areas,
m2
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Up to 2,000 2 10
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2,001 to 5,000 4 24
5,001 to 25,000 6 60
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25,001 to 50,000 8 80
Above 50,001 8 160
Table 3: Recommended reference area selection
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2.1.5 Surfaces that have deteriorated beyond the acceptable level of breakdown within the warranty
period shall be repaired by the Contractor at Contractors cost. The Contractor shall also bear the
cost for materials, equipment, labour, transportation and storage necessary for the repair.

2.1.6 Initial acceptance of any new coating work by the Owner will not relieve the Contractor of his
obligations under this section until the final inspection has been carried out and acceptance of
the completed work has been agreed in writing.

2.1.7 A final inspection shall be carried by TPI to be agreed between the Contractor and the Owner
before expiry of the coating work warranty period.

2.1.8 In case of a dispute on the condition and quality of the coating work that has been applied, an
independent consultant shall be engaged to conduct a review inspection. Both the Owner and the

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Contractor shall accept the inspection findings by this independent consultant.

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2.1.9 Owner may engage a consultant as their representative in the event that requires detailed coating
failure investigation, services which shall include all the required laboratory and failure analysis.

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2.1.10 In the event where dispute arises to assign responsibility of defect between the Contractor and
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the coating manufacturer, an independent consultant shall be appointed by the coating
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manufacturer and Contractor to arbitrate the issue. The Owner shall at no times be liable to this
process.
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2.1.11 The degree of compensation coverage shall be on a diminishing value of 10% coverage starting
from 100% until the end of first year, 90% till the end of the second year and so on until the end
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of the warranty period.

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3.0 COATING AND COATING SYSTEMS

COATING SYSTEMS SELECTION

3.1.1 General
i. This section addresses the selection of coating system for external and internal
application. Selection of coating systems and products which are not listed shall
require approval from the Owner.
ii. Prior to execution of coating works, the items below shall be qualified to the
requirements of this PTS:
a) Coating Systems (Appendix 1)

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b) Abrasive materials (Appendix 11)

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iii. Recycled abrasive must comply with tests mentioned in Appendix 11

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iv. Maintenance and touch-up coating systems shall be compatible with the New

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Construction coating systems. Coating system compatibility shall be tested using
patch test methods described in ASTM D5064.
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3.1.2 Primer
i. Sacrificial-type primer such as organic or inorganic Zinc-rich primer shall contain a
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high percentage of zinc dust of greater than 80% by mass in the non-volatile portion
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of the primer. The zinc dust shall comply with the requirements specified in ASTM
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D520 (Type II or III) or ISO-3549. The zinc-rich primers shall be overcoated with
chemically resistant coatings to avoid direct exposure acid and strong alkalis such as
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in marine environment. Cleaning using freshwater or power scrubbing shall be

required to remove contaminants prior to overcoating. Damaged inorganic zinc-rich
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primers shall be repaired with an organic zinc-rich coating.

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ii. Organic inhibitive primer contains inhibiting pigments that produce alkaline
conditions to protect the base metal against corrosion when exposed to moisture.
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Overcoats are required to ensure the effectiveness of this inhibitive primer due to the
reactive pigments content.

3.1.3 Intermediate Coats and Topcoats

Intermediate coats and topcoats function as barrier to restrict the permeation of water vapor,
oxygen and active chemical ions. The application of topcoat is to provide added abrasion, impact,
UV light and solvent resistance. Topcoat also adds aesthetic value to the surface. Generic
characteristics of intermediate coats and topcoats include the following:
i. Chemically Cured Thermoset Coatings. These materials are usually epoxies, epoxy
phenolics, polyesters, or vinyl esters.
ii. Polyurethanes or Polysiloxanes. These materials are used exclusively as a topcoat in
the atmospheric zone to provide UV resistance. In general, polysiloxane provides
better UV resistance than polyurethane.
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3.1.4 Organic and Inorganic Zinc-Filled Coatings

i. The metallic zinc content in the zinc dust shall be a minimum of 94%.
ii. Zinc content by percentage weight for Inorganic Zinc Silicate and Organic Zinc Epoxy
should comply with SSPC-Coating 20 (Zinc rich primer, Type I 'Inorganic ' and Type II
'Organic') requirement or equivalent.
iii. Organic Zinc Epoxy is preferred due to the ease of application. Although Inorganic
Zinc Silicate provides better corrosion in aggressive environments, its limitations such
as tendency to crack in access of 75 microns thickness and requirement for humid
environments for curing makes it undesirable.
iv. If shop primer for temporary protection is applied, then it must be 100% full blasted
to the requirement stated in section 5.0 prior to the application of the full coating

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v. For primed surface, a secondary surface preparation shall be performed. All zinc salt

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formation shall be sweep blasted. All other possible contaminants shall be sand down

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and solvent cleaned before top coating. For damaged areas, welding joints and rusty
area, spot blast to Sa 2.5 followed by one coat of epoxy zinc rich or power tool cleaned
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to St 3 and followed by Surface Tolerant epoxy, subject to Owner approval.
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3.1.5 Selection and Application of Top Coats

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i. For areas to be applied with polyester glassflake, all shop primer shall be removed
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completely to Sa 2.5.
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ii. The minimum volume solids for high solid epoxy shall be 75%. As an alternative,
surface tolerant high solid epoxy coating may be applied.
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NEW CONSTRUCTION COATING SPECIFICATIONS

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3.2.1 For new construction, single coating manufacturer responsibility shall be maintained by using
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primers, intermediate coats and topcoats from the same Manufacturer.

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3.2.2 For some systems, there are options available and the application of LCC shall be considered
during development of CDBM.

3.2.3 Unless otherwise stated by Manufacturer, the surface preparation for new construction shall be
blast cleaned to ISO 8501-1, Sa 2.5.

3.2.4 The list of approved coating products can be found under Appendix 3. This list will be updated
during the next PTS review. New coating products shall be tested to comply with the new DFT
requirements specified in this PTS and shall be certified by PETRONAS approved testing
laboratories. PRSB shall be the main body for any testing work or owners approved testing
bodies. Any deviations from the approved systems in Table 3-1 or Table 3-3, though not advisable,
requires MOC with approval from the highest Technical Authority.
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System Paint and Coating Min DFT Target DFT

Service(j) Coat
ID Specifications (m) (m)
1 Zn Rich Primer 50-75 75
2 Epoxy 125-175 125
N1-1(a) 3 Polyurethane 50-75 75
Total 225-325 275
N1
Epoxy Primer 125-175 125
Carbon Steel
1 Epoxy 125-175 125
Atmospheric zone N1-2 Polyurethane 50-75 75
-50C to 120C With/Without
Insulation Total 300-425 325

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1 Thermal Spray Aluminium 250-375 250

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2 Thinned Sealer (Epoxy)
N1-3

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3 Sealer (Epoxy)
Total 250-375 250

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N2 1 High Solid Epoxy Phenolic
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Carbon Steel 2 High Solid Epoxy Phenolic 100 100
N2-1(b) 3 High Solid Epoxy Phenolic 100 100
Atmospheric zone
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-70C With Insulation Total 300 300

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1 Zinc Rich Primer 50-75 75

2 High Solids Epoxy 125-175 125
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N3-1 3 Antiskid Epoxy 125-175 125

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4 Polyurethane 50-75 75
Total 350-500 400
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1 Epoxy Primer 125-175 125

2 High Solids Epoxy 125-175 125
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N3
Offshore Platform Decks N3-2 3 Antiskid Epoxy 125-175 125
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(Including Primary and 4 Polyurethane 50-75 75

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Secondary Structures) Total 350-500 450

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1 Thermal Spray Aluminium 250-375 250

2 Thinned Sealer (Epoxy)
N3-3 3 Sealer (Epoxy)

Total 250-375 250

Vendor Vendor
N3-4 1 Antiskid High Build Epoxy
Specification Specification
1 Zinc Rich Primer 50-75 75
2 High Solids Epoxy 200-300 250
N4-1 3 Antiskid Epoxy 200-300 250
4 Polyurethane safety marking 50-75 75
N4
Offshore Platform Decks Total 500-750 650
(Decks and Floors -Heavy Duty 1 Epoxy Primer 125-175 125
and Helidecks) 2 High Solids Epoxy 125-175 125
N4-2 3 Antiskid Epoxy 125-175 125
4 Polyurethane 50-75 75
Total 425-600 450
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System Paint and Coating Min DFT Target DFT

Service(j) Coat
ID Specifications (m) (m)
1 Thermal Spray Aluminium 250-375 250

2 Thinned Sealer (Epoxy)
N4-3 3 Sealer (Epoxy)

Total 250-375 250

N4-4 1 Antiskid High Build Epoxy
1 Glass Flake Epoxy(c) 450-550 500
N5-1 2 Glass Flake Epoxy 450-550 500
Total 900-1100 1000
N5 1 Thermal Spray Aluminium 250-375 250
Carbon Steel 2 Thinned Sealer (Epoxy)
N5-2

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Splash zone and spray zone 3 Sealer (Epoxy) (d)

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<60C Total 200-250 250

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1 Primer 25-50 25

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N5-3 2 Bonding Agent 25-50 25

3 Polychloroprene Rubber
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N6
1 Primer 25-50 25
Carbon Steel
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N6-1 2 Bonding Agent 25-50 25

Splash zone and spray zone
3 Polychloroprene Rubber(e) 6-13 mm
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between 70C to 100C

N7
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1 Primer 25-50 25
Carbon Steel
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N7-1 2 Bonding Agent 25-50 25

Splash zone and spray zone
3 EPDM Rubber(f) 6-13 mm
between 100C and 130C
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1 High Solids Epoxy

2 Stripe Coat
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N8-1 3 High Solids Epoxy

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N8 Total 75-125 125

Carbon Steel
1 Thermal Spray Aluminium 250-375 250
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Exterior Submerged zone <60C

2 Thinned Sealer (Epoxy)
N8-2 3 Sealer (Epoxy)

Total 75-125 125

1 Inorganic Zn Rich Primer 50-75 75

N9-1 2 Silicone Acrylic 25-50 50
N9
Carbon Steel Total 75-125 125
Atmospheric Zone, surface 1 Thermal Spray Aluminium 250-375 250
temperature at 110C to 150C, 2 Thinned Sealer (Epoxy)
Without Insulation N9-2 3 Sealer (Epoxy)

Total 75-125 125

N10 1 Epoxy Phenolic 100-125 125

Carbon Steel N10-1 2 Epoxy Phenolic 100-125 125
Atmospheric Zone, surface
Total 75-125 125
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System Paint and Coating Min DFT Target DFT

Service(j) Coat
ID Specifications (m) (m)
temperature at 110C to 150C, 1 Thermal Spray Aluminium 250-375 250
With Insulation 2 Thinned Sealer (Epoxy)
N10-2 3 Sealer (Epoxy)

Total 75-125 125

1 Thermal Spray Aluminium 250-375 250

2 Thinned Sealer (Epoxy)
N11-1 3 Sealer (Epoxy)
N11
Carbon Steel Total 75-125 125
Atmospheric Zone, surface
temperature at 150C to 450C, 1 Inorganic Zinc Rich Primer 50-75 75
With/Without Insulation 2 Silicone(g) 25-50 50

y
N11-2 3 Silicone 25-50 50

nl
O
Total 100-175 175
N12

se
1 Epoxy 150-200 150
Galvanised Steel 2 Polyurethane 50-75 75
N12-1
lU
Atmospheric Zone, surface
temperature at -50C to 150C Total 200-275 225
na

N13
Stainless Steel 1 Epoxy(h) 150-200 200
er

Atmospheric zone N13-1 2 Polyurethane 50-75 75

nt

-50C to 120C With/Without

-I

Insulation Total 200-275 275

N14
AS

1 Epoxy Phenolic 100-125 125

Stainless Steel
2 Epoxy Phenolic 100-125 125
Atmospheric zone N14-1
N

120C to 150C With/Without

Total 200-250 250
O

Insulation
TR

N15 1 Epoxy 150-200 200

Stainless Steel N15-1 2 Polyurethane 50-75 75
PE

Atmospheric zone
150C to 450C With/Without Total 200-275 275
Insulation N15-2 1 Thermal Spray Aluminium 50-100 75
Inorganic Zinc Rich Epoxy
1 (compatible with Cathodic 50-100 100
N16 Protection)
Carbon Steel Storage Tank Coal Tar-free, High Build
N16-1
Underside (External) 2 Epoxy 200 200
3 Coal Tar-free, High Build 200 200
Epoxy
Total 400 400
1 Aluminium Wood Primer 50 50
N17 2 Alkyd Semi-gloss finish 50 50
N17-1 3 Alkyd Semi-gloss finish 50 50
Timber Decks
Total 150 150
N18
N18-1 1 Aliphatic Polyurethane 50 50
Markings
 PTS 15.20.03
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System Paint and Coating Min DFT Target DFT

Service(j) Coat
ID Specifications (m) (m)

N19
Living Quarters, Pressurised
N19-1 1 Surface Tolerant Epoxy 150 150
Building, Interior Control Room
(Interior)

1 Amine Adduct Epoxy 125 125

N20
N20-1 2 Amine Adduct Epoxy 125 125
Fuel Gas (Sweet & Sour)
Total 250 250

N21-1
Roof 1 Amine Adduct Epoxy 125 125

y
and 2 Amine Adduct Epoxy 125 125

nl
Shell

O
Plate
N21 Total 250 250

se
Carbon Steel Storage Tank N21-2 1 Amine Adduct Epoxy 100 100
(Internal) Bottom 2 Amine Adduct Epoxy
lU 100 100
Crude/Condensate (Sweet & Plate & 3 Amine Adduct Epoxy 100 100
Sour), Emulsion/Slop Vessels Total 300 300
na

N21-3 1 Amine Primer 50 50

er

Bottom 2 Amine Glass Flake 200 200

Plate 3 Amine Glass Flake 200 200
nt

Alterna
-I

tive Total 450 450

N22
AS

Carbon Steel Storage Tank

1 Amine Adduct Epoxy 125 125
(Internal)
N

2 Amine Adduct Epoxy 125 125

Light/Heavy/Treated Naphtha, N22-1
O

Reformate, Jet A-1 Fuel, Fuel

TR

Oil, Gasoline (leaded & un-

leaded) and Diesel Total 250 250
PE

1 Amine Adduct Epoxy 125 125

N23-1 2 Amine Adduct Epoxy 125 125

N23
Potable Water(i) Total 250 250
(Drinking/Aerated/Non-
Aerated), Seawater, 1 High Solids Epoxy 125-175 125
Produced/Brackish Water, N23-2 2 Stripe Coat
Demineralised Water and Brine Ballast 3 High Solids Epoxy 125-175 125
Water 4 Stripe Coat
Tank 5 High Solids Epoxy 125-175 125

Total 375-525 375

N24 1 Epoxy Phenolic 150 150

Steam Condensate and Boiler N24-1 2 Epoxy Phenolic 150 150
Feed Water
Total 300 300
 PTS 15.20.03
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System Paint and Coating Min DFT Target DFT

Service(j) Coat
ID Specifications (m) (m)
1 Amine Adduct Epoxy 125 125
N25-1 2 Amine Adduct Epoxy 125 125
Total 250 250
Polyester Glass Flake or Epoxy
N25 N25-2 1 400 400
Glass Flake
Utility Air
N25-3 1 Vinyl Ester Glass Flake 400 400
1 Epoxy Phenolic 125 125
N25-4 2 Epoxy Phenolic 125 125
Total 250 250

1 Vinyl Ester Glass Flake 800-1500 1500

y
N26

nl
Corrosion Inhibitors, N26-1 2 Vinyl Ester Glass Flake 800-1500 1500
Demulsifier, Oxygen Scavenger

O
Total 1600-3000 3000

se
1 Epoxy Phenolic 125 125
N27 2 Epoxy Phenolic 125 125
N27-1
lU
Methanol and
Perchloroethylene (PERC) Total 250 250
na

N27-2 1 Inorganic Zinc Silicate 75-100 100

er

1 Amine Adduct Epoxy 125 125

nt

N28-1 2 Amine Adduct Epoxy 125 125

-I

Total 250 250

N28
AS

1 Epoxy Phenolic 125 125

Triethylene Glycol and
N28-2 2 Epoxy Phenolic 125 125
Methylethylene Glycol
N

Total 250 250

O

1 Vinyl Ester Glass Flake 800-1500 1500

TR

N28-3 2 Vinyl Ester Glass Flake 800-1500 1500

Total 1600-3000 3000
PE

Table 3-1: New Construction Coating Systems

Notes:
ID Legend:
N XX Y ; e.g. N28-2

N N for new coating

XX Sytem number i.e. System 28
Y System option i.e. 2nd option in System 28

Do not add to total DFT

End user specification
Vendor specification

(a) Structural steel and piping can be coated in the shop with the first two coats. The third coat can be applied at
site after erection. A mist coat will be required following the application of primer as per Manufacturers
specifications
 PTS 15.20.03
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(b) Applicable for surface of cold insulated steel pipe operated down to -70C under wet insulation
Coating may also be carried out in 2 coats (150 microns each)
(c) The average surface profile shall be 75 microns
(d) Allow thinned sealer to dry >30 minutes before application of next sealer coat.
(e) For service temperature >700C, polychloroprene rubber shall only use carbon black pigment, which gives better
thermal resistance.
(f) Ethylene Propylene Diene Elastomer
(g) High Temperature Silicone coating should not be applied more than 40 microns thick which could lead to
blistering. Alum colour can withstand temperature more than 200C.
(h) Never use zinc based coating on stainless steel which can cause Liquid Metal Embrittlement during fire.
(i) Coating system applied for potable water system shall be accompanied with a health certificate.
(j) The temperature described in Table 3-1: New Construction Coating System shall be of design temperature.
(k) For Service N13, the stainless steel surface described is for Austenitic type stainless steel. 22%Cr and 25%Cr
stainless steels shall be painted in accordance to System N13 for operating temperatures 50C and 80C

y
respectively.

nl
O
MAINTENANCE COATING SPECIFICATIONS

se
Unless otherwise stated by the Manufacturer, the surface preparation for maintenance works
shall be Power Tool Cleaning to ISO 8501-1, St 3, as a minimum. Where maintenance coating
lU
systems are not listed, the new construction specifications shall be followed.
na

3.3.1 Types of Maintenance

er

Depending on the condition of the coating, one or more of the following three (3) types of
nt

maintenance coating shall be applied.

-I

i. Touch-up or Spot Repair

AS
N

If the coating film, apart from local rust areas, is sound and adequate (Ri=3), the areas
O

that are corroded, approximately 100 cm2 in size, shall be spot cleaned and touched
TR

up using a single pack system to full film thickness with Owner approval.
All corrosion products shall be removed and the interface between the sound coat
PE

and cleaned areas shall be properly prepared.

ii. Maintenance or Renovation

For renovation (Ri=4), spot repairs shall be carried out to the existing coating and a
full topcoat shall be applied. The existing coating system shall be sound and adequate
while the new topcoat shall enhance the corrosion protection.

iii. Refurbishment or Total Recoating

Refurbishment requires total removal of the existing coating system (Ri5). Surface
preparation and application of a new coating system shall be carried out in
accordance with Section 3.0 of this PTS.
 PTS 15.20.03
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Table 3-2 contains recommendations for appropriate type of maintenance coating

based on the surface condition. Maintenance coating should not be necessary for
coated surfaces where less than 1% of the surface area is corroded (Ri 3).

Rust scale Minimum recommended

Coating surface condition (ISO 4628- Maintenance surface pretreatment
3) (ISO 8501)
Contaminated, Ri 0 Preventive -
No Corrosion Cleaning
1% of Surface Area Ri 3 Spot Repair St2
Corroded
<10% of Surface Area Ri 4 Renovation St3 or Sa2

y
Corroded

nl
>10% of Surface Area Ri 5 Refurbishment Sa2.5

O
Corroded

se
Table 3-2: Typical Maintenance Practices
lU
System Min DFT Target DFT
na

Service Coat Paint and Coating Specifications

ID (m) (m)
er

1 Inorganic Zn Rich Primer 50-75 75

nt

2 Surface Tolerant Epoxy 125-175 125

M1-1
-I

3 Polyurethane 50-75 75
Total 225-325 275
AS

M1 Epoxy Primer 125-175 125

Carbon Steel 1 Surface Tolerant Epoxy 125-175 125
N

Atmospheric zone M1-2 Polyurethane 50-75 75

O

-50C to 120C With/Without Total 300-425 325

TR

Insulation
1 Moisture Cured Urethane Primer 75-125 100
PE

2 Moisture Cured Urethane Primer 75-125 100

M1-3 3 Moisture Cured Urethane Primer 75-125 100

Total 225-375 300

1 Epoxy Phenolic 100-125 125
M2 M2-1 2 Epoxy Phenolic 100-125 125
Carbon Steel Total 200-250 250
Atmospheric Zone, surface
temperature at 110C to 150C, 1 Silicone Based High Build Coating 100-200 150
With/Without Insulation M2-2 2 Silicone Based High Build Coating 100-200 150

Total 200-400 300

1 Epoxy Primer 125-175 125
M3 2 High Solids Epoxy 125-175 125
Offshore Platform Decks 3 Antiskid Epoxy 125-175 125
M3-1
(Including Primary and 4 Polyurethane 50-75 75
Secondary Structures)
Total 425-600 450
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System Min DFT Target DFT

Service Coat Paint and Coating Specifications
ID (m) (m)
M3-2 1 Antiskid High Build Epoxy
1 Epoxy Primer 200-250 250
M4 2 Antiskid Epoxy(b) 200-250 250
Offshore Platform Decks M4-1 3 Polyurethane safety marking 50-75 75
(Decks and Floors -Heavy Duty
Total 450-575 575
and Helidecks)
M4-2 1 Antiskid High Build Epoxy

M5-1 1 Glass Flake Epoxy(d) 450-550 500

1 Epoxy Primer(d) 125-175 125

M5 M5-2 2 Glass Flake Epoxy 200-500 375

y
Carbon Steel

nl
Total 325-675 500
Splash zone and spray zone

O
<60C M5-3 1 Surface Tolerant Epoxy 300-2000

se
Underwater Curable Epoxy Primer
M5-4 1 + 2 half fibreglass composite outer
lU
sheaths
M6
na

Carbon Steel M6-1 1 Underwater Curable Epoxy 500-1000

Exterior Submerged zone <60C
er
nt

M7
-I

Carbon Steel M7-1 1 Underwater Curable Epoxy 375-750 500

Water condensing surface
AS

1 High Solids Epoxy 200-250 200

M8
N

2 Stripe Coat
Carbon Steel M8-1 3 High Solids Epoxy 200-250 200
O

Ballast Water Tank

TR

Total 400-500 400

M9-1 1 Thermal Spray Aluminium 50-100 75
PE

1 Silicone 25-50 50
M9 M9-2 2 Silicone 25-50 50
Carbon Steel
Total 50-100 100
Atmospheric Zone, surface
temperature at 150C to 450C, 1 Silicone Based High Build Coating 100-200 150
With/Without Insulation 2 Silicone Based High Build Coating 100-200 150
M9-3
200-400 300

M10 1 Epoxy 150-200 150

Galvanised Steel 2 Polyurethane 50-75 75
N10-1
Atmospheric Zone, surface
temperature at -50C to 150C Total 200-275 225

M11
1 Epoxy(h) 150-200 200
Stainless Steel M11-1
2 Polyurethane 50-75 75
Atmospheric zone
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System Min DFT Target DFT

Service Coat Paint and Coating Specifications
ID (m) (m)
-50C to 120C With/Without
Total 200-275 275
Insulation
M12
1 Epoxy Phenolic 100-125 125
Stainless Steel
2 Epoxy Phenolic 100-125 125
Atmospheric zone M12-1
120C to 150C With/Without
Total 200-250 250
Insulation
1 Epoxy 150-200 200
M13
M13-1 2 Polyurethane 50-75 75
Stainless Steel
Atmospheric zone Total 200-275 275

y
150C to 450C With/Without 1 Thermal Spray Aluminium 50-100 75

nl
Insulation M13-2
Total 400 400

O
1 Aluminium Wood Primer 50 50

se
M14 2 Alkyd Semi-gloss finish 50 50
M14-1 3 Alkyd Semi-gloss finish 50 50
Timber Decks
lU
Total 150 150
na

Table 3-3: Maintenance Coating Systems

er

Notes:
nt

ID Legend:
-I

M XX Y ; e.g. M13-2
AS

M M for maintenance coating

XX Sytem number i.e. System 13
N

Y System option i.e. 2nd option in System 13

O
TR

Vendor specification
PE

(a) Applicable for surface of cold insulated steel pipe operated down to -70C under wet insulation
Coating may also be carried out in 2 coats (150 microns each).
(b) Antiskid grits should be mixed with the liquid coating prior to application to obtain good wetting of
the grits. Fine grits should be used with the application of antiskid epoxy.
(c) DFT of the applied coating shall be calculated prior to the addition of antiskid grits.
(d) The average surface profile shall be 75 microns minimum.
(e) For service temperature >700C, polychloroprene rubber shall only use carbon black pigment, which gives
better thermal resistance.
(f) Ethylene Propylene Diene Elastomer.
(g) Average surface profile shall be 75 micron minimum.
(h) Temperatures described in Table 3-3: Maintenance Coating Systems are operating temperature whereby
evident operating experiences have been established and such that operating limits shall not exceed the range
described. In case of operating conditions shall be as per design limit, then Table 3-1: New Construction
Coating Systems shall be referred.
(i) For Service M11, the stainless steel surface described is for Austenitic type stainless steel. 22%Cr and 25%Cr
stainless steels shall be painted in accordance to System N13 for operating temperatures 50C and 80C
respectively.
 PTS 15.20.03
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COATING SYSTEM PRODUCT APPROVAL REQUIREMENT

3.4.1 New coating products, upgrading of existing product or formulation changes of approved coating
products shall be submitted for a full laboratory screening before the product can be considered
as an approved product.

3.4.2 Details of the testing required are explained under Appendix 1.

3.4.3 For qualifications of coating system other than those already qualified and/or specified in
Appendix 3, Contractor shall engage with Owner on the test method and requirements.

PRODUCT QA/QC REPORT

3.5.1 Coating Manufacturers shall submit QA/QC reports on the coating products that passed the

y
nl
laboratory screening tests. The QA/QC reports must have the following information:

O
i. Coating Product Name

se
ii. Manufacturer lU
iii. Batch number
iv. Manufacturing date
na

v. Testing date
er

vi. Drying time

nt
-I

vii. Hold up property

viii. Glossiness
AS

ix. Specific gravity

N

x. Viscosity
O
TR

xi. Coatings Fingerprint Certificate

PE

3.5.2 Coating Manufacturers shall ensure that the properties of their coating systems selected for
actual coating work will be the same as the ones that passed the laboratory screening tests.
Owner may collect ad-hoc coating samples for verification an approved independent testing
agency to verify conformance to the QA/QC report stated herein.

3.5.3 Whenever deemed necessary, Owner may carry out a non-conformance audit on the coating
manufacturers.

COATING QUALITY CONTROL BATCH CERTIFICATE

3.6.1 Coating Manufacturers shall furnish their Coating Quality Control Batch certificates to ensure that
the properties of the products supplied are consistent with the laboratory tested products. The
Coatings Fingerprint Certificate shall be produced per batch per coating manufactured and data
stored in digital format. This data shall be submitted to the Owners MCI representative from the
project team during delivery of coating products.
 PTS 15.20.03
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Example of the Coatings Fingerprint Certificate can be found under Appendix 2.

Note that coating fingerprinting will only be enforced for coating projects involving 5000 m2 of
total surface to be coated.

3.6.2 Owner retains the right to conduct random coatings fingerprinting test at any given point during
the course of the project as it deems fit. This shall be referenced against fingerprinting results
submitted by the Manufacturers.

3.6.3 As a minimum, the following information shall be provided:

i. Manufacturer's name
ii. Factory location

y
iii. Date of manufacture

nl
iv. Batch number

O
v. Product name

se
vi. Generic name lU
vii. Key composition/components description:
na

a) Resin
er

b) Pigments
nt

c) Curing Agent (generic name)

-I

d) Solvent (generic name)

AS

viii. QC Test Results including Test Standard, Pass Criteria, Actual Results:
a) Colour
N
O

b) Viscosity
TR

c) Density/S.G.
PE

d) Fineness
e) Drying
f) Time
g) Hiding
h) Power
i) Gloss

3.6.4 All QC test results shall be provided by coating manufacturer as and when requested by
the Owner.
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4.0 COATING CONTRACTORS RESPONSIBILITIES

GENERAL

4.1.1 The Contractor, in addition to his responsibilities under the general conditions of the contract
shall be responsible for the quality of the work which shall be performed in strict accordance with
this PTS and all other relevant documents, such as site regulations, safety rules and requirements,
product data sheets, referenced standards and codes.

4.1.2 The Contractor shall be fully responsible for all QA and QC activities. The Contractor shall submit
for any major coating work an appropriate work planning and a QP for implementing this PTS for
review and approval by the Owner. Copies of this PTS, work planning and the QP shall be made
available to the Contractors representative at site. The representative shall confirm his

y
understanding on the contents of the PTS, work planning and the QP.

nl
O
4.1.3 The Contractor shall conduct a pre-job meeting to ensure that job and quality requirements are
fully understood. Attendees shall be a representative of the Owner, Contractor Coating Advisor,

se
the Coating Inspector and the Coating Manufacturers representative.
lU
4.1.4 The Contractor shall conduct a site coating selection via panel test. This is to be executed before
na

any major projects or major maintenance work. The Contractor shall shortlist a minimum of 3
coating manufacturers for this exercise. The Contractor Coating Advisor shall witness and accept
er

the panel test results together with Owner.

nt

4.1.5 The unmixed actual coating used for panel testing shall be marked, retained and properly sealed
-I

in a minimum 2 diameter by 2 height stainless steel container for traceability and to avoid
AS

product contamination. Owner may conduct fingerprinting test as deemed necessary.

N

4.1.6 The accepted test panels and retained unmixed coating samples shall be properly labeled and
O

stored. The coating samples, test panels and QA/QC documents shall be included as handover
TR

items in the project handover checklist. MCI representative from Owner shall acknowledge
receipt of items in the handover documents.
PE

4.1.7 Coating manufacturer shall be consulted if the Contractor is not familiar with the coating materials
to be applied.

4.1.8 The Contractor shall display his capability to Owner in achieving the requirements as specified in
the contract.

HSE

4.2.1 The Contractor shall be responsible for all aspects of HSE. Environmental regulations and rules
shall be met.

4.2.2 Safe working is of the greatest importance particularly during coating works in confined spaces
such as tanks and vessels. Site safety regulations shall be adhered to.
 PTS 15.20.03
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4.2.3 All personnel shall be provided with approved PPE suitable to the working environment as well as
weather e.g. protective clothing, safety glasses, safety shoes, hard hats, goggles, respirators,
earplugs, fresh-air-fed hood and any other necessary safety equipment.

PPE made of fabrics such as coveralls and gloves that do not provide chemical resistant protection
shall not be used to avoid dermal exposure to hazardous material during coating application. As
a minimum, leather gloves are required when handling abrasive blasting equipment and airless
spray gun. All safety equipment shall be maintained in good working condition adequate for all
work requirements.

4.2.4 Adequate warning signs shall be prominently displayed on each access way to all areas where
abrasive blasting and coating is in progress.

y
4.2.5 Handling and disposal of hazardous waste resulting from the Contractor's coating activities shall

nl
be in accordance with regulations and specific contract requirements. However, the Owners

O
regulations on chemical management or banned materials shall be strictly adhered to.

se
4.2.6 Schedule waste disposal shall be under the Contractors scope.
lU
HAZARDOUS COATING COMPONENTS
na
er

4.3.1 The Contractor shall ensure that all layers of a coating system and blasting materials comply with
any local and/or regional standards or regulations on banned materials such as lead, chromate,
nt

crystalline silica, and coal tar. The Owners regulations on chemical management or banned
-I

materials shall be strictly followed. Any coating system shall fully comply with any local and/or
regional air quality or Volatile Organic Compounds (VOC) levels or emission standards or
AS

regulations.
N

4.3.2 Reference to Occupational Safety and Health (Use and Standards of Exposure of Chemicals
O

Hazardous to Health) Regulations shall be made in the event of any hazardous components are
TR

expected to be present for the identification of OEL/MEL. Coatings shall contain maximum 0.1%
Monomeric Isocyanate at the time of coating. If the CSDS/MSDS of the coating does not specify
PE

the content of the isocyanate groups, Owner shall have the right to request for laboratory
assessment of the monomeric isocyanate content in the coating. Refer to ASTM D2572 or ISO
14896/3 for the testing procedures.

PERSONNEL

4.4.1 Refer to Section 8.0: Resource Requirement.

PROTECTION OF EQUIPMENT AND STRUCTURAL MEMBERS

4.5.1 The Contractor shall protect all equipment, structures and any other areas from mechanical
damage, environmental damage, blockage or obstruction, damage caused by over blasting,
coating droppings and splashes or overspray.
 PTS 15.20.03
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BLASTING AND SPRAYING EQUIPMENT

4.6.1 The Contractor shall demonstrate that blasting and spraying equipment to be used are in good
condition and well maintained. Blasting and coating equipment shall fully comply with any local
and/or regional regulation. Wherever applicable, valid Certificate of Fitness for blasting and
spraying equipment from local authority shall be made available for reference by Owner.

4.6.2 The blasting and spraying equipment shall be capable of achieving the quantity and quality
requirements as prescribed in the contract.

4.6.3 Blasting equipment, its operators and the equipment being blasted shall be properly earthed to
prevent the occurrence of electrostatic discharges. Abrasive blast cleaning equipment shall be of
intrinsically safe construction and equipped with a remote shut-off valve triggered by the release

y
of a dead man's handle at the blasting nozzle.

nl
O
4.6.4 Where air-operated equipment is used, the operator's hood or headgear shall be ventilated by
clean, cool air supplied through a filter, to prevent blast cleaning residues from being inhaled.

ACCESS
se
lU
na

4.7.1 Access for coating work shall be constructed to provide safe and adequate access for surface
preparation, coating and inspection of all surfaces.
er
nt

4.7.2 Scaffolding shall be constructed in accordance with local regulations and the requirements of the
Owner.
-I
AS

4.7.3 Where abseiling is required, the Contractor shall consult the Owner to conduct JHA prior to
execution and approval shall be at the discretion of the Owner.
N

HANDLING OF COATED PARTS/COMPONENTS

O
TR

4.8.1 To minimise the risk of damage, no lifting, transportation, erection or fabrication operations shall
be done before the coating has been fully dried and/or cured. Welding shall not be carried out on
PE

the external surfaces of internally coated tanks or vessels.

4.8.2 Where transportation is required, canvas or nylon slings shall be used for lifting and wooden
blocks applied for securing the structure. If weather change is expected during transportation,
plastic wrapping may be applied based on the risk of coating deterioration of the structure.

4.8.3 Any damages to the coating from premature curing due to Contractors act of welding, erection,
fabrication or lifting activities shall be repaired by the Contractor as per original specification.
 PTS 15.20.03
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STORAGE PROTECTION

4.9.1 The Contractor shall ensure the coating cans are stored in compliance to Manufacturers
recommendations, particularly in regards to storage temperature. As a general rule, all containers
containing coating materials shall be stored under cover giving protection from direct sunlight
and rain at a temperature below 35C. The storage condition shall also allow for adequate
ventilation to minimize coating container deterioration from humidity. Materials shall be
systematically stored after delivery so that a First-In-First-Out (FIFO) withdrawal procedure can
be adopted.

4.9.2 The Contractor shall supply all the necessary protection when prefabricated coated steel or
coated steel for climate controlled areas has to be stored in the open air prior to erection, to avoid
premature failure of the applied coating layers.

y
nl
4.9.3 Coating cans shall be stored away from any source of ignition.

O
4.9.4 The Owner has the right to audit and inspect the storage area while the materials are still kept or

se
stored. lU
4.9.5 Prior to removal of the material from storage area, a joint inspection by Owner and Contractor
na

shall be done to verify the condition of the material. Acceptance shall be as per agreed QA/QC
requirement.
er
nt

SHELF-LIFE
-I

4.10.1 The Contractor shall ensure that in the event that the quoted shelf-life period has been exceeded,
AS

the usability of the product shall be confirmed by the Manufacturer and notified to the Owner.
The procedure described in ASTM D869 shall be used to evaluate the degree of settling of coating.
N

A coatings fingerprint is also required to be conducted to ensure product quality is in accordance

O

with Appendix 2. This needs to be accepted in conjunction with other tests.

TR

4.10.2 Coating which has deteriorated during storage shall not be used and disposed of accordingly.
PE
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5.0 SURFACE PREPARATION

SURFACE PROFILE

5.1.1 Roughness or anchor pattern measurement shall be carried out by the Contractor using
instruments and procedures approved by the Owner. Where anchor patterns are not specified in
the coating manufacturers technical data sheet, Table 5-1 below shall be used as a guide for
determining the anchor pattern.
Dry film thickness Anchor pattern
125-200 microns (5-8 mills) 25-50 microns (1 -2 mills)
200-500 microns (9-20 mills) 50-76 microns (2-3 mills)
> 500 microns (>20 mills) 75-125 microns (3-5 mills)

y
Table 5-1: Relationship between coating thickness and anchor pattern

nl
O
5.1.2 Abrasives used in blast cleaning steels shall generally be in accordance with ISO 8504-2 and Table
5-2. In the event of other type of abrasive media not described in ISO 8504-2 and Table 5-2 is to

se
be used, prior written approval from Owner shall be obtained.
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Type of abrasive Generic Name Characteristics Standard
na

Iron grit >1.7% carbon ISO 11124-2

Metallic
Steel grit 0.8% to 1.2% carbon ISO 11124-3
er

Olivine Magnesium/iron silicate ISO 11126-8

nt

Non-metallic
Staurolite Iron/aluminium silicate ISO 11126-9
-I

Specular hematite Crystaline Fe2O3

Natural Mineral
Garnet Calcium iron silicate ISO 11126-10
AS

Coal/copper furnace
Non-metallic Aluminium silicate ISO 11126-4
N

slag
Synthetic Mineral or
O

Aluminium oxide Crystalline corundum ISO 11126-7

Industrial by-product
TR

Iron furnace slag Calcium silicate ISO 11126-6

Table 5-2: Abrasive specifications
PE

5.1.3 Aluminium oxide or other abrasives (free from any chloride or iron/steel contamination) shall be
used for blasting stainless steel.
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GRADES OF SURFACE FINISH

5.2.1 Acceptable surface finish grades are summarized in Table 5-3.

Abrasive blast cleaning SSPC ISO 8501-1 NACE
White metal blast cleaning SP5 Sa 3 No. 1
Near white metal cleaning SP10 Sa 2.5 No. 2
Commercial blast cleaning SP6 Sa 2 No. 3
Brush-off (Sweep) blast cleaning SP7 Sa 1 No. 4
Power-tool cleaning (to bare metal) SP11 - -
Commercial grade power tool SP15 - -

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Power-tool cleaning SP3 St 2 or 3 -

nl
Hand-tool cleaning SP2 St 2 -

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Solvent cleaning SP1 - -

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Pickling to white metal SP8
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High and ultrahigh pressure water jetting SP12 - No. 5
na

Water jet cleaning SP12 - No. 5

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Clean to bare substrate water jetting SP12- WJ-1 No.5 WJ-1

nt

Very thorough water jetting SP12- WJ-2 No.5 WJ-2

-I

Thorough water jetting SP12- WJ-3 No.5 WJ-3

AS

Light water jetting SP12- WJ-4 No.5 WJ-4

Wet abrasive blasting TR2 - 6G198
N

Table 5-3: Surface Finish Grades

O
TR

SURFACE PREPARATION BY HAND AND POWER TOOL CLEANING

PE

5.3.1 The most technically effective surface preparation method is blast-cleaning. Manual preparation
shall only be used when blast-cleaning is either not feasible or not strictly required, e.g. for rust
scale Ri3.

5.3.2 Manual cleaning shall be performed using hand wire brushes or mechanically operated tools
(grinders, bristle blaster, chippers or wire brushes) in accordance with ISO 8504-3. The surface
shall be left roughly abraded and a burnished surface shall be avoided.

5.3.3 If the surface being prepared lies adjacent to a coated surface which is not to be refurbished, the
power tool cleaning shall overlap the coated surface by at least 50 mm.

5.3.4 The following two preparation grades (in accordance with ISO 8501-1) are recognised for hand or
power tool cleaning:
i. St 2 : Thorough hand and power tool cleaning
ii. St 3 : Very thorough hand and power tool cleaning
NOTE: Preparation grade St 1 is considered an unsuitable surface for coating.
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SURFACE PREPARATION METHOD- STAINLESS STEEL, GALVANIZED STEEL, NICKEL ALLOY AND
NON-FERROUS ALLOY
Acceptable surface preparation methods can be varied for this specification dependent on the
size and the access to the item being coated.
Vessels, cabinets, large bore pipe and valves shall be Brush off blast cleaned to standard NACE
No. 4/SSPC SP 7.
Small bore piping, valves and instruments may be prepared by hand tool cleaning by sanding to
achieve an abraded surface profile to enable adequate coating adhesion.

5.4.1 Pre-Blasting Operations

All adjacent coated carbon steel, GRP piping, sight glasses, gauges and instruments to be

y
adequately protected to avoid either direct (over blast) damage or indirect damage by dust

nl
accumulation / contamination (equipment / instrumentation)

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5.4.2 Abrasive Brush-off blasting method

se
i. The surface to be blasted shall be washed down with Owner approved biodegradable
lU
alkali based detergent or degreaser applied as per the manufacturers instructions in
such a manner to remove all surface contamination that would be detrimental to the
na

coating.
er

ii. The surface shall then be washed with potable water (chloride content to be below
nt

20ppm) at high pressure (e.g. 200 psi) to remove the contaminated detergent or
-I

degreaser before it dries on the surface.

iii. The surface shall then be Brush off blast cleaned to standard NACE No. 4/SSPC SP
AS

7 to give a dense surface profile of no more than 25 m. The purpose of the blast
cleaning in this instance is to give the primer a suitably roughened surface to enable
N

good adhesion while also removing any minor corrosion products. Fine size abrasives
O

with low nozzle pressure (approx. 50-60 psi) shall be used for this blasting method.
TR

iv. Significant areas of corrosion pitting or metal loss that are exposed during blasting
PE

operations shall be referred to Owner for inspection prior to any further coating of
these areas.

5.4.3 Hand Preparation Methods

i. The surface to be prepared shall be washed down with an Owner approved
biodegradable alkali based detergent or degreaser applied as per the manufacturers
instructions in such a manner to remove all surface contamination that would be
detrimental to the coating.
ii. The surface shall then be washed with potable water (chloride content to be below
20 ppm) at high pressure (e.g. 200 psi) to remove the contaminated detergent or
degreaser before it dries on the surface.
iii. While the surface is still wet using abrasive paper (rating 100 120) vigorously rub
the surface to achieve a 100% abraded surface suitable for the primer to adhere to.
iv. Surface shall be kept wet during the operation (using potable water) and rinsed
afterwards to ensure the sanding residue does not dry on the surface to be primed.
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6.0 APPLICATION

PRE-APPLICATION PROCEDURES

6.1.1 Coating Materials Storage and Handling

i. Coating materials shall be furnished in the manufacturers original, unopened
container and clearly labeled to enable identification of the contents. Each container
shall have full identification, information including manufacturers name, product
identification, batch number and colour.
ii. Hazardous chemicals shall be classified, packaged and labelled appropriately in
compliance with the Occupational Safety and Health (Classification, Packaging and
Labeling of Hazardous Chemicals) Regulations 1997. Safety requirements shall also be

y
specified in the MSDS.

nl
iii. Manufacturers specified shelf life for coating components shall be followed.

O
iv. Thinners or cleaners shall comply with the coating manufacturers recommendation,

se
or if independently purchased, shall be of compositions approved by the coating
lU
manufacturer.
v. Solvent can closures shall be kept tight at all times to prevent the entrance of humid
na

air, which can lead to condensation.

er

6.1.2 Coating Material Mixing and Thinning

nt

i. All coating materials shall be thoroughly mixed in accordance with the

-I

Manufacturers instruction.
AS

ii. Mixing of different brands or generic types of coating material is not permitted unless
respective manufacturers consent has been received which shall not nullify the
N

overall warranty by the Contractor.

O
TR

iii. Hand mixing of coatings shall only be permitted for containers up to 5 liters. All larger
containers shall be mixed by mechanical agitators and brought to a uniform
PE

consistency. Where pigment separation readily occurs, provision shall be made for
continuous mixing during application. If the pigment settles, it shall be redispersed
with a power mixer to form a uniform mixture.
iv. Two-pack coatings shall be mixed in strict compliance with Manufacturer's
instructions including any necessary induction period. Partial mixing is strictly not
allowed. The pot life of such coatings shall be specifically noted. Any mixed coating,
which has exceeded its pot life, shall be discarded irrespective of its apparent
condition.
v. Sticks or similar tool shall not be used for mixing to avoid contamination.
vi. Coating applied by brush shall not be thinned down without the approval of the
Owner Site Representative. In such cases, thinners recommended by the coating
manufacturer shall only be used.
vii. Hardeners, catalyst and thinners shall be strictly used in accordance with the coating
manufacturer's instructions. Any modification to coating materials at site is
prohibited. This includes but not limited to pigmentation, adding solvents, tints etc.
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APPLICATION CONDITION

6.2.1 Coating shall be applied to dry, clean, prepared surface under conditions recommended in the
manufacturers product data sheet. The Contractor shall comply with the QP for work execution.
Where deviation may exist, it is the responsibility of the Contractor to highlight the deviations and
obtain the necessary approval from Owner Site Representative.

6.2.2 Coating shall not be applied when any of the following conditions exist:
i. The surface temperature is less than 3C above dew point.
ii. The surface temperature is below 5C as it could adversely affect the curing of
coatings. Refer to product data sheet for systems that can be applied at temperatures
below 5C.

y
iii. The relative humidity (RH) is greater than 85%, except for moisture-cured urethane

nl
coating systems which may be used at higher than 85% RH.

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iv. The metal surface temperature is above 50C or higher than that recommended by

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the Manufacturer for application. lU
v. Surface preparation has not been completed or oil, grease and dust are present on
the substrate to be coated.
na

vi. Poor weather conditions example rain, heavy fog or blowing sand.
er

vii. When there is a deposition of moisture in the form of rain, condensation etc. on the
nt

surface. Probability of condensation may be determined in accordance with

-I

procedures described in ISO 8502-4.

AS

viii. Where the available light is less than 500 lux.

ix. Coating may be suspended at the discretion of the Owner Site Representative due to
N

wind speed, wave height, or when adverse weather conditions are likely to develop
O

before coating could be carried out, or for other reasons deemed inappropriate to
TR

proceed.
PE

6.2.3 It is important to ensure residual salt contamination particularly from chloride ion is kept to as
minimal as possible. Contractor to agree with Owner on random residual salt test that shall be
conducted for these conditions:
i. Prior to primer application
ii. Subsequent coating layer application after a long interval e.g. after 1 day curing of
previous coating application.

6.2.4 The assessment of soluble chloride ion content shall be carried out in accordance with ISO 8502-
6 and 8502-9 or any approved commercial field test kit by the Owner. The soluble chloride ion
limit shall be 20mg/m2, except for maintenance coating works for other than stainless steels in
atmospheric zone where 50mg/m2 is acceptable. The test shall be carried out once per 200m2
area with a minimum of three times per shift.
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6.2.5 If the soluble chloride ion content is high and obtaining a clean surface is too costly, the allowable
soluble chloride ion content shall be agreed by the Contractor and Owner.

6.2.6 Other restrictions on coating applications include:

i. Applied coatings for offshore and onshore near marine environment shall not be left
without overcoating for a period more than 3 days or the maximum over coating time
recommended by the Manufacturer whichever is shorter. If this is exceeded, high
pressure (e.g. 200 psi) fresh water washing shall be conducted prior to the application
of the subsequent coats and validated with soluble chloride ion test.
ii. Applied coatings for onshore away from marine environment shall not be left without
overcoating for a period of more than 14 days or the maximum over coating time
recommended by the Manufacturer whichever is shorter. If this is exceeded, high
pressure (e.g. 200 psi) fresh water washing shall be conducted prior to the application
of the subsequent coats and validated with soluble chloride ion test.
iii. Zinc or aluminium in the form of coating pigments or metal spray shall never be
allowed to come into contact with stainless steel, nickel-based alloys or copper-based
alloys.
iv. Any coatings or coatings used on stainless steel, nickel based alloys and copper based
alloys shall be chloride free and also free of low melting point metals such as zinc,
aluminum, tin and lead.
v. On structural steel areas subject to be assembled by high tension bolts, contact
surface shall be primed only with Inorganic Zinc Silicate. Intermediate and final coat
shall not be applied.

6.2.7 Compatibility with Existing Coating System:

i. For spot repair and renovation the selected coating systems shall be the same as or
compatible with existing coating systems.
ii. Epoxies and polyurethanes may only be applied on top of alkyd coatings in
exceptional cases and only after a thorough investigation has been conducted into
the softening and adhesion of the proposed coating system. In such cases the coating
manufacturer shall be consulted.
iii. Silicate-based coatings shall not be applied on top of organic coatings or organic shop-
primers as there is insufficient intercoat adhesion.
iv. Some hot-surface-applied maintenance coatings may be used for application on high-
temperature surfaces if their performance has been demonstrated. The temperature
measurements shall be made a minimum of three times per shift during the progress
of the work.

APPLICATION METHODS

6.3.1 General Requirements

i. The completed coating shall be uniform and free from defects such as runs, sags,
pinholes, fish eyes, bubbles, orange peel, grit or dust inclusions, or other deleterious
anomalies, and be of good visual appearance. The topcoat shall completely hide the
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color of the underlying coat.

ii. Particular care shall be taken to ensure that sharp edges, welds, irregular shaped
structures, crevices, corners, weld lines, bolt heads, nuts, small brackets and
inaccessible areas are adequately coated to the full film thickness. To achieve this,
sharp edges and welds shall be precoated (stripe coated) by brush application
immediately prior to application of each coat of coating.
iii. Edges of existing coating shall be feathered towards the substrate prior to over-
coating to ensure good adhesion.
iv. Inaccessible surfaces after assembly, including the surface of lap joint flanges, nozzle
necks, lap joint stub ends, lap rings, bolt holds and some welded joints, shall receive
the complete coating system. Contact surface of bolted connections shall be primed.
v. Contrasting colour shall be used for each coat of coating so as to ensure different
coats are applied to meet the required dry film thickness.
vi. Zinc silicate primers shall be sealed with a tie coat as soon as practical after complete
curing has taken place to avoid salt or chemical contamination.
vii. A holding or temporary protective primer may be used to facilitate shop or site
handling procedures. Such primers shall in no way replace the function or part of the
film thickness of the priming coat originally quoted in the applicable coating
specification.
viii. Other considerations:
a) Coating of small bore pipework (3" NPS) and smaller shall be applied by brush
or pipe roller.
b) Externally marine exposed non-galvanised bolts and nuts which cannot be
over coated due to operational requirements shall be encased in a corrosion
resistant lubricant based on the approval of Owner.
c) Valve stems and threaded stems shall be applied with suitable corrosion
resistant lubricant, subject to approval of Owner.
ix. Type of application is as per Table 6-1 below.

Type of
Recommended Usage Description Notes
Application
Airless Spray For large areas Coatings are sprayed at Spray patterns have
application higher pressure without to be observed as
compressed air. Twice as clogging may occur
fast, provides higher film and different spray
build, higher transfer patterns may
efficiency and more require different
economical. nozzle.
Conventional Air Not Applicable Versatile use but often Not Applicable
Spray leads to overspray and
uneconomical costing.
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Type of
Recommended Usage Description Notes
Application
Brush When spraying is not Good for complex shaped Correct application
Application possible substrate that cannot be and technique may
spray coated. avoid overcoating
i.e. too thick or thin
Roller When spraying is not Not Applicable Not Applicable
possible and primer
has been roller coated
as well
Table 6-1: Types of Application

REPAIRS AND TOUCH UP COATING

6.4.1 General Requirements

i. Procedure for repair and/or touch up coating for each generic coating system shall be
submitted by contractor for Owner approval.
ii. Before application of any subsequent coating material, all damages from previous
coats shall be repaired. All loose coating shall be removed to a firm edge. All surface
irregularities and contaminations shall be removed. Hard, glossy surface may require
abrading to obtain a suitable surface for coating. Surface preparation shall refer to
Maintenance Coating requirements of this PTS.
iii. If the surface being prepared lies adjacent to a sound coated surface, the surface
preparation shall overlap the coated surface by at least 50mm. The remainder of
existing coated surface shall be properly protected with shields or screens to prevent
any possible damage to the coating.
iv. Inorganic Zinc primer shall not overlap adjacent intermediate and finish coats. Areas
with inadequate coating thickness shall be thoroughly cleaned and if necessary,
abraded, and additional compatible coats are applied until the specified thickness is
met. These additional coats shall blend in with the final coating on adjoining areas.

6.4.2 Damaged Coating Not Exposing Substrate Surface

Surface to be overcoated shall be cleaned by solvent cleaning and/or lightly brush blasted to
ensure that the surface is free from contaminants. Contaminants shall be removed by dry
compressed air and wiped by hand with clean, dry rags. The coating around the damaged area
shall be chamfered by sanding to ensure continuity of the patch coating. The full coating system
shall then be reapplied strictly in accordance to the Maintenance Coating requirements of this
PTS.

6.4.3 Damaged Coating Exposing Substrate Surface

The damaged area shall be cleaned to the original or maintenance coating system specified for
that item. The full coating system to be reapplied in accordance with the application data. The
cleaning shall carry over onto tightly adhering surrounding coating for not less than 25 mm all
around and the edges shall be chamfered by sanding to ensure continuity of the patch coating.
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6.4.4 Repair of Zinc Ethyl Silicate Primer

Damaged surface of zinc primer shall be cleaned to remove all loose materials and blast cleaned
with a portable vacuum blast cleaning unit. The surface shall be coated with one coat of the primer
which is the same as the damaged primer.
If blast cleaning is not practical, power tool cleaning may be used subject to Owner approval. In
such cases, subject to operating temperature limitations, one or two packs of recoatable zinc
primer may be used in lieu of zinc silicate primer subject to Owner approval.

6.4.5 Repair of Fully Cured Epoxy Coating

In case of repair to damage fully cured epoxy coatings and aged epoxy coating, the coating work
shall only be carried out after the surface has been suitably abraded to provide an adequate
anchor for the coating to be applied. The repair coating shall be compatible with the existing
coating as describe in ASTM D5064.

6.4.6 Inadequate Coating Thickness

Areas with inadequate coating thickness shall be thoroughly cleaned and if necessary abraded
and additional coats applied shall blend in with the final coating on adjoining areas.

6.4.7 Handling and Shipping of Coated Items

Coated items shall be carefully handled to avoid damage to coated surface. No handling shall be
performed before the coating system is cured to an acceptable level. Packing, handling and
storage facilities shall be of non-metallic type.
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7.0 QUALITY CONTROL (QC)

GENERAL

7.1.1 Compliance to this PTS shall be controlled through inspection and testing during all phases of
surface preparation and coating application.

7.1.2 Owner shall have the right to inspect and assess the coating work at all stages of preparation and
application and to reject any or all tools, instrument, materials, equipment, personnel or work
which does not conform to this PTS.

7.1.3 All QC requirements and acceptance criteria shall be stated in Project Specification and
incorporating the requirement of this PTS, the Owner and coating manufacturer.

7.1.4 All and any coating activity greater than 2000 m2 shall be supervised by a certified Owner
appointed Coating Inspector, and under no circumstances will the Contractors Coating Inspector
substitute this QA/QC role. All exceptions or deviations to this rule will be reviewed under an
approved MOC for approval by Owner.

QUALITY REQUIREMENTS

7.2.1 The Contractor shall be fully responsible for ensuring that all surface preparation, coating and
wrapping work meets the relevant Owner QC standards, in addition to being carried out in a
timely and professional manner.

7.2.2 The Contractor and his Sub-Contractors shall operate a Quality Management System meeting the
requirements of the relevant parts of ISO 9001.

7.2.3 Prior to placement of the contract, the Contractor and Sub-Contractors shall demonstrate the
compliance of their Quality Management System with Owner requirements by submitting their
QA Manual for review and approval. The QA Manual, as a minimum, shall contain:
i. The company profile and Quality Policy Statement.
ii. The management structure organogram and details of individual managerial
responsibilities.
iii. Detailed list of all the activities carried out by the company with their interactions,
preferably accompanied by a Flowchart.
iv. The QC Plans for each activity from material purchasing and handling through to final
inspection, testing and document control, including the treatment of non-
conformances and corrective actions.
v. Document Control System for the review and update of procedures and the retention
of quality control records related to each contract.
vi. Employee training and education system and records.
vii. Auditing methods procedures, including incident or accident investigation.
viii. Safety and environmental policy and assessment of each activity.
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7.2.4 The Contractor and Sub-Contractors shall be subject to audit by Owner prior to placement of the
contract and during the execution of the contract, as deemed necessary.

7.2.5 All personnel involved in the preparation, coating work and any Sub-Contractor proposed for this
work shall be formally approved by the Owner, before the work begins.

7.2.6 Prior to commencement of the work, a formal minuted Pre-start Meeting shall be held between
the Owner, Contract Administrator, relevant Contractor management and supervisory staff and
Coating Inspectors. The full scope of the work required under the contract shall be discussed. All
issues relating to the clarity or consistency of the surface preparation and/or coating
requirements detailed within the tender documents and on relevant drawings shall be formally
raised and clarified at this meeting. This will enable the quality requirements for the work to be
mutually agreed.

INSPECTION AND TESTING

7.3.1 Prior to commencement of the work, the Contractor shall submit his ITP (sample in Appendix 13)
to Owner for review and approval. This shall detail the individual preparation, coating activities
involved and the inspection and test methods that will be used to ensure that they are carried out
to an acceptable standard. The ITP will generally be in table form and will indicate the type and
level of inspection and testing that is required at each stage of the work. It shall also contain
references to verifying documents, acceptance criteria and personnel responsible for each
activity.

7.3.2 The Contractor shall maintain a comprehensive recording and reporting system on all aspects of
surface preparation, coating application and QC inspection and testing. This shall as a minimum
meet all the requirements of this PTS. A final report shall be submitted to Owner, summarizing all
the work performed and the inspection and test results for approval.

PROCEDURE AND REPORT

7.4.1 Prior to commencement of coating activities, Contractor shall submit surface preparation coating
application procedure which includes inspections and tests to be conducted for approval by
Owner.

7.4.2 All observations, data and test result of the surface preparation and coating application activities
shall be documented by Contractor in pre-approved format. These reports shall include:
i. Names of the Contractor and the responsible personnel including blaster, Painter, and
coating and lining applicator.
ii. Date, time and duration when coating activities were carried out, including surface
preparation, coating application, inspection and testing activities.
iii. Equipment, materials, abrasive media and techniques used for surface preparation
and coating application.
iv. Type and calibration validity of instruments and tools used.
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v. Environmental conditions including relative humidity, dew point temperature and

surface temperature.
vi. Condition of structure to be coated before and after surface preparation.
vii. Information on coating systems and coating material being applied including
manufacturer, type, batch number and shelf life.
viii. Mixing tools and techniques prior to application.
ix. Type and results of inspection and testing performed and compliance to standard and
specification.

7.4.3 All report shall be reviewed and approved by Owner.

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8.0 RESOURCE REQUIREMENT

COATING CONTRACTOR

8.1.1 Coating contractors shall have the personnel, organisation, qualifications, procedures, knowledge
and capability to produce surface preparation and coating application of the required quality. The
procedure for evaluating qualifications of coating contractors is described in SSPC-QP1.

8.1.2 Functional areas to be evaluated shall include the following:

i. Management Procedures: Company policy and management procedures
ii. Technical Capabilities: Personnel qualifications, technical resources, procedures,
equipment, facilities and experience
iii. Quality Control: Personnel qualifications, inspection procedures and recording
systems
iv. Safety: Safety procedure, record systems and resource materials

Roles Responsibilities Qualifications Notes

Coating To ensure the coating quality is Certified with either one of IMM Coatings
Inspector in accordance with the below as a minimum. Fingerprint
specification. The inspector may Institute of Materials Quality Controller
be required, as a minimum, to Malaysia (IMM) Level 1
review, validate, witness, verify Coating Inspector Level certification is an
and document the work at II advantage
various inspection points as per NACE International
the ITP as per Appendix 13. Certified Coating Abseiling
Inspector Level I certification may
Note that this Coating Inspector SSPC PCI Level I be required
is only responsible for his area of FROSIO Level II
work. Overall coating project
responsibility lies with the And minimum 3 years
coating advisor working experience in
coating inspection with
Note that this role does not good working knowledge on
absolve the Coating Contractor all aspects of coating such
of their overall QA/QC as procedures, specification,
responsibilities. coating performance,
application and able to use
The Coating Inspector is in coating inspection tools.
charge of areas 5000m2 area
to be coated in a single project.

Coating To ensure the overall project Certified with either one of IMM Coatings
Advisor coating quality is in accordance below as a minimum. Fingerprint
with the specification. The role Institute of Materials Quality Controller
of the advisor is to oversee all of Malaysia (IMM) Level 1
the coating inspectors activities. Coating Inspector Level certification is an
II advantage
This role is an ad-hoc position by NACE International
appointment given to a qualified Certified Coating
Owner. Note that this role does Inspector Level II
not absolve the Coating SSPC PCI Level II
Contractor of their overall FROSIO Level III
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Roles Responsibilities Qualifications Notes

QA/QC responsibilities.
And minimum 5 years
The Coating Advisor is typically working experience in
in charge of areas 10,000m2 coating inspection with
area to be coated in a single good working knowledge on
project. all aspects of coating such
as procedures, specification,
coating performance,
application and able to use
coating and coating
inspection tools.

Roles Responsibilities Qualifications Notes

Blasting The Blaster and Coating Shall be certified with Not Applicable
and Supervisor assumes the either one of below as a
Coating overall execution of any minimum.
Supervisor coating activity Institute of Materials
Shall participate in Malaysia (IMM)
developing JSA and JHA. Blasting and Coating
Shall develop job plans and Supervisor
ensure adequate QC Institute of Materials
coverage based on Malaysia (IMM)
projected schedules or Coating Inspector Level
minimum QC coverage by II
crew, structure, location, or SSPC C7 Abrasive
working hours. Blasting Program, C12
Able to troubleshoot any Spray Application
application issues and help Program, or
raise MOC. SSPC Coating
Ensure understanding of Applicator Specialist
work scope, requirements Level I
of work and safety
compliance among team
members. And minimum 7 years
Ensure surface preparation working experience in
and coating application is coating inspection with
done properly by adherence good working knowledge in
and compliance to specification and
procedures, technique, procedures. Knowledge
environment, equipment shall include:
setups and limitations etc. Corrosion
to avoid defects. Coating and Properties
Ensure timely and quality Marine environment
job completion with most for coating
economical approach Volume of solid
avoiding wastage. Coating defects
Keep track and act upon Quality control
daily progress, material Inspection
consumption and ordering Safety
of stock. Role of Supervisor
Ensure equipment and Human relations
material are stored
according to manufacturer
recommendations.
Lead Shall be able to carry out Shall be certified with
Blaster the company accepted either one of below as a
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Roles Responsibilities Qualifications Notes

and surface preparation and minimum.
Painter application of coatings Institute of Materials
safely and to the minimum Malaysia (IMM)
required quality of this PTS. Certified Lead Blaster
Shall be able to work and Painter
independent of any direct Akademi Binaan
supervision. Malaysia/CIDB
Shall supervise up to a Certified Blasters and
maximum of ten (10) Painters
blasters and Painters. SSPC Abarasive
Shall be able to understand Blasting Program (C7)
and apply PTW, JSA, JHA; and Spray Application
read and apply Program (C12), or SSPC
manufacturers data sheet, Coating Applicator
MSDS and coating system Specialist Level I
sheets, coating
specifications And minimum 5 years
Shall be competent and working experience in
skilful with the following blasting and coating.
operations (as a minimum):
i. Blasting;
Equipment Set Up (Type of Nozzle,
Compressor Pressure, Type of Hose,
After Cooler).
Abrasive (Type, Size).
Surface Quality Achieved.
ii. Coating;
Equipment (Application Method, Air
Pressure, Tip Size)
Specialist Coatings and Linings
Applications (Product used, Generic
name, Mixing Ratio, Mixing Method,
Thinner, Percent thinning, Expected
Pot Life, Thickness required)

Lead Blaster or Painter should be capable

of working effectively from scaffolding or
temporary structures and at heights up to
300m above water.

Blaster Shall be able to carry out Shall be certified with Abseiling certification may
and the company accepted either one of below as a be required
Painter surface preparation and minimum.
application of coatings Institute of Materials
safely and to the minimum Malaysia (IMM)
required quality of this PTS. Certified Blaster and
Shall be working under the Painter
supervision of a lead blaster Akademi Binaan
and Painter. Malaysia/CIDB
Shall be competent and Certified Blasters and
skilful with the following Painters
operations (as a minimum): SSPC Abarasive
i. Blasting; Blasting Program (C7)
Equipment Set Up (Type of and Spray Application
Nozzle, Compressor Pressure, Program (C12)
Type of Hose, After Cooler).
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Roles Responsibilities Qualifications Notes

Abrasive (Type, Size). And minimum 1 years
Surface Quality Achieved. working experience in
ii. Coating; blasting and coating.
Equipment (Application
Method, Air Pressure, Tip Size)
Coating Used (Product used,
Generic name, Mixing Ratio,
Mixing Method, Thinner,
Percent thinning, Expected Pot
Life, Thickness required)

Blaster or Painter should be capable of

working effectively from scaffolding or
temporary structures and at heights up to
300m above water.

Table 8-1: Resource Requirements

INSPECTION EQUIPMENT

8.2.1 The coating inspection equipment shall be provided by the Inspection Agency and the Contractor.
The appropriate instruments with valid calibration where applicable, to be used at various
inspection points, but not limited to the following:

Item No Item Description Purpose

1 Sling Psychrometer
2 Surface Thermometer 0C to 150C Weather Condition Check
3 Psychrometric Tables
4 Hypodermic Needle Pressure Gauge
Blasting Equipment Check
5 Blast Nozzle Aperture Gauge
6 Surface Profile Gauge
7 Surface Preparation Standards
8 Inspection Mirror
Surface Quality Check
9 Illuminated Magnifier
Salinity Refractometer / Salt
10
Contamination Meter
11 WFT Gauge
Coating Thickness Check
12 DFT Gauge for Ferrous or non-Ferrous
13 Low voltage Holiday Detector
Holiday Detector
14 High voltage Holiday Detector
15 Cutter for tape Adhesion Test
Adhesion Check
16 Hydraulic Adhesion Tester
17 Blotter Test Kit (ASTM D4285) Air Cleanliness

Table 8-2: Recommended inspection equipment

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9.0 HEALTH, SAFETY AND ENVIRONMENT (HSE)

SAFETY AND HEALTH REGULATIONS

9.1.1 For international projects, all coating activities shall comply with the HSE requirements of the host
country.

9.1.2 Coating activities shall be in compliance to Factories and Machinery (Mineral Dust) Regulations,
1989 or equivalent, permissible exposure limit, exposure monitoring, methods of compliance,
personal protective equipment, housekeeping, medical examinations, changing rooms and
lockers, employee information and training, record keeping and warning signs.

9.1.3 If existing coating contains metallic lead, the removal of lead base coating shall comply with
Factories and Machinery (Lead) Regulations, 1984 or equivalent.

9.1.4 Coating products and abrasives shall be in compliance with Occupational Safety and Health
(classification, labelling and safety data sheet of hazardous chemicals) regulations 2013 on
packaging, labelling, safety data sheet, inventory of hazardous chemicals and confidential
business information.
Site blasting area shall have approval from the Local Authority of the host country (e.g. DOSH).

9.1.5 Owner shall have a stake in ensuring that Contractors employed have the capability to comply
with health and safety regulations, and that hazardous operations in the protective coatings
industry are recognized such as:
i. Materials
a) Fire Hazards and Explosions
b) Health Hazards
ii. Coating Application
iii. Surface Preparation
iv. Access and Ringing
a) Ladders
b) Fall Hazards
c) Confined Spaces
v. Equipment Grounding
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9.1.6 Contractor shall submit and has full responsibility for maintaining a proper and sufficient safety
loss and prevention programme covering the work and covering the employees.

9.1.7 Contractor HSE Programme shall be designed to comply with PETRONAS Corporate Policy
Statement on Health, Safety and Environment (Appendix 10), the Malaysian National Council for
Occupational Safety and Health Act (OSHA), 1994 which states that it shall be the duty of every
employer and every self-employed person to ensure, as far as practicable, the safety, health and
welfare at work of all his employees.

9.1.8 The purpose of an OSHA Compliance Programme is to make further provisions for securing that
safety, health and welfare of persons at work, for protecting others against risks to safety or health
in connection with the activities of personnel at work.

9.1.9 The components of an OSHA Compliance Programme shall include:

i. Policy statement establishing goals and commitment of management and the means
for communicating these to all employees.
ii. Delegation of responsibilities for implementing the programme.
iii. Methods of identifying hazards and hazardous activities and for controlling them.
iv. Commitment to on-going training and education of all supervisors and employees on
all aspects of job safety and health.
v. Proper reporting and record keeping, and investigation of all incidents, injuries and
illness.
vi. Methods and procedures for complying with specific OSHA regulations.
vii. Periodic review of programme with revisions made as necessary.

ENVIRONMENTAL REGULATIONS

9.2.1 Under the Environmental Quality (Scheduled Wastes) Regulations 2005, every waste generator
shall ensure that the scheduled waste generated is properly treated, stored and disposed of.

9.2.2 Every waste generator shall ensure that the scheduled waste that is subjected to movement or
transfer be packaged, labelled and transported in accordance with the guidelines prescribed by
the director-general of the Department of Environment.

9.2.3 Scheduled waste shall be stored in containers which are compatible with the waste and durable
to prevent spillage or leakage.

9.2.4 All handling of waste materials including but not limited to spent abrasives, coatings, thinners,
solvents and cleaners shall be performed in safe and legal manner and shall comply with all
applicable regulations and laws.

9.2.5 For regulations on abrasives, coating products, waste production, product storage and leaching
of coatings, refer to Appendix 19.
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10.0 COLOUR SCHEMES

STRUCTURAL COLOUR SCHEMES

10.1.1 The colour scheme for structures shall be as per Appendix 9.

PIPING COLOUR SCHEMES AND IDENTIFICATION SYSTEM

10.2.1 The colour scheme for piping shall be as per Appendix 8. The piping identification system shall be
as per Appendix 7.

10.2.2 For insulated and non-insulated piping identification, the product contained shall be marked by a
legend specifying product name in full or abbreviated form. Arrows shall be used to indicate
direction of flow. In cases where the piping changes direction or where pipe passes through walls
or floors, arrows shall be placed in positions which are easily visible. As a minimum, arrows shall
be placed at each location where the direction of the flow changes or prior to penetration of wall
or floor.

10.2.3 Pipe marking may be done by either coating or using tape or markers. The application of tapes
for pipe identification shall be limited to 60C for non-insulated pipe and no temperature limit for
insulated pipe. The detailed dimension, location and number of markings shall be based on
particular piping system as specified in Appendix 8.

10.2.4 For systems not described in Appendix 8, the facilities owner shall determine the marking as
appropriate based on ANSI A13.1- Scheme for Identification of Piping System.

10.2.5 Each line shall be labelled in English with its service and to/from designation (such as "Crude to
L.P Separator Train 1"). The labelling shall be as short as possible, but concise. The labelling shall
be applied only at the starting and termination of a line.

EQUIPMENT COLOUR SCHEME

10.3.1 The colour scheme for equipment shall be as per Appendix 9. The storage tank identification
system which includes product content and the tank number shall be as described in Appendix 6.

PIPELINE/RISER IDENTIFICATION SYSTEM

10.4.1 Each pipeline/riser shall be marked in accordance with piping identification system as per
Appendix 7. The pipeline marking shall be easily visible.
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10.4.2 The marking location shall be determined by the Owner. As a minimum, the marking should be at
beginning and end of pipeline.

For offshore pipeline, the marking can be made at the launcher to riser section and at the receiver
section.

For onshore above ground pipeline, the marking can be made at the pipeline section before and
after the pipeline is being buried.

SAFETY COLOUR SCHEME

10.5.1 The colour scheme and marking for escape route shall be as per Appendix 10.
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11.0 BIBLIOGRAPHY

In this PTS, reference is made to the following Standards/Publications. Unless specifically

designated by date, the latest edition of each publication shall be used, together with any
supplements/revisions thereto:

PETRONAS TECHNICAL STANDARDS

Index to PTS PTS 00.01.01

Requirements, General Definition of Terms, Abbreviations & Reading PTS 00.01.03

Guide

Control Valves : Selection, Sizing and Specifications PTS 14.10.04

Offshore Temporary Refuges PTS 11.20.01

MALAYSIAN REGULATIONS

Environment Quality Act (EQA) 1974

Environmental Quality (Prescribed Premises)(Schedule Wastes 1989

Treatment and Disposal Facilities) Order

Environmental Quality (Prescribed Premises)(Schedule Wastes 1989

Treatment and Disposal Facilities) Regulations

Factories and Machinery (Mineral Dust) Regulations 1989

Factories and Machinery (Lead) Regulations 1984

Occupational Safety and Health (Use of Standards of Exposure of 2000

Chemicals Hazardous to Health) Regulations

Occupational Safety and Health (Classification, Labelling and Safety 2013

Data Sheet of Hazardous Chemicals) Regulations

Environmental Quality (Scheduled Wastes) Regulations 2005

Malaysian National Council for Occupational Safety and Health Act

(OSHA) 1994
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INTERNATIONAL STANDARDS

Schedule of Coating for Building Purposes BS 4800

Framework for Colour Co-ordination For Building Purposes BS 5252
RAL Colour Chart RAL
Standards for Offshore Helicopter Landing Areas CAP 437
Technical Safety NORSOK S-001
Assignment of Degree of Rusting ISO 4628-3
Zinc Dust Pigments for Coatings ISO 3549
Coatings and Varnishes Pull-Off Test for Adhesion ISO 4624
Preparation of Steel Substrates before Application of Coatings and ISO 8501
Related Products Visual Assessment of Surface Cleanliness
Preparation of Steel Substrates before Application of Coatings and ISO 8502
Related Products Tests for the Assessment of surface Cleanliness
Preparation of Steel Substrates before Application of Coatings and ISO 8503
Related Products Surface Roughness Characteristics of Blast-Cleaned
Steel Substrates
Preparation of Steel Substrates before Application of Coatings and ISO 8504
Related Products Surface Preparation Methods
Plastics Polyurethane Raw Materials Determination of Isocyanate ISO 14896
Content
Preparation of Steel Substrates before Application of Coatings and ISO 11124
Related Products Specifications for Metallic Blast-Cleaning Abrasives
Preparation of Steel Substrates before Application of Coatings and ISO 11125
Related Products Test Methods for Metallic Blast-Cleaning Abrasives
Preparation of Steel Substrates before Application of Coatings and ISO 11126
Related Products Specifications for Non-Metallic Blast Cleaning
Abrasives
Preparation of Steel Substrates before Application of Coatings and ISO 11127
Related Products Test Methods for Non-Metallic Blast Cleaning
Abrasives
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Coatings and Varnishes Corrosion Protection of Steel Structures by ISO 19840

Protective Coating Systems Measurement of, and Acceptance Criteria
for, the Thickness of Dry Films on Rough Surfaces
Quality Management Systems Requirements ISO 9001
Coatings and Varnishes Determination of Flow Time by Use of Flow ISO 2431
Cups
Coatings and Varnishes Determination of Viscosity Using Rotary ISO 2884
Viscometers
Coatings and Varnishes Determination of Density ISO 2811
Coatings, Varnishes and Plastics Determination of Non-Volatile- ISO 3251
Matter Content
Coatings and Varnishes Determination of Pigment Content ISO 14680
Graphical Symbol Safety Colours and Safety Signs ISO 3864
Standard Practice for Conducting a Patch Test to Assess Coating ASTM D5064
Compatibility
Standard Specification for Zinc Dust Pigment ASTM D520
Standard Test Method for Isocyanate Groups in Urethane Materials or ASTM D2572
Prepolymers
Standard Test Methods for Field Measurement of Surface Profile of ASTM D4417
Blast Cleaned Steel
Standard Test Method for Indicating Oil or Water in Compressed Air ASTM 4285
Standard Practice for Operating Salt Spray (Fog) Apparatus ASTM B117
Standard Test Method for Evaluation of Coated or Coated Specimens ASTM D1654
Subjected to Corrosive Environments
Standard Test Method for Pull-Off Strength of Coatings Using Portable ASTM D4541
Adhesion Testers
Standard Test Methods for Measuring Adhesion by Tape Test ASTM D3359
Standard Test Method for Resistance of Organic Coatings to the Effects ASTM D2794
of Rapid Deformation (Impact)
Standard Test Method for Abrasion Resistance of Organic Coatings by ASTM D4060
the Taber Abraser
Standard Test Methods for Cathodic Disbonding of Pipeline Coatings ASTM G8
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Standard Practice for Operating Xenon Arc Light Apparatus for ASTM G155
Exposure of Non-Metallic Materials
Standard Test Methods for Evaluating Coatings for High Temperature ASTM D2485
Service
Standard Practice for Cyclic Salt Fog/UV Exposure of Coated ASTM D5894
Metal.(Alternating Exposures in a Fog/Dry Cabinet and a UV
Condensation Cabinet)
Standard Test Method for Specular Gloss ASTM D523
Standard Test Method for High-Shear Viscosity Using a Cone/Plate ASTM D4287
Viscometer
Standard Test Method for Viscosity of Coatings and Related Materials ASTM D5125
by ISO Flow Cups
Standard Test Method for Consistency of Coatings Measuring Krebs ASTM D562
Unit(KU) Viscosity Using a Stormer-Type Viscometer
Standard Guide for FT-IR Fingerprinting of a Non-Aqueous Liquid ASTM D7588
Coating as Supplied in the manufacturers Container
Standard Test Methods for Water Vapour Transmission of Organic ASTM D1653
Coating Films
Standard Test Method for Evaluation of Painted or Coated Specimens ASTM D1654
Subjected to Corrosive Environments
Standard Test Method for Indentation Hardness of Rigid Plastics by ASTM D2583
Means of a Barcol Impressor
Standard Practice for Testing Water Resistance of Coatings Using Water ASTM D870
Immersion
Standard Test Method for Tensile Properties of Organic Coatings ASTM D2370
Standard Test Method for Measuring Humidity with a Psychrometer ASTM E337
(the Measurement of Wet- and Dry-Bulb Temperatures)
Standard Practice for Discontinuity (Holiday) Testing of Nonconductive ASTM D5162
Protective Coating on Metallic Substrates
Zinc Rich Primers(Type I, Inorganic, and Type II, Organic) SSPC-Coating 20
Mineral and Slag Abrasives SSPC-AB 1
Cleanliness of Recycled Ferrous Metallic Abrasive SSPC-AB 2
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Ferrous Metallic Abrasive SSPC-AB 3

Procedure for Determining Conformance to Dry Coating Thickness SSPC PA 2
Requirements
Solvent Cleaning SSPC-SP 1
Hand Tool Cleaning SSPC-SP 2
Power Tool Cleaning SSPC-SP 3
White Metal Blast Cleaning SSPC-SP 5/NACE
No.1
Commercial Blast Cleaning SSPC-SP 6/NACE
No.3
Brush-Off Blast Cleaning SSPC-SP 7/NACE
No.4
Pickling SSPC-SP 8
Near White Blast Cleaning SSPC-SP 10/NACE
No.2
Power Tool Cleaning to Bare Metal SSPC-SP11
Surface Preparation and Cleaning of Metals by Waterjetting Prior to SSPC-SP 12/NACE
Recoating No.5
Commercial Grade Power Tool Cleaning SSPC-SP15
Guide and Reference Photographs for Steel Surfaces Prepared by Dry SSPC VIS 1
Abrasive Blast Cleaning
Field Methods for Extraction and Analysis of Soluble Salts on Steel and SSPC Guide 15
Other NonPorous Substrates
Wet Abrasive Blast Cleaning SSPC-TR 2/NACE
6G198
Dehumidity and Temperature Control During Surface Preparation, NACE 6A 192
Application, and Curing for Coatings/Linings of Steel Tanks, Vessels, and
Other Enclosed Spaces
Discontinuity (Holiday) Testing of New Protective Coatings on NACE RP 0188
Conductive Substrates
Scheme for Identification of Piping System ANSI A13.1
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APPENDIX 1: COATING SYSTEM PRODUCT APPROVAL REQUIREMENT

A.1 Test Panels

One (1) set of test panels shall be prepared for each generic coating system as per the various
ASTM test requirements listed in the table in section 6.5.2 below; depending on the types of tests
to be carried out.

The test panels shall be prepared in the field, for example in a coastal fabrication yard, to simulate
field application condition where adverse climatic conditions may prevail. Each test panel shall be
surface cleaned and coated to the requirement as prescribed in this specification.

All test panels should be kept indoors for a period of seven (7) days for curing before any testing.

A.2 Laboratory Testing

The test panels shall be submitted to an approved third party testing agency for laboratory testing.
Recommended laboratory test methods shall include, but not limited, to the following:

Types of Laboratory Tests

Type Test Method Purpose Acceptance Criteria

Salt Spray ASTM B117 To study the creep resistance Blast Cleaned Surface
(Scribed) ASTM D1654 of Flawed coatings under 3,000 hours, coating defects as per
(Proc. A) accelerated conditions of the ASTM D 1654 Proc. A, Rating 4-5 at
corrosive environment. scribe.

Power Tool Cleaned Surface

3,000 hours, coating defects as per
ASTM D 1654 Proc. A, Rating 3 at scribe.
Salt Spray ASTM B117 To observe the performance 4,500 hours, coating defects as
(Unscribed) ASTM D1654 of coatings subject to per ASTM D1654 Proc. B, area failed
(Proc. B) accelerated conditions of the Rating No.9
corrosive environment.

Adhesion ASTM D4541 To give a quantitative 500 psi (Splash Zone)

indication on the adhesion 300 psi (Atmospheric Zone)
properties of the coating To conduct after 7 days cured period
systems with DFT > 200 m. from the final coat

ASTM D3359, To give a quantitative For ASTM D3359 Method A, the

Test Method A indication on the adhesion acceptance criteria is 3A
properties of the coating
systems with DFT < 200 m.
Impact ASTM D2794 To give a quantitative 18 J (Intrusion)
indication of the ability of
coatings to resist cracking due
Abrasion ASTM D4060 to
To impact loading.
assess quantitatively the 150 mg/ 1000 cycles/ 1kg load using
abrasion resistance of the wheel CS10
coatings.
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Cathodic ASTM G8 To assess resistance of < 10 mm disbondment.

Disbonding coating to Cathodic
Accelerated ASTM G155 disbondment.
To study the effects of 2,000 hours without any
Weathering weather on coatings. coating defects (except a max. degree of
chalking rate of 6)

Heat- ASTM D2485, To evaluate the heat-resistant Gradual increase in temperature to the
Resistance Test Method B properties of coatings requirement as per specific requirement
designed to protect steel of section 6.2. Cool down the panel to
surfaces exposed to elevated room temperature before salt spray for
temperatures during their 24hr. Result, without coating defect
service life. such as rust, blister & loss of adhesion

Cyclic Salt ASTM D5894 To observe the performance 4,200 hours, coating defects as per
Fog/UV of coatings subject to ASTM D1654 Proc. B, area failed Rating
Exposure accelerated conditions of the No. 9.
cyclic corrosion/UV exposure :
Salt Spray duration 72 hours
Drying in air duration 16
hours
UV-A 340 nm duration 80
hours
Note : 25 cycles at 168 hours per
Users may select ASTM D5894 test method to replace ASTM B117, ASTM D1654 and ASTM G 26.
cycle

Polyurethane topcoated coating systems for testing shall be measured for "glossiness" and colour
retention using Specular Excluded (SPEX) method at 60 angle (Specular Reflectance) depicted in
ASTM D523.
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APPENDIX 2: COATING FINGERPRINT CERTIFICATE FOR 2-COMPONENT INTERMEDIATE

MATERIALS OF POLYMERIC COATINGS

B.0 COATING FINGERPRINT CERTIFICATE FOR 2-COMPONENT INTERMEDIATE MATERIALS OF

POLYMERIC COATINGS

Company name: Country:

Section 1: General information
Product name: Product type: e.g. epoxy, polyurethane,
polyester, inorganic zinc,
epoxy zinc, etc.
Date of issue: Base material
Curing agent / hardener
(e.g. epoxy / epoxy zinc /
(e.g. amine / isocyanate / peroxide / ethyl-
polyacrylate / polyester /
silicate)
inorganic zinc)
Specify base material & e.g. epoxy e.g. amine
curing agent
Trade name
Generic
Factory location
Batch number
Production date
Shelf life
Section 2: Test Methods and Results
Section 2A: Physical analyses
Specification
Parameters Method (state method Result Specification Result
used)
Viscosity e.g. ASTM D4287
ASTM D5125
ASTM D562
ISO 2431
ISO 2884-1
Density e.g. ISO 2811-4
Colour code e.g. BS 4800
OSHA
Non-volatile
e.g. ISO 3251
matter (by mass)
Weight Solid:
Zn metal/Total Zn
Note: submit
certificate of %
purity by e.g. ISO14680-2
manufacturer
Note: applicable to
organic and
inorganic zinc only
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Section 2B: Structural analysis

Infrared spectra Wet sample as supplied in can. Matching criteria 0.9
Std. Ref. Base Hardener
Base material: epoxy ASTM D7588 600-4000 cm-1 600-4000 cm-1
Curing agent: amine ASTM D7588 1000-1300 cm-1 1000-1400 cm-1
-1
ASTM D7588 700-900 cm N/A N/A
-1
Base material: ASTM D7588 600-4000 cm 600-4000 cm-1
-1
polyacrylate / polyester ASTM D7588 1600-1800 cm 2000-2500 cm-1
Curing agent: isocyanate ASTM D7588 3000-3800 cm -1
3000-3800 cm-1
-1
Base material: polyester ASTM D7588 600-4000 cm 600-4000 cm-1
-1
Curing agent: peroxide ASTM D7588 1600-1800 cm 900-1200 cm-1
ASTM D7588 2700-3100 cm-1 N/A N/A
-1
Base material: epoxy zinc ASTM D7588 600-4000 cm 600-4000 cm-1
-1
Curing agent: amine ASTM D7588 1000-1300 cm 1000-1400 cm-1
-1
ASTM D7588 700-900 cm N/A N/A
Base material: inorganic ASTM D7588 600-4000 cm-1 600-4000 cm-1
zinc ASTM D7588 N/A N/A 2700-3200 cm-1
Curing agent: ethyl- N/A N/A 1000-1500 cm-1
silicate ASTM D7588

Section 3: FTIR test details (as per ASTM D7588)

Analyst & company
name
Brand & model of FTIR
Benchtop: ATR crystal e.g. diamond, zinc selenide (ZnSe), zinc sulfide (ZnS), germanium
material
Spectral correction YES / NO
Note: correction is NOT e.g. automatic baseline correction
recommended.
Spectral range (cm-1) e.g. 600-4000 cm-1
No. of sample scans (min e.g. 32 scans
32)
Resolution (min 4 cm-1) e.g. 4 cm-1
Correlation search Note: Correlation search algorithm of the FTIR software must depend on both x-
algorithm for matching % (wavenumber) and y- (absorbance) vectors.
in absorbance mode Dependence on x-vector YES / NO Dependence on y-vector YES / NO
(wavenumber / cm-1) (absorbance / a.u.)
Trade name and batch
number of reference
spectrum for base
material
Trade name and batch
number of reference
spectrum for curing agent
/ hardener
Notes:
1. Full range of FTIR spectra for both base and curing agent without automatic baseline correction and
in absorbance mode are to be attached with this report (raw data).
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2. Compliance to matching criteria values do not exclude meeting the requirements of other QA/QC
checks e.g. drying time, gloss, hiding power etc.
3. Methods used shall reference latest published document.
Authorized QA/QC Executive:- Validated by:-

-
Signature: Signature:
- -
- Date: - Date:
- - IMM membership member:
- -

Section 4: Compulsory appendices (to be submitted in CD or other digital format)

Appendix Overlay reference and sample FTIR spectra for base materials
1 (Note: In addition, raw data of reference and sample FTIR spectra must be provided in two raw
data files)
Appendix Overlay reference and sample FTIR spectra for curing agent / hardener
2 (Note: In addition, raw data of reference and sample FTIR spectra must be provided in two raw
data files)
Appendix Relevant MSDS
3
Appendix Certificate of analyses which are relevant to the in-house standard testings
4
Appendix Certificate of % purity of zinc by metal manufacturer for organic zinc and inorganic zinc
5
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APPENDIX 3: APPROVED VENDOR COATINGS LIST

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APPENDIX 4: GLASS FLAKE POLYESTER GENERIC SPECIFICATION

This specification establishes the minimum requirements of a glassflake filled polyester
coating. This is recommended to be applied for both topsides and splash zone.

D.1 Type of Polyester

The polyester resin shall be either Bisphenol A or Isophtalic.

D.2 Wax Content

Wax-free coating is preferred. Where wax layers are unavoidable, the wax content shall be
as low as possible. The maximum content shall be 0.1% (wt).

D.3 Glass Flakes

The glassflakes used shall be of the chemical resistance type (Type C). The minimum
glassflake content shall be 20% by weight. However, the percentage of glass loading can be
variable without compromising the system performance with respect to water resistance
during immersion and its acceptance shall be based on the results of a successful qualification
test.

The maximum thickness of the glassflake shall be 5 2 microns. The glassflake particles shall
be of 20 microns to 400 microns in any one direction of the planer surface. A maximum of
4% may be allowed outside the above range. Extenders such as silica flour, mica or talc shall
not be used.

The glassflake is an added product to give a low permeability. Therefore, the maximum
permeability should be 0.015 perm cm (0.0006 perm inches) measured in accordance with
ASTM D1653.

D.4 Application Properties

The product shall be capable of being applied in one single coat through wet to wet technique
by airless spray up to a thickness of 800 microns at a temperature of up to 35 C without
curtains or sags and in one spray application.

D.5 Volume Solids

The product shall have a volume solid of 95% minimum.

D.6 Pigment Content

The pigment content shall be maximum 3.5% by weight of the resin component. If required,
the manufacturer may add UV stabiliser provided the above maximum is adhered to.

D.7 Shelf Life / Pot Life

The shelf life of the base product shall be 6 months minimum at a temperature of 35C when
not stored in direct sunlight. The MEK peroxide shall be stored at a temperature of
maximum 30 C. The pot life shall be 30 minutes minimum at a temperature of 23 C.

D.8 Drying Time

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The final product shall be dry to touch within one hour and dry to walk on within three hours
at a temperature of 35 C.

D.9 Hardness
The Barcol hardness shall be within the range of 35 45 as measured in accordance with
ASTM D2583.

D.10 Abrasion Resistance

The maximum loss in weight shall be below 150 mg when using a Taber Abrasion Tester with
a CS-10 wheel, a 1 kg load applied for 1000 cycles.

D.11 Other Properties

A good flexibility of the product is required for the coating to be able to withstand mechanical
damage. The required properties shall be
Minimum Requirement
- Tensile strength (test speed 50 mm/min) - 30 N/mm
- Elongation - 0.9 %

The coefficient of thermal expansion shall be in the same order as that of steel i.e. between
10-90 x 10 -6/ C.

D.12 Salt Spray Test

The coating shall be able to withstand a salt spray test according to ASTM B117 for 10,000
hours without showing a coating failure.

D.13 Immersion
The coating shall be able to withstand immersion in sea water and distilled water according
to ASTM D870-92, test for 6,000 hours at ambient temperature without showing a coating
failure such as blistering, loss of adhesion, softening, or embrittlement.

D.14 Cathodic Disbondment Test

The coating shall pass a cathodic disbondment resistant test (<10 mm disbondment) in
accordance with ASTM G8 at a potential of -1450 mV (against Ag/Ag Cl) at 30 C.

D.15 Safety
The Manufacturer shall provide the Owner and the relevant applicator with a valid Materials
Safety Data Sheets (MSDS).
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APPENDIX 5

E.0 GLASS FLAKE EPOXY GENERIC SPECIFICATION

This specification establishes the minimum requirements of an epoxy glassflake filled
coatings recommended for application on both topsides and splash zone. The required dry
film thickness shall be 800 microns.

E.1 Type of Epoxy

The epoxy resin will be based on liquid epoxy.

E.2 Glass Flake

The glassflake used shall be of the chemical resistance type C glass. The minimum content
shall be 10% by weight. The minimum thickness of the glass flake shall be 52 microns with
an average length of 400 microns in any direction of the planner surface.

However, the percentage of glass loading can be variable without a compromise on system
performance with respect to water resistance during immersion; and its acceptance shall be
based on the results of a successful qualification test.

The glassflake is an added product to give a low permeability. Therefore, the maximum
permeability should be 0.015 perm cm (0.0006 perm inches) measured in accordance with
ASTM D1653.

E.3 Spray Application

The product is high in viscosity and it is necessary to ensure all equipment is in good working
order before attempting to apply. Pump should have a minimum ratio of 45:1. Filters should
be removed to avoid filtering out glass flake. It also advisable to check that adequate air
volume is present, otherwise a consistent spray fan will not be obtained.

E.4 Volume Solids

The product should have a minimum volume solids of 90%.

E.5 Shelf Life/Pot Life

The shelf life of this product shall be 6 months minimum at a temperature of 35C when not
stored in direct sunlight. The pot life shall be 30 minutes at a temperature of
23C.

E.6 Drying Times

The product shall hard dry within 4 to 10 hours at temperature range of 25 to 40 C.

E.7 Hardness
The Barcol hardness shall be within the range of 40 50 as measured in accordance with
ASTM D2583. (Model GYZJ 935)

E.8 Abrasion Resistance

The maximum loss in weight shall be below 150 mg when using a Taber Abrasion Tester with
a CS-10 wheel, a 1 kg load applied for 1000 cycles.
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E.9 Other Properties

Other properties required to achieve good mechanical properties are as follows:
Tensile Strength (ASTM D2370) - 10 M Pa (1450 psi.)
Elongation (ASTM D2370) - 2%

The coefficient of thermal expansion shall be in the same order as that of steel i.e. between
10-90 x 10 -6/ C.

E.10 Salt Spray Test

The coating shall be able to withstand a salt spray test according to ASTM B117 for 10,000
hours without showing a coating failure.

E.11 Immersion
The coating shall be able to withstand immersion in sea water and distilled water according
to ASTM D870-92 test for 6,000 hours at ambient temperature without showing a coating
failure such as blistering, loss of adhesion, softening, or embrittlement.

E.12 Cathodic Disbondment Test

The coating shall pass a cathodic disbondment resistant test (<10 mm disbondment) in
accordance with ASTM G8 at a potential of -1450 mV (against Ag/Ag Cl) at 30 C.

E.13 Safety
The Manufacturer shall provide the Owner and the relevant applicator with a valid MSDS.
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APPENDIX 6: STORAGE TANK IDENTIFICATION SYSTEM

LOCATION OF ITEM NUMBER AND SIZE OF LETTERING FOR STORAGE TANK

=

2 1
=
3 2

2
=
3

1
=
12

Lettering : Black
Location : Fixed at field
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APPENDIX 7: PIPING IDENTIFICATION SYSTEM

G.1 PIPING IDENTIFICATION MARKING

FLOW
IDENTIFICATION LEGEND DIRECTION
TYPE PIPE O.D.
ARROW
A B C D E
1 0.75 1.25 0.5 0.75 8.00 0.75 4.00
2 1.50 2.00 0.75 1.00 8.00 1.00 5.00
3 2.50 6.00 1.25 2.25 12.00 2.25 8.00
4 8.00 10.00 2.25 4.00 24.00 4.00 12.00
5 Over 10.00 3.75 5.00 32.00 5.00 16.00
Note: Unit in Inches
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APPENDIX 8: PIPING COLOUR IDENTIFICATION LEGEND

COLOUR
IDENTIFICATION
SERVICE DIRECTION
LEGEND CODE BACKGROUND CODE
ARROW
PROCESS LINE
Gas Gas Black 00E53 OSHA Yellow RAL 1003
Liquid Liquid Black 00E53 OSHA Yellow RAL 1003
Process Process Black 00E53 OSHA Yellow RAL 1003
DRAIN & RELIEF
Drain, Hot Oil Hot oil drain Black 00E53 OSHA Yellow RAL 1003
Drain, Pressurised Pressure, drain Black 00E53 OSHA Yellow RAL 1003
Drain, Hazard Hazard, drain Black 00E53 OSHA Yellow RAL 1003
Drain, Condensate Cond. drain Black 00E53 OSHA Yellow RAL 1003
Flare, High Pressure H.P. Flare Black 00E53 OSHA Yellow RAL 1003
Flare, Low Pressure L.P. Flare Black 00E53 OSHA Yellow RAL 1003
Vent Vent line OSHA Blue RAL 5005 White 00E55
Vent, Atmospheric Atm. vent OSHA Blue RAL 5005 White 00E55
STEAM & CONDENSATE
Condensate Condensate Black 00E53 OSHA Yellow RAL 1003
Steam Steam Black 00E53 OSHA Yellow RAL 1003
Boiler Feed Water Boiler H2O Black 00E53 OSHA Yellow RAL 1003
UTILITY WATER
Cooling Water Cooling H2O OSHA Green RAL 6032 White 00E55
Firewater Fire H2O OSHA Red RAL 3001 White 00E55
Potable Water Potable H2O OSHA Green RAL 6032 White 00E55
Service Water Service H2O OSHA Green RAL 6032 White 00E55
Ballast Water Service H2O OSHA Green RAL 6032 White 00E55
Sea Water Washdown Service H2O OSHA Green RAL 6032 White 00E55
Chilled Water Chilled H2O OSHA Green RAL 6032 White 00E55
UTILITY AIR & GENERAL
Air, instrument inst. air OSHA Blue RAL 5005 White 00E55
Air, utility utility air OSHA Blue RAL 5005 White 00E55
UTILITY GAS & FUEL
Blanket gas blanket gas Black 00E53 OSHA Yellow RAL 1003
Diesel fuel diesel fuel Black 00E53 OSHA Yellow RAL 1003
Aviation fuel aviation fuel Black 00E53 OSHA Yellow RAL 1003
Fuel gas fuel gas Black 00E53 OSHA Yellow RAL 1003
Nitrogen nitrogen OSHA Blue RAL 5005 White 00E55
Gas, Instrument inst. gas Black 00E53 OSHA Yellow RAL 1003
Gas, Utility utility gas Black 00E53 OSHA Yellow RAL 1003
UTILITY OIL
Lube oil lube oil Black 00E53 OSHA Yellow RAL 1003
Seal oil seal oil Black 00E53 OSHA Yellow RAL 1003
Hot oil hot oil Black 00E53 OSHA Yellow RAL 1003
Hydraulic hydraulic Black 00E53 OSHA Yellow RAL 1003
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COLOUR
IDENTIFICATION
SERVICE DIRECTION
LEGEND CODE BACKGROUND CODE
ARROW
CHEMICALS
Chemical chemical Black 00E53 OSHA Yellow RAL 1003
Glycol glycol Black 00E53 OSHA Yellow RAL 1003
Caustic caustic Black 00E53 OSHA Yellow RAL 1003
chlorine chlorine Black 00E53 OSHA Yellow RAL 1003
Chemical chemical Black 00E53 OSHA Yellow RAL 1003
GENERAL
Treated water treated H2O OSHA Green RAL 6032 White 00E55
Black water black H2O OSHA Green RAL 6032 White 00E55
Grey water grey H2O OSHA Green RAL 6032 White 00E55
Hot water hot H2O Black 00E53 OSHA Yellow 1003
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APPENDIX 9: COLOUR SCHEME FOR ONSHORE/OFFSHORE INSTALLATION AND EQUIPMENT

I.1 STRUCTURE COLOUR SCHEME

CODE
NO COMPONENTS COLOUR
BS4800 RAL BS381C RGB
1.1 Splash Zone/Spider Deck
- Offshore structural members steel
below castellation point (shim
connection splash zone Yellow 10E53 - - 233;193;0
substructures), spider deck and boat
landing
1.2 Cellar Deck to Main Deck including
Bridge Structure
- Structural member, from cellar deck
up to the main deck, castellation Yellow 10E53 - - 233;193;0
point outwards, beam, girder, pipe
& cable support, conduits barrel
1.3 Deck Plate
Yellow 10E53 - - 233;193;0

1.4 Chequer Plate

Yellow 10E53 - - 233;193;0

1.5 Footway, walkway, stairway supports

and monkey ladder Yellow 10E53 - - 233;193;0

1.6 Grating panel (maintenance only)

Yellow 10E53 - - 233;193;0

1.7 Handrail and kick plate

OSHA orange - 2009 - 222;83;7

1.8 Module (including Living Quarter)

- Interior Wall and Interior Ceiling White 00E55 - - 241;242;234
- External part of partition wall at Yellow 10E53 - - 233;193;0
module
- Deck Top of Living Quarter Yellow 10E53 - - 241;242;234
- Production Shed & Equipment Store White 00E55 - - 233;193;0

1.9 Helideck Structure

- Structure and underside helideck Yellow 10E53 - 309 233;193;0
- Netting frame WhiteWhite 00E55 - - 241;242;234

1.10 Helideck landing area (as per CAP437 Dark Green 14C39 - 267 66;94;79
and PTS 37.19.10.31) Red 04E53 - 537 160;68;59
White - 9010/ - 241;242;234
9003
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1.11 Brucker Davit Structure for Lifeboat OSHA Yellow - 1003 - 249;168;38
- The colour may be selected from the OSHA Orange - 2009 - 222;83;7
options listed according to specific OSHA Red - 3001 - 155;36;35
operator practise. OSHA Green - 6032 - 35;127;82
OSHA Blue - 5005 - 0;83;135
1.12 Conductor pipe (splash zone and above)
Yellow 10E53 - - 233;193;0

1.13 Riser (splash zone until

launcher/receiver) Yellow 10E53 - - 233;193;0

1.14 Pipe rack along with its support legs (for

onshore application) White 00E55 - - 241;242;234

1.15 Instrument Control Panel, Instrument &

Lighting Stand White 00E55 - - 241;242;234

1.16 Offshore flare boom inclusive of piping

and associated structure from bottom
of the structure to the top of flare boom
Aluminium - 9006 - 161;161;160
Note: High temperature coating system
for application at flare boom.
1.17 Onshore flare tower OSHA Red - 3001 - 155;36;35
White 00E55 - - 241;242;234
(in seven
alternate
bands)
1.18 Communication tower OSHA Red - 3001 - 155;36;35
White 00E55 - - 241;242;234
(in seven
alternate
bands)
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I.2 PIPING COLOUR SCHEME

CODE
NO COMPONENTS COLOUR
BS4800 RAL RGB
2.1
Pipework
White 00E55 - 241;242;234
Note: This excludes firewater line and foam line.

2.2
Pipework for firewater service OSHA Red - 3001 155;36;35

2.3 Process/Utility piping operating above 110oC

Aluminium - 9006 161;161;160
Note: This is also applicable for piping along flare
boom.
2.4
Pipework for foam system OSHA Yellow - 1003 249;168;38

I.3 VALVE COLOUR SCHEME

CODE
NO COMPONENTS COLOUR
BS4800 RAL RGB
3.1 Valve body

Note: This is applicable for all valves except valves White 00E55 - 241;242;234
for fire water system
3.2 Valve for fire water system
OSHA Red - 3001 155;36;35

3.3 Pressure relief valve and other operated ON/OFF As per

actuated valve or selector valve operation - -
practise
3.4 Actuated Control Valve
- Body White 00E55 - 241;242;234
- SDV / ESD Valve Actuators OSHA Red - 3001 155;36;35
- BDV Actuators OSHA Green - 6032 35;127;82
- MOV Actuators Grey 00A05 - 177;176;174
- Control Valve actuators (Fail Close) OSHA Red - 3001 155;36;35
- Control Valve actuators (Fail Open) OSHA Green - 6032 35;127;82

3.5 Hand wheel/handle for valve Black 00E53 - 47;47;48

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I.4 EQUIPMENT COLOUR SCHEME

CODE
NO COMPONENTS COLOUR
BS4800 RAL RGB
4.1 Pressure vessels, columns, heat exchangers
White 00E55 - 241;242;234

4.2 Wellheads Irish Green 14E53 - 43;147;104

4.3 Storage tank
White 00E55 - 241;242;234

4.4 Inside drip pan including pipeworks Black 00E53 - 47;47;48

4.5 Jib crane and gantry crane booms and monorail Alternate 00E53 - 47;47;48
track
Black & Yellow 10E53 - 233;193,0

4.6 Pedestal crane - inclusive of crane structures

(pedestal adaptor, machinery deck, powerpack
and other steel structures), crane boom, Yellow 10E53 - 233;193;0
operator cabin and tank
Pumps, motors, generators and other rotating
4.7 equipment Irish Green 14E53 - 43;147;104
Note : Excluding firewater pump
4.8 Compressor casing
Note: Other components colour scheme shall Irish Green 14E53 - 43;147;104
be as per OEM specification.
4.9 Equipment package skid
- Structure Yellow 10E53 - 233;193;0
- Piping White 00E55 - 241;242;234
- Tank White 00E55 - 241;242;234
- Pump & motor body Irish Green 14E53 - 43;147;104

4.10 Launcher & receiver barrel including end

closure White 00E55 - 241;242;234

4.11 Chemical injection skid

- Structure Yellow 10E53 - 233;193;0
- Piping White 00E55 - 241;242;234
- Tank White 00E55 - 241;242;234
- Pump & motor body Irish Green 14E53 - 43;147;104

4.12 Corrosion coupon/probe cover OSHA Blue - 5005 0;83;135

or as per
manufacturer
specification
4.13 Nitrogen package skid
- Structure Yellow 10E53 - 233;193;0
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- Piping White 00E55 - 241;242;234

- Nitrogen bottle As per manufacturer - -
specification
4.14 Foam System
OSHA Yellow - 1003 249;168;38

4.15 Pig signaller As per

manufacturer - -
specification

I.5 SAFETY COLOUR SCHEME

CODE
NO COMPONENTS COLOUR
BS4800 RAL RGB
5.1 Escape route on deck and grating OSHA Yellow at - 1003 249;168;38
pathway with
OSHA Yellow and
Black (in alternate 00E53 - 47;47;48
bands) at border and
Black arrow
showing the direction

5.2 Dangerous obstructions (inclusive piping & OSHA Yellow and - 1003 249;168;38
structure) Black 00E53 - 47;47;48
(in alternate bands)
5.3 Dangerous or exposed parts of machinery OSHA Orange - 2009 222;83;7
5.4 Fire Equipment and services OSHA Red - 3001 155;36;35
5.5 Firewater line including sprinkler system OSHA Red - 3001 155;36;35
5.6 Foam System OSHA Yellow - 1003 249;168;38
5.7 First Aid Equipment OSHA Green - 6032 35;127;82

I.6 MISCELLANEOUS
CODE
NO COMPONENTS COLOUR
BS4800 RAL RGB
6.1 Platform Nameplate
- Background Yellow 10E53 - 233;193,0
- Lettering Black 00E53 - 47;47;48

6.2 Fire proofing inclusive of Passive Fire As per equipment/

- -
Protection (PFP) structure colour
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APPENDIX 10: ESCAPE ROUTE

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APPENDIX 11: INSPECTION AND TESTING REQUIREMENTS

Reference
Test Type Method Frequency Acceptance Criteria Consequence
Standard
Environmental Ambient and steel Before start of each In accordance with specified No blasting or
Condition temperature work activity + Every 2 requirements and Coating coating
Relative humidity Hours during surface Manufacturers TDS application or
ASTM E 337 preparation and coating rejection of
Dew point
operations prepared or
Wind speed coated surface
Abrasive Materials Particle Size and SSPC AB 1 Every new batch and In accordance with specified No blasting
Sharpness check by SSPC AB 2 spot checks requirements, as per
visual at all work SSPC AB 3 Certificate checks relevant sections of ISO
sites ISO 11126 11126 and ISO 11127-6
ISO 11127-6 Test plates shall be abrasive
blasted for use as reference
of visual appearance /
anchor profile
Compressed Air Standard Test Method ASTM Before start of each No visible contamination Service,
Cleanliness for Indicating Oil or D4285 shift or change in air clean and
Water in Compressed system replace
Air
Visual Visual Inspection for N/A 100% of all surfaces No defects No blasting or
Examination of sharp edges, weld coating
Pre-Cleaned Metal splatter, Slivers, application until
lamination, structurally defect is
deleterious defects, rust repaired
grade etc.
Surface Visual Assessment of SSPC VIS 1 100% visual of all In accordance with specified Re-blasting
Cleanliness Surface Cleanliness or ISO 8501 surfaces requirements Re-cleaning
(visual) ISO 8502-3 Spot checks - and
retesting
until
acceptable

Soluble Salts Extraction: ISO 8502-6 Immersion Service: Average conductivity Steam or clean
(Not required if ISO 8502-6 (Bresle) ISO 8502-9 6 samples/2000 m2 corresponding to 20 mg/m2 water washing
Final surface Assessment: (20,000 ft2) but not and maximum conductivity and retesting
ISO 8502-9 less than 2 samples/ corresponding to 30 mg/m2 until entire 2000
preparation by
(Conductometric) pieces of equipment water soluble salt(s). m2 (20,00 ft2)
UHP Water or structure test area is
Jetting) (or) acceptable

Extraction: SSPC Guide Atmospheric Average conductivity -

SSPC Guide 15 Section 15 Surfaces: corresponding to 30 mg/m2
4.6 (Section 4.6 & 2 samples/2000 m2 and maximum conductivity
(Elcometer130 SC400) 5.3) (20,000 ft2)but not corresponding to 40 mg/m2
Assessment: less than 2 samples/ water soluble salt(s)
SSPC Guide 15 Section pieces of equipment
5.3 or structure
(Conductometric)

Roughness Comparator, Replica ISO 8503 Each component or As specified Re-blasting

tape or Stylus once per 10m2.
instrument
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Reference
Test Type Method Frequency Acceptance Criteria Consequence
Standard
Visual Visual to determine: N/A 100% of surface after None observed Repair of
Examination of Curing, contamination, each coat defects.
Coating solvent retention,
pinholes/popping,
sagging, surface
defects

Dry Film Thickness Measurement by Dry SSPC PA2 As per SSPC PA2 The average DFT of each Repair,
Film Thickness Gauge ISO 19840 requirements measurement point shall be additional
Calibration on smooth 100% specified DFT, coats, or
surface No single measurement shall recoating as
be less than 20% below the appropriate
specified DFT

Holiday Test NACE RP 0188 NACE As per system No holidays Repair and
(Supplementary Voltage, ref. TABLE 1 RP0188 specification / retesting
Test) ASTM 100% Surface of each
D5162 coat
Holiday Detection
only for Internal
Lining or
Immersion/Buried
Surfaces
Adhesion Standard Test Method ASTM Spot check not to be For coating types other than Repair and
(Supplementary for Pull-Off Strength of D4541 used for coatings to be PFP minimum 5MPa (72PSI) retesting
Test) Coatings Using ISO 4624 placed in immersion
Portable Adhesion
Testers
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APPENDIX 12: RISK MATRIX

Risk Evaluation
The overriding or ultimate consideration in evaluating risks associated with coatings is
whether the coating is maintaining structural integrity or if coating degradation is allowing
corrosion to proceed, leading to the possibility of structural failure. There is no standard
method to evaluate risks;
However, the most basic approach is to compare estimated partial or total metal work
replacement costs with the estimated costs of a maintenance coating program. Safety to the
public and workers may also be a major consideration, and these associated costs may be
difficult to assess. To provide a basis for risk evaluation, inspection of the coating and
substrate is recommended.

PETRONAS GHSE RISK MATRIX

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APPENDIX 13: TYPICAL COATING QUALITY INSPECTION AND TEST PLAN CHECKLIST

(SUB) CONTRACTOR COATING SCHEDULE

WORK LOCATION DOCUMENT REF. NO.
PROJECT TITLE EQUIPMENT
CONTRACT NO. DATE

ITM. DESCRIPTION OF ITEM INSPECTION REQD ACTIONS BY REMARKS

T.P.I. OWNER
1.1.1.1.1.1
A THROUGHOUT WORKING DAY
1 Safety/condition of equipment/machinery Visual inspection H H H
2 Correct PPE is worn by all personnel Visual inspection H H H
3 Atmospheric relative humidity/dew point Psychrometer and Tables I W R/H
4 Metal surface temperature Contact thermometer I W R/H
B BEFORE PREPARATORY CLEANING
1 Work methods/QC system/safety Record inspection I H H
measures
2 Permit to work in order and authorised Record inspection H H H
3 Control/inspection instruments calibrated Visual/record inspection H H H
4 Presence of surface-breaking defects Visual inspection I R R
5 Defects found are satisfactorily removed Visual inspection I R R
6 Presence of gross surface contamination Visual inspection I R R
7 Rust grade/degree of coating breakdown Visual inspection I H H
8 Type of water/brand of degreasing agent Visual inspection I R R
9 Presence of residual oil or grease Water spray test I R R
10 Presence of residual salts* Salt test I R R
11 Type, brand and grade of abrasive used Visual inspection I R R
12 Acceptance of power/hand tool cleaning Visual inspection I W W/H
C DURING PREPARATORY CLEANING
1 Batch number and date of abrasive used Visual inspection I R R
2 Presence of oil/water in compressed air Blotting paper at exhaust I R R
3 Air pressure used for blast cleaning Hypodermic needle gage. I W W
4 Blast cleaning surface cleaning standard Visual inspection v. Std. I W/H W/H
5 Profile height of blast cleaned surfaces Replica tape/comparator I W/H W/H
6 Residual dust and matter on surfaces Tape/pocket microscope I W W
7 Type/condition of power/hand tools used Visual inspection I R R
8 Standard of power/hand tool cleanliness Visual inspection I W/H W/H
9 Presence of residual millscale *(only if Copper sulphate test I R R
applicable)
10 Presence of salts* Salt Test I R R
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ITM. DESCRIPTION OF ITEM INSPECTION REQD ACTIONS BY REMARKS

OWNER
T.P.I.
D DURING COATING OR COMPOSITE TAPE WRAP APPLICATION
1 Types, brands, dates, condition of coatings Visual inspection I R R
2 Coating storage conditions Visual inspection I R R
3 Coating mixing procedure and control Visual inspection I W W
4 Rust present on blast cleaned surfaces Visual inspection I R R
5 Time between blast cleaning and priming Record inspection I R R
6 Coating/Wrap application technique and Visual inspection I W W
quality
7 Stripe priming of edges, corners, crevices Visual inspection I R R
8 Full primer coat thickness Wet/dry film tkns. Check I H H
9 Primer profile and appearance Visual inspection I H H
10 Time between primer and first midcoat Record inspection I R R
11 First midcoat and stripe thickness Wet/dry film tkns. Check I W W
12 First midcoat and stripe profile/appearance Visual inspection I W W
13 Time between first and second midcoat Record inspection I R R
(only if applicable)
14 Second midcoat and stripe thickness (only Wet/dry film thickness. I W W
if applicable) Check
15 Second midcoat /stripe Visual inspection I W W
profile/appearance(only if applicable)
16 Time between second midcoat and topcoat Record inspection I R R
17 Complete coating coating/wrapping Wet/dry film thickness. I H H
thickness check
18 Complete coating coating profile/appearance Visual inspection I H H
19 Final curing time for coating system Record inspection I R R
20 Presence of holidays in coating (where Low or high voltage test I H H
applicable)
21 Adhesion of coating (where applicable) Dolly pull-off test I W W
22 Identification of areas for repair Use of indelible marker I W W
23 Coating/wrapping appearance after repair Visual inspection I H H
24 Complete QIT form and associated docs. Record inspection I H H

KEY: * Subsidiary inspection test to be carried out at discretion of Owner

I Inspection item to be carried out where operation involved forms part of Contract work scope
R Inspection reports and records to be fully reviewed and approved
W Inspection activity to be witnessed and approved
H Mandatory Hold Point in schedule beyond which work shall not proceed without formal
approval

CONTRACTOR T.P.I. ( If Applicable) OWNER

Signature
Name
Position
Date
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APPENDIX 13: COATING DAILY INSPECTION REPORT TEMPLATE

COATING - DAILY INSPECTION REPORT
Do not leave empty boxes. If Not Applicable please enter N/A
CONTRACTOR COATING SYSTEM NO.
WORK LOCATION REPORT REF. NO.
PROJECT/ITEM TITLE ITEMS COATED
CONTRACT NO. DATE
WEATHER CONDITIONS
Time / Date
Rel. Humidity (%)
Dewpoint ( C)
Metal Temp. ( C)

SURFACE CONDITION AND DEGREASING (Circle/Highlight as necessary)

Original Status Coated Wrapped Bare
Metal Condition Defect-free Laminated/Pitted Ground Rejected
Metal Rust Grade ^^ A B C D
Coating Breakdown ## Ri 0 / 10 Ri 3 / 6 Ri 4 / 4 Ri 5 / 1
Contamination Heavy Light
Degreasing Agent . Swabbed Sprayed Water Tested

SURFACE PREPARATION (Circle/Highlight as necessary) *= ISO 8501-1

Method Dry Blasting Sweep Blasting Wet Blasting Power Tool Hand Tool
Abrasive Used Type. Brand. Batch No... Size Range..
Prep. Standard SSPC SP 5/*Sa 3 SSPC SP 10/*Sa 2.5 SSPC SP 7/*Sa 1 SSPC SP 3/*St 3 Other.
Profile Ht. (um) 35-50 50-75 75-100 Range... Using.
Other Tests Salts... Yes/No

COATING APPLICATION (Circle/Highlight as necessary)

Method Airless Spray Air Spray Brush Trowel Other.
When Priming Time Since Cleaning.. Visible Surface Rusting...Yes/No
Product Details Product Base Batch Additive Thinner # and Overcoating WFT Range DFT Range
No. Batch No. percentage Period (um) (um)
Stripe Coat
Primer
First Midcoat
Second Midcoat
Topcoat

FINAL TESTING AND REPAIR (Circle/Highlight as necessary)

Thickness/Appearance DFT - Accept/Reject Appearance - Accept/Reject
Holiday Detection Test LV/HV Tester Test Voltage.. Pass/Fail
Coating Adhesion Test Adhesion Tester Pull Off Stress Accept/Reject
Repaired Areas % of Total Area.. Primary Locations. Rejected Because.

GENERAL COMMENTS:
CONTRACTOR T.P.I. ( If Applicable) OWNER
Signature
Name
Position
Date
## CORRESPONDING DEGREES OF COATING RUSTING STANDARDS(ISO 4628-3 / SSPC Vis. 2):
Ri 0/10- No visible rusting of coating; Ri 3/6- Marked localised rusting of 1% of surface area;
Ri 4/4- Widespread localised rusting of 10% surface area (8% for Ri.4); Ri 5/1- Extensive rusting of up to 50% of surface area
^^ Bare Metal Rust Grade standard according to Visual Standard SSPC-Vis 3
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APPENDIX 15: ITEMS TO BE EXCLUDED FROM PTS 15.20.03

Category Type PTS No. and Description Typical Use

Coating Bituminous 11.32.05: Bituminous Enamel Coating of Steel Buried Pipelines

Enamel Linepipe External

Concrete 11.32.09: Concrete Coating of Linepipe Subsea Pipeline

External

Ceramic New PTS Heater Tubes

External

Elastomer 11.32.08: Elastomer Coatings and Monel Offshore Riser

Sheathing for Offshore Riser Protection External

External 11.32.03: External Polyethylene And Buried Pipelines

Polyethylene Polypropylene Coating Of Linepipe External
And
Polypropylene
Fusion Bonded 11.30.07: Pipeline and Riser Engineering Buried Pipelines
Epoxy (FBE) External

Thermal Spray 15.20.05: Thermal Spray Coatings - Offshore Facilities

Application Aluminium and 85/15 Zinc/Aluminium Alloy Corrosion Under
(TSA) Insulation (CUI)
Mitigation
High temperature
swing operations e.g.
Regeneration system
Subsea To refer to Norsork Standards or other Subsea equipment,
industry recognized standards structure, piping etc.

Lining Cement 15.20.04:Cement Lining of Pipes Pipeline Internal

Seawater Piping
Internal
Glass Flake 15.20.10: Glass Lined Steel Equipment and Vessel and Tank
Piping Internal

Rubber 15.20.07: Rubber-Lined Process Equipment Sea Cooling Water

Exchanger Internal
Vessel and Piping
Internal
Thermoplastic 11.32.06: Thermoplastic Lined Pipelines Pipeline Internal

Surface New PTS Bolts and nuts

Others treatment +
PTFE
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Other Exceptions:
GRP Gratings
Equipment or Instrumentation designated to be hand or machine tool cleaned
All Electrical Wiring, Cables, and cable Trays
Safety Equipment, Sensors and Alarms
All piping/equipment operating above 55C (NOTE: This refers to surface temp
during coating operations, not service temperatures)
Shock Cell Pads and Wear pads on boat landing
Fire Proofed Surfaces and Cryogenic Lines (external Surfaces)
Greased nipples and fittings and lubricated surfaces
Machined and close working tolerance surfaces
Gasket contact surfaces and exposed seals, bearings and Glands.
Threaded Connections shall not be coated unless otherwise specified.
Friction grip surfaces
Equipment identification plates and information / warning signs.
Valve stems, stem threads, movable linkages, pump shafts.
Glass components, Sensitive parts of Instrumentations and Gauges. (Instrument
tubing)
Area of component to be site welded or welds subsequently to be modified
especially during Shutdown.
Bolt and Nuts which are subjected to removal
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APPENDIX 16: MAINTENANCE COATING

Maintenance coating shall consist of two types of activity as follows:

i. Large-scale maintenance for existing facilities which have complete coating

deterioration or technical integrity and safety impaired. In this case, local repairs
are not economically justified and application of new coating system according to
Section 3.0 is the only option.

ii. Repair work to rectify coating damage caused by corrosion, ageing facilties, fire
damage and mechanical damage.

Maintenance coating shall ensure coverage of field weld tie-in points which shall comply with
the relevant coating system.

The following needs to be considered to determine coating application requirements:

Determine objectives
Design life of equipment or piping
Budget restraints
Maintenance philosophy
Special requirements

Assess condition-related factors

What is the substrate? What is the substrate condition?
Any on-site application constraints?
What is the existing coating system? Was it effective? Any problems reported?
What is the existing coating age?
What is the overall condition? Chalked? Peeling? Sagging?
What is the extent of existing issues? Is it cost effective to spot repair?
Is there hazardous material in the coating e.g. lead requiring removal?
What is the probable cause of existing problems? Materials, specification,
workmanship, maintenance, age, damage?

Define service environment/exposure

Operating temperature (min/max)
pH (min/max)
Specific exposures e.g. sunlight, marine, immersion, splash, abrasion etc.
Chemical exposure and compatibility

Establish service requirements

Colour coding compliance, gloss, special texture, conductive, non-skid etc
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Identify limiting conditions

Online or offline blasting?
Any work schedule limitations e.g. monsoon season, relative humidity, applied at
high temperatures etc.?
Ventilation requirement

Determine approach
New application or maintenance
For maintenance repair - spot repair only, spot repair and full recoat or total system
replacement?
Prioritisation of repair area, projected maintenance life, cost of application,
expected performance etc.

Select candidate coating systems

What are the systems candidates (pros/cons)
Technical merit, track record (experience), service and availability
Surface preparation requirements
Life Cycle Cost evaluation
Any disassembly required?
Any special requirements?
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APPENDIX 17: SURFACE PREPARATION BY BLAST CLEANING

Q.1 GENERAL

Q.1.1 For optimum coating performance surfaces to be coated or coated shall be completely dry
and free from burrs, weld spatter, flux, rust, loose scale, dirt, dust, grease, oil and other
foreign matter before any coating is applied. If dry blast-cleaning is not strictly necessary or
not feasible (e.g. due to limited access, risk of damage to equipment, light gauge steel, the
proximity of electrical components or instrumentation) then power tool cleaning shall be
applied.

Q.1.2 If the surface has been exposed to pollutants such as salt-lade from atmosphere, it shall be
washed down with clean fresh water prior to blasting or power tool cleaning.

Q.1.3 Prefabrication primers are allowed. However, after assembly, these primers shall be removed
by blasting and the surface shall be blasted to the initial specified surface cleanliness unless
otherwise agreed by the Owner.

Q.1.4 Alternative surface cleaning is only acceptable with written approval by the Owner.

Q.1.5 Alternative surface preparation such as power tool cleaning is not acceptable for areas
difficult to access such as areas exposed to water, steelwork to be insulated or to be buried
and the internal surfaces of equipment and tanks.

Q.1.6 Stainless steel surfaces shall not be treated with carbon steel cleaning tools.

Q.1.7 Any grit, dust or other contaminants shall be removed after substrate surface preparation.
Primer layer shall be applied within four (4) hours after blasting to avoid corrosion initiation
or recontamination occurs.

Q.1.8 Solvent cleaning or detergent degreasing shall be in accordance with SSPC-SP 1.

Q.1.9 Automated blast-cleaning machines are economically desirable as a means of preparing

plate, beams, and tubular members prior to fabrication.

Q.1.10 Surface preparation performed outdoors should be completed during daylight hours, and
early enough to permit proper priming of the surface prior to the development of any
moisture or flash rusting of the prepared surface.

Q.1.11 At the time of surface preparation and priming, the surface temperatures shall be at least
3C above the dew point.
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Q.2 PRE-CLEANING

Q.2.1 Prior to the blast cleaning and/or prior to any coating works, the surface shall be free of any
contamination and any excessive rust scale shall be removed by impact cleaning tools or high
pressure water jetting.

Q.2.2 Biodegradable detergent or freshwater solution treatment followed by copious rinsing with
clean, potable water shall be used to remove oil or grease contamination.

Q.2.3 All edges shall be ground to a minimum radius of 2 mm or otherwise agreed with the Owner.
Flame cut areas should be ground flushed. Weld spatter also shall be ground flushed. If this
is not the case, the Owner shall be informed, and corrective action shall be taken prior to the
application of the first layer of the coating system.

Q.2.4 All bolt holes shall be solvent cleaned prior to the commencement of blast cleaning. Solvent
cleaning shall be carried out in accordance with SSPC, SP1 Solvent Cleaning.

Q.2.5 Maintenance coating should always start with a high pressure steam or detergent cleaning
to remove dirt, grease and/or salt deposits. In addition, after a long interval prior to the
application of the subsequent layers of a coating system or exposure to a storm at offshore,
the surface shall be cleaned by using high-pressure water/steam or water wash before the
application of the next coating layer. In the specific case of uncoated stainless steel
components, water/ or steam cleaning shall not be allowed if the water temperature equal
to or above 50C. The requirements regarding the soluble salts and other surface
contaminants in this document shall be adhered to at all times.

Q.2.6 All welded areas and appurtenances shall be given special attention for removal of welding
flux in crevices. Welding splatter, slivers, laminations and underlying mill scale which are not
removed during fabrication shall be removed prior to coating activities by the best
mechanical means and the edges smoothed or rendered flush.

Q.2.7 Before performing abrasive blast cleaning, all equipment which could be damaged by blast,
dust or particulate matter shall be suitably protected by masking, wrapping, taping or other
means to prevent damage. Where required, the degree of contamination shall be assessed
in accordance with procedures described in ISO 8502-3. The equipment shall include but not
necessarily limited to the following:
i. Bearings
ii. Control panels
iii. Control valves
iv. Conduit
v. Instrument dials
vi. Expansion joint bellows
vii. Machined surfaces
viii. Shafts
ix. Push buttons
x. Tags
xi. Screws
xii. Exposed moving parts
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Q.2.8 Adequate barricading of the work area by either canvas, tarpaulin or suitable material shall
be constructed and accepted by the Owner in order to avoid damage to other areas or
equipment. This enclosure shall be constructed such that to contain any waste produced
from the surface preparation activity. Any necessary equipment i.e. exhaust fan, air cooler,
lighting for night work and other related HSE requirement shall be installed within this
enclosure.

Q.2.9 Where rectification has been necessary on blast-cleaned surfaces, the dressed areas shall be
pre-cleaned as initially specified. All grating panels to be removed to expose supporting
structure.

Q.2.10 The level of free halides in cleaning materials to be used on stainless steel shall be confirmed
and reviewed by Owner. Particular care shall be given to areas which are not self-draining,
so that water collected is removed and not allowed to evaporate leaving salt deposits on the
surface. Flushing activity shall be less than 10 ppm while actual concentration shall be
maintained between 20 to 30 ppm.

Q.2.11 Detergents with a pH more than 9 shall not be used on aluminium substrates.

Q.3 SURFACE PREPARATION BY BLAST CLEANING

Q.3.1 General
Q.3.1.1 Blast cleaning shall be carried out through ISO 8504-2 to the required visual standard in
accordance with ISO 8501-1 or equivalent. The minimum requirement for successful surface
preparation shall be Sa2.5 at the time of coating, unless specified by coating manufacturer on
their surface tolerant coating systems.

Q.3.1.2 Blast clean shall not be done close to coating operations or wet coated surfaces to prevent
dust and abrasive contamination. Environmental restrictions shall be observed.

Q.3.1.3 Blast clean steel surfaces shall not be touched by bare hands.

Q.3.1.4 If the surface being cleaned lies adjacent to a coated surface, which is not to be repaired, the
blast cleaning shall overlap the coated surface by at least 50 mm. The edges of the existing
coating system shall be feathered. The remainder of the existing coated surface shall be
properly protected with shields or screens to prevent any over blast damage. The following
four preparation grades (in accordance with ISO 8501-1) are recognized:

i. Sa 1 : Light blast-cleaning
ii. Sa 2 : Thorough blast-cleaning
iii. Sa 2 : Very thorough blast-cleaning
iv. Sa 3 : Blast-cleaning to visually clean steel
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Q.3.1.5 No acid wash, cleaning solvents or other chemical treatments shall be used on metal surfaces
after they have been (dry) blast cleaned. This restriction includes inhibitive washes intended
to prevent rusting.

Q.3.1.6 The surface profile or anchor pattern for carbon steel and low alloy steels to be coated with
liquid organic coatings shall be in accordance with the written recommendation of the coating
manufacturer. When not specified by the coating manufacturer or when otherwise specified
in this document, the surface profile shall be between 40 m and 70 m.

Q.3.1.7 If stainless steel, galvanised or non-ferrous metal surfaces are to be coated with liquid
(organic) coating materials, blast cleaning of these surfaces shall be carried out by smooth
sweep blasting, using fine sized non-iron containing abrasive (e.g. aluminium oxide). On
galvanised surfaces, the zinc layer shall not be damaged, a smooth uniform surface roughness
shall be achieved, no defects such as break through or crisping of the zinc layer shall occur.
Surface roughness shall be in the range of 20 m to 30 m or shall be agreed with coating
manufacturer.

Q.3.1.8 After approval by the Owner, abrading with sandpaper or light grinding with a suitable
(flexible) disc maybe used for surface preparation if sweep blasting is impossible. In addition,
when aluminium or galvanised components have to be coated, white zinc or aluminium
corrosion products and/or rust present shall be removed.

Q.3.2 Post Blast cleaning

Q.3.2.1 All masking to be removed and mechanical / hand tool cleaning / coating to be carried out on
exceptions as required.
Q.3.2.2 Scaffold contact points and surrounding GRP grating clamp screw points uncoated after
removal of scaffold to be coated to specification standard.
Q.3.2.3 Verify anchor profile in accordance with ASTM D4417 by using a spring-loaded micrometer
and/or either a coarse or extra coarse replica tape, as required by the anchor profile depth.
(Random-Spot check)

Q.3.3 Blast Cleaning Equipment

Q.3.3.1 The compressed air supply used for blast cleaning shall be free from water and oil. Adequate
separators and traps shall be provided, installed in the coolest part of the system. They shall
be emptied regularly to prevent carry-over of water and oil. Accumulations of oil and moisture
shall be removed from the air receiver by regular purging.

Q.3.3.2 Air cleanliness of air compressors shall be as described in Section 7.0 Quality Control. Air
compressors shall not be allowed to deliver air at a temperature above 110 C.

Q.3.3.3 Where air-operated equipment is used, the operator's hood or head gear shall be ventilated
by clean, cool air served through a regulator filter, to prevent blast cleaning residues from
being inhaled.
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Q.3.4 Blasting Abrasives

Q.3.4.1 Blasting abrasives for use in blast cleaning carbon steels and low alloy steels are specified in
ISO 8504-2. Recommended blasting abrasives are as follows but not limited to:
i. Chilled iron grit or shot
ii. Steel and malleable iron grit or shot
iii. Natural mineral abrasives
iv. Non-metallic abrasives

Q.3.4.2 Where abrasives which are specified as a Scheduled Waste are used, the waste shall be
collected and disposed-off at prescribed premises as per the requirement of the
Environmental Quality Act (EQA) 1974.

Q.3.4.3 Sand or other materials producing silica dust shall not be used.

Q.3.4.4 All metallic blast cleaning abrasives shall meet the requirements of ISO 11124 and shall be
tested in accordance with test methods specified in ISO 11125 Part 1-7.

Q.3.4.5 All non-metallic blast cleaning abrasives shall meet the requirements of ISO 11126 and shall
be tested in accordance with test methods specified in ISO 11127 Part 1-7.

Q.3.4.6 Product shall be sealed in hermetic packaging. Any product delivered in defective packaging
shall be rejected. Products must be stored sheltered from the elements.

Q.3.4.7 The blast profile and angular anchor pattern shall be of that recommended by the coating
manufacturer to suit the minimum requirement of their respective primers and the minimum
peak-to-valley height shall be 25 microns.

Q.3.5 Selection of abrasives

Q.3.5.1 Pre-qualification of the blast cleaning abrasives shall be conducted subject to acceptance and
approval by the Owner prior to their use. The pre-qualification test shall be carried out in
accordance with a set of procedure covering field trials and laboratory testing to determine
their physical and chemical properties, efficiency and effectiveness that can support the
economics for their usage.

Q.3.5.2 Steel or iron grit is commonly used as recyclable abrasives. In general, when steel shot is used,
it shall be used together with steel grit and approved by the Owner.

Q.3.5.3 The abrasives shall be free from oil, grease, moisture, chloride contamination etc. Each batch
of abrasive should be tested to check the abrasive meets the requirements as specified in the
relevant ISO standard.

Q.3.5.4 The conductivity of abrasives to be used on carbon steels shall be less than 150 S/cm.

Q.3.5.5 The salt contamination of abrasives shall be less than 30 mg/m2.

Q.3.7 Removal of residual salts from pitted areas

Q.3.7.1 Where pitting corrosion has been located, pressure water/steam wash with fresh water shall
be performed after the initial abrasive blasting. Should instant rust-back or black-spotting
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occur, the pressure wash shall be repeated to remove the residual salts residing in the micro
pits.

Q.3.8 Techniques and Restrictions

Q.3.8.1 In enclosed areas such as in tanks and vessels where some adverse conditions (i.e.
environmental conditions outside the range of the specifications or short turnaround time
allotted) may prevail, dehumidification is recommended to prevent flash rusting. In the event
that dehumidification is employed. The Relative Humidity (RH) within such environment shall
be maintained at a maximum of 50% except for inorganic zinc silicate. NACE publication 6A
192 may be referred to determine the types of dehumidification equipment suitable for the
work.

Q.3.8.2 Abrasive blasting shall not be conducted in open areas close to coating operations or wet
coated surfaces to prevent dust and grit contamination. Normally, grit blasting shall be
permitted only during daylight hours. The illumination of the surface during final blasting shall
be at least 500 Lux and all environmental restrictions shall be observed.

Q.3.8.3 Work is recommended to be blocked out in 30cm square and each square blasted evenly until
complete. Blasting shall continue a minimum of 25 mm into any adjacent coated areas,
and the edges shall be feathered.

Q.3.8.4 Any blast cleaned steelworks on which rust develops shall be re-blasted prior to being coated.

Q.4 ALTERNATIVE METHODS OF SURFACE CLEANING

Q.4.1 General
Q.4.1.1 Alternative surface cleaning is only acceptable after obtaining written approval from the
Owner. Alternative surface preparation such as power tool cleaning is not acceptable for areas
difficult to access such as under cellar and helidecks, areas exposed to water, steelwork to be
insulated, steelwork to be buried and internal surfaces of equipment and tanks.

Q.4.1.2 Alternative primers such as surface tolerant primers may be required for alternative methods
of surface cleaning and be in accordance with coating manufacturers recommendations.
Alternative primers need the approval of the Owner.

Q.4.2 Wet abrasive blasting and water jet cleaning

Q.4.2.1 Wet abrasive blast cleaning techniques using potable water can be used to avoid dust or in
cases where fire and/or explosion risks are present. The cleaned surface should be washed off
immediately after blast cleaning using potable water.

Q.4.2.2 Corrosion inhibitors should not be used unless written approval from the Owner has been
obtained. Corrosion inhibitor such as 0.3% sodium nitrite and 1.2% ammonium phosphate
may be used. However, use of Chromate inhibitor is not permitted. Disposal of corrosion
inhibitor into the sea should not be allowed. The coating manufacturer shall approve the use
of an inhibitor or the removal of residues of the inhibitor before coating.

Q.4.2.3 The cleaned surface shall be dry at the time of coating. Particular care shall be given to dry
areas that are not self-draining to avoid water collection.
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Q.4.3 Water Jetting

Q.4.3.1 High-pressure and ultrahigh-pressure water jetting utilising potable water may be used for
maintenance coating only and if abrasive blasting is not permitted for certain areas where
dusting and over-blasting may damage process equipment.

Q.4.3.2 Where black spots occur in pits or other surface defects, the surface shall be cleaned again at
higher pressure to remove the residual salts.

Q.4.3.4 The cleaned surface shall be thoroughly dry at the time of coating. Particular care shall be
taken to dry areas, which are not self-draining, so that water collected is removed.

Q.4.4 Sponge Jet Blasting

Q.4.4.1 Sponge Jet blast cleaning is recognized as a dry and low dust system. This cleaning type shall
only be used upon agreement with the Owner. Metallic or non-metallic abrasive used in the
sponge jet media matrix shall conform to the ISO 11124 or ISO 11126 blast abrasive
classification.

Q.4.4.2 It shall be conducted in accordance with the vendor/manufacturer recommendation which

includes proper site preparation, equipment set-up, choice of media and application.

Q.4.4.3 A range of surface profile 25, 50, 75 and 100 microns shall be achieved using the different
sponge jet media.

Q.4.4.4 A recycler shall be used to segregate light debris, dust and heavy collected waste from the
spent sponge jet media before being used again for blast cleaning.

Q.4.4.5 Personnel carrying out the blast cleaning shall be qualified and trained on the use of sponge
jet equipment and operation. A vendor technical representative shall be present at the work
site to assist during the execution of the blast cleaning activity.

Q.4.5 Centrifugal Abrasive Blasting

R.4.5.1 A portable blasting machine may be used to prepare steel decks and tank floors using
recyclable steel abrasives.

Q.4.6 Vacuum Blasting

R.4.6.1 Vacuum blasting may be used in the areas where open abrasive blasting is not permitted or
desirable for spot repair of damaged or corroded areas.

Q.4.7 Power-tool Cleaning

Q.4.7.1 Power-tool cleaning should be confined to minor areas and preferable to bare metal. Unless
otherwise specified, it shall be done as outlined in ISO 8504-3. Power-tool cleaning to bare
metal shall be done in accordance with SSPC SP11.

Q.4.7.2 When power-tool cleaning to bare metal is not feasible, the surface cleanliness shall at
minimum meet the visual standard St 3 in accordance with ISO 8501-2 at the time of coating.
Care shall be taken to ensure that the steel surface does not become polished after power-
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tool cleaning. Hand-tool cleaning is permitted prior to power-tool cleaning. If the surface being
prepared lies adjacent to a coated surface, the power-tool cleaning shall overlap the coated
surface by at least 50 mm and the coated surface shall be feathered.

Q.4.8 Performance and application conditions

Q.4.8.1 Blast-cleaning shall only be performed in conditions suitable for coating.

Q.4.8.2 Sometimes it may be advantageous to use the wet abrasive or moisture injection blast
cleaning techniques, so as to avoid dust or in cases where fire and/or explosion risks are
present. Fresh water may be either mixed with the abrasive in the pressure tank or
introduced directly behind or ahead of the blast nozzle.

Q.4.8.3 To prevent rusting the cleaned surface should be washed off immediately after blast cleaning
using fresh water containing a suitable corrosion inhibitor such as 0.3wt% sodium nitrite with
1.2wt% ammonium phosphate. A suitable corrosion inhibitor in the water used for blast-
cleaning should also be considered.

Q.4.8.4 The cleaned surface shall be thoroughly dry before any coating is applied. In general it is not
necessary to remove residues of the inhibitor before coating. However, the coating
manufacturer should be consulted on the inhibitor/primer compatibility.
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APPENDIX 18: RECOMMENDED ORGANISATION CHART FOR COATING WORK EXECUTION

OWNER

Contractor

Blasting and
Manufacturer Painting
Supervisor

Lead Blaster and

Coating Advisor Painter

Blaster and
Painter
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APPENDIX 19: REGULATIONS ON ABRASIVES, COATING PRODUCTS, WASTE PRODUCTION,

PRODUCT STORAGE AND LEACHING OF COATINGS

S.1 ABRASIVE BLAST CLEANING

S.1.1 Significant quantities of dust from the abrasive and the surface debris are made airborne and
can contribute to air pollution. This dust is recognized as a fugitive emission that is often
regulated. Control of mineral dust exposure shall be in compliance with the Environmental
Quality (Clean Air) Regulations 1989 and Factories and Machinery (Mineral Dust) Regulations
1989. The PEL averaged over an 8-hour period without respirators shall be:

i. Less than 10mg/m3 concentration of free silica in total dust

ii. Less than 0.05mg/m3 concentration of respirable cristobalite in crystalline silica
iii. Less than 0.1mg/m3 concentration of respirable quartz in crystalline silica
iv. Less than 0.05mg/m3 concentration of respirable tridymite in crystalline silica

S.1.2 If respirators are used by employee and all control measures related to this hazard has been
employed, the exposure level shall be determined by the protection factor provided by the
respirator

S.2 COATING APPLICATION

S.2.1 In the process of spraying, a substantial portion of the liquid coating does not coach the
substrate but is lost due to overspray. In addition, most coatings have appreciable quantities
of volatile organic compounds (VOC) that can contribute to smug formation.

S.3 WASTE PRODUCTION

S.3.1 Both coating removal and coating application generate waste products, which must be
properly disposed of. In many instances, the waste may be classified as hazardous by the
Environmental Quality Act (EQA) 1974 because of heavy metal (e.g. lead) content of the
residue, or the solvents of unused coating or thinner.

S.3.2 The control of Scheduled Wastes shall be in compliance with the Environmental Quality Act
1974 (Act 127) Part IV A Section 34B. Scheduled wastes as identified in Environmental Quality
(Schedule Wastes) Regulation, 1989 First Schedule (Regulation 2) Part I Schedule Wastes
from Non Specific Sources and Part II Schedule Wastes from Specific Sources shall collected
and disposed of at Prescribed Premises.

S.3.3 These Prescribed Premises shall be in compliance with the Environmental Quality (Prescribed
Premises) (Schedule Wastes Treatment and Disposal Facilities) Order, 1989 and
Environmental Quality (Prescribed Premises) (Scheduled Wastes Treatment and Disposal
Facilities) Regulations, 1989.

S.4 PRODUCT STORAGE

S.4.1 The storage of certain products is regulated by EQA 1974 because of the potential ecological
damage that could result from a spill or leak from storage vessels.
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S.5 LEACHING OF COATINGS

S.5.1 Under certain circumstances, toxic or otherwise undesirable components of applied coating
films may leach into the environment.

S.5.2 The above activities collectively can affect almost all the major environmental receptors i.e.
air, soil, groundwater, surface water, potable water.

S.5.3 Contractor Environmental Programme shall comply with the Malaysian Environmental Quality
Act (EQA), 1974 relating to the prevention, abatement, and control of pollution and
enhancement of the environment.

S.5.4 Contractors hired to remove hazardous coating shall be qualified in accordance with the
procedures described in SSPC-QP 2(I). The qualification process shall evaluate four (4)
functions:

i. Management of Hazardous Coating Removal

ii. Technical Capabilities
iii. Qualification of Personnel
iv. Safety and Health