Overseas Technical Coatings & Services Company (LLC)

KARAN UTILITIES AND CO-GENERATION PROJECT

SAUDI ARAMCO CONTRACT 6600021903 (IK)

METHOD STATEMENT
FOR
SURFACE PREPARATION AND PAINTING ON ALLOY PIPING EXTERNAL SURFACES WITH APCS-113-A

MS -IC- 002

Prepared for Approval

09 July, 2011

Rev

02

Date

Prepared By Hertel OTC

Checked By

Reviewed By

Approved By

OTC/QCP.Doc, MS-IC-002 (Rev 02)

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Overseas Technical Coatings & Services Company (LLC)

Index
1. Scope 2. Definitions 3. References 4. Procedure 4.1 Pre-Blast Checks 4.2 Surface Preparation 4.3 Cleaning 4.4 Paint, Storage & Preparation 4.5 Shop & Field Weld joints Paint Application 4.6 Repairs 4.7 Quality Control Procedure 5. Personnel Qualifications 6. Safety

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1. SCOPE This procedure covers minimum requirements of APCS 113A (liquid type epoxy coating) for Alloy steel piping on shop application & filed weld joints external coating in buried piping spools and associated fittings in accordance with SAES-H-002. 2 DEFINITIONS 2.1 2.2 2.3 2.4 2.5 2.6 3. COMPANY EPC CONTRACTOR CLIENT PROJECT JOB NO. : SAUDI ARAMCO : PETROFAC : MMG : KARAN UTILITY AND CO-GENERATION : 6600021903

COATING CONTRACTOR : Overseas Technical Coatings & Services (OTC)

REFERENCES SAEP-316 SAES-H-002 SAES-H-002V : Performance Qualification of Coating Personnel : Internal & external coating of pipeline and piping : Approved Saudi Aramco Data Sheets for the pipelines Maintenance external coating : Coating Matls & Application Requirements for Industrial Facilities : Safety Requirements for Coating Application : Storage, Handling and Installation of Externally Coated Pipe : Renovation& Repair coating for Submerged Services APCS-113A
: The requirements of External. Liquid Coatings for Buried P/L & Piping

SAES-H-100 SAES-H-102 SAES-H-200 SATIP-H-002-06

09-SAMSS-113

SSPC-SP1 SSPC-SP2 SSPC-SP3 SSPC-SP10

: Solvent Cleaning Specification : Hand Tool Cleaning Specification : Power Tool Cleaning Specification : Blast Cleaning to Near White Metal Specification
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SSPC VIS-1 SSPC-PA2 4 PROCEDURE 4.1 Pre-Blast Check : Pictorial Surface Preparation Standards for Painting Steel Structures : Measurement of Dry film Thickness

4..1.1 QC Inspector shall carry out checks before blasting to determine whether cleaning is required either with the use of chemicals or solvents. Solvent clearing if required shall be carried out in accordance with SSPC - SPI. 4..1.2 No abrasive blasting shall be carried out unless the steel surface is at least minimum 3C above the Dew Point temperature. 4..1.3 Prior to start for blasting, all sharp edges and cut-offs shall be rounded to a smooth radius and all weld spatters shall be removed. 4..1.4 The compressed air supply shall be checked free of oil, moisture and contamination. As a minimum, the inspector shall check and approve the air quality at the start & midpoint of each 8-hour period. The method of checking shall be in accordance with SAES-H-100 Para 5.4.1 4..1.5 All compressed air hoses and paint lines shall be circular in section, free of cuts, kinks and twists. Any change in direction shall be by long radius curves to maintain constant and unrestricted flow where possible. 4..1.6 All hoses and nozzle connections shall be inspected prior to commencement of work to ensure they are secure. Any defective connection will be immediately replaced. 4.2 Surface Preparation:

4.2.1 Surface preparation shall be carried out in accordance with the relevant coating system as specified in SAES H-002, APCS-113-A 4.2.2 The type of abrasive to be used shall be determined by degree of cleanliness and surface Profile requirements as specified in SAES-H-002. 4.2.3 Abrasives shall be kept dry and free of contamination. and shall comply in accordance with SAES-H-100 Para 5.2.1 4.2.4 Sufficient capacity compressors shall be used to supply free air to all elements of the abrasive and coating operation as per SAES-H-100 Para 5.4 4.2.5 The Blast profile shall be measured with PRESS-O-FILM (Testex tape X coarse replica tape) and Profile thickness gauge. The replica tape shall be attached with inspection report as a permanent record.
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Overseas Technical Coatings & Services Company (LLC)

4.2.6

Residual chloride on the surface shall not exceed 40 mg/m.

Cleaning 4.2.1 Used abrasives shall be removed from external surfaces using a dry brush, blow down with clean dry compressed air. 4.3 Paint, Storage and Preparation

4.3.1 Paint and thinner shall be stored in wellventilated building at storage temperature as recommended in the manufactures data sheet 4.3.2 The date of manufacture shall be clearly marked on each paint container and paints that have exceeded their shelf life shall be discarded 4.3.3 Paints that show signs of leakage or have gelled shall be discarded and any skins that have formed shall be cut and removed before application. Paint preparation shall be in accordance with manufacturers recommendation and/ or accordance with SAES-H-100- Para-7. 4.3.4 All paints shall be thoroughly mixed before application, quantities over 5 liters shall be mixed using a power mixer. If the paint cannot be mixed uniformly (thick sediment at the bottom of the can) it shall be discarded. 4.4 Paint Application

4.4.1 The prepared surface shall be visually inspected for cleanliness and profile prior to coating. 4.4.2 Prepared surface shall be coated within a maximum of four hours and before any deterioration begins. Surfaces that have begun to deteriorate, or have exceeded the four hours shall be reblasted. 4.4.3 Approved Paint materials for APCS 113-A as per SAES-H-002V shall be used for external application of Alloy spools including associated fittings to specify DFT. WFT will be monitored to control the required DFT. 4.4.4 Paint shall only be applied if the following conditions are met and as specified by the Manufacturer: Surface temperature to be above 10oC and below 60oC. Surface temperature to be also at least minimum 3oC above dew point temperature. The surface shall be free of oil, grease, dirt, loose paint, dust, rust and other surface contaminants.

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There is protection from adverse weather conditions, such as winds that may blow sand, or other foreign bodies on the painted surface or it may disrupt the paint pattern or cause dry spray.

4.4.5 Recoating intervals shall be maintained as per manufacturers data sheet. Color contrast between coats shall also be maintained. 4.4.6 Dry film thickness of each coat shall be measured in accordance with SSPC-PA2 using a suitable non ferrous thickness gauge. 4.4.7 All the work shall be documented for future reference. 4.6 Repairs 4.6.1 All defective areas shall be cleaned with solvents or detergents. 4.6.2 Areas less than 0.1M2 shall be hand abraded or ground back to the surface substrate using at least 80 grit disc sanders and paint touch up shall be by brush only. 4.6.3 Areas greater than 0.1M2 shall be blast cleaned to original specification and paint application shall be airless spray. 4.7 Quality Control Procedure 4.7.1 Quality control requirements are to be carried out in accordance with Inspection and test plan of the project. All documents shall be the latest version. 4.7.2 Abrasive blasting/Painting equipment shall be checked by the crew supervisor for suitability prior to the start of the surface preparation and coating activities (as per approved ITP) 4.7.3 Record on a daily basis critical in process inspection activities.(As per approved ITP) 4.7.4 Paint/Coating and Equipment check list is required to be completed and signed by the Coating Crew Supervisor and verified and signed by the client Inspector (As per approved ITP) 4.7.5 TESTEX tape for the profile reading of the blasted area. Minimum 3 tests shall be performed during each shift.

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5. PERSONNEL QUALIFICATION 5.1 OTC personnel involved in preparation, application, direct supervision or inspection of coatings shall be qualified and certified by Hertel-OTC and ARAMCO as per SAEP-316. This includes abrasive blasters, coating applicators, crew supervisors and QC inspectors.

6. SAFETY. 6.1 Safety Requirements for Painting shall be observed at all times and shall be strictly followed in accordance with SAES-H-102 The Project safety plan will be fully enforced during the duration of the work. During application process, all lighting will be of the explosion proof type as per SAESH-102 item 4.1 A standby man will be at the work at all times during the work. His role will be observing activities in the painting work and to stop the work immediately while any safety concern arises. All operators will wear full personal protective equipment including coveralls, safety boots, gloves, helmets and positive air feed breathing masks in accordance with SAES-H102 item 4.3 All recommendations of the Material/Equipments manufacturers concerning the safe handling and application of their products shall be followed as per SAES-H-102 item 4.4.

6.2 6.3

6.4

6.5

6.6

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