MID TERM EXAMINATION

COATING AND INHIBITION

ADAM HIDANA YUDO SAPUTRO

1406582480

DEPARTMENT OF METALLURGY AND MATERIAL

FACULTY OF ENGINEERING
UNIVERSITY OF INDONESIA
DEPOK
2015
Flow Chart Coating.

Coating is a covering surface of material to prevent from environment with a certain

grade of corrosivity. The process of coating depends on material type, or use of
material. The selection of coating depends in some factor, such as environment,
material, temperature, and economic view. In this assignment, some flowchart for
certain type material or use of material will be explained below generally. NORSOK
Standard in document M-CR-501 explain about surface preparation and protective
coating in general. The coating starts with surface preparation, coating application,
inspection and testing. Beside of that, There are some qualifications requirements
should be accomplished such as pre-qualification of products, qualification of
personnel and qualification of procedures. Based on NORSOK, The coating
manufacturer shall provide Coating System data Sheet (CSDS) for each coating
system to be used, containing at least following information for each product:
Surface pre-treatment requirements.
Wet film thickness/dry film thickness (max, min. and specified).
Maximum and minimum recoating intervals at 5 C, 10 C and 23 C.
Information on thinners to be used (quantities and type).
Mixing, handling and application requirements/recommendations.
Hiding power of top coat for specified colours according to ISO 2814. Contrast
ratio shall not be less than 94% at the specified top coat thickness.
Table pre- qualification tests for coating materials

For Inspection and testing, NORSOK gives table about inspection and testing
condition.
Table Inspection and Testing

External Coating Process Flowchart

1. The entrance control of
pipes. Visual Inspection

2. Preliminary heating in
the gas furnace

3. Abrasive cleaning of
external pipes surface in a
shotblast unit by steel
chipped fraction

4. Removal of dust from

pipes Internal cavity by a
purge

8. Three layer PE and

polypropylene coating
a. Epoxy primer Coating
b. Adhesive coating
c. Polyethylene coating

9. Water cooling of coated pipes

10. Uniformly coating

inspection with high-voltage
flaw detector

11. Coating removal from pipe

ends

5. Visual Inspection of pipe

12. Final quality inspection of
coated pipes (visual)
6. Having heated pipes

7. One and two-layer FBE

coating
a. Epoxy Powder paint
coating

13. Pipe marking. Pipe Storage

Internal Coating Process Flowchart

1. Pipe storage before pipe

delivery

2. Pipe incoming control

10. Internal surface preparation

quality inspection

11. Coating application on pipes

(in coating chamber)

3. Pipe Heating
12. Internal coating pre-curing
4. Internal pipe surface
degreasing
13. Pipe Induction heating
5. Second heating pipe

6. Internal pipe surface blast

cleaning in shot blaster no 1

7. Blaster internal surface

quality examination
8. Internal pipe surface blast
cleaning in shot blaster no 2

14. Pipe coating curing in the

full-polymerization chamber

15. Internal flow coating quality

inspection

16. Marking of coated pipes.

Stocking of pipes provided
tarpaulin protective caps

9. Internal surface blowout

Another example coating procedure specification for ABB electric motors according
to NORSOK M-501 Standard.

Assembly, Protection, Cleaning (1)

Surface Pretreatment (2)

Zinc Coating (3)

Tie Coat (4)

Intermediate Paint (5)

Protection removal and delivering (6)

Topcoating of assembled motor (7)

Inspection and testing plan (ITP) (8)

1. Assembly, protection and cleaning

Component assembly with handtools and machined surfaces are protected
with steel plates, sharp edges are rounded to R min. 2mm and soiled surfaces
are cleaned with alkaline detergent.

2. Surface pretreatment
Assembled motors are Grit blasted (G34 mesh size 0,85- 1,18mm) in a
separate blasting chamber. When all the paint is gone,blasters takes another
hose from where it comes
new grit. With this solution we can ensure a sufficiently rough surface through
the process.
3. Zinc coating
Zinc coating is done using an EcoArc 350 machine in separate chamber.
Appropriate dust extraction resulting in minimal environmental pollution.
4. Tie coat
Zincrich epoxyprimer is used for stripecoating on minor areas and tiecoat
spread using brush and airless paintsprayer.
5. Intermediate paint
Brush and airless paintspraying is used. For stripecoating good quality
brushes are used.
6. Protection removal and delivering
Protections are removed and the motor is disassembled. The motor is
carefully packed and
delivered to ABB for assembly.
7. Topcoating of assembled motor
The motors are carefully washed and lightly roughened. Shafts etc. are
masked during painting process. Brush and airless paint spraying is used.
8. Inspection and testing plan (ITP)

Coating Quantity

Knowing quantity of coating that used for covering surface is important to order the
coating, and it relates to cost for coating. To know quantity of coating, the area of
material and also the type and thickness of coating should be known. The example
of calculation of quantity coating will be shown below. The material is pipe with
outside diameter is 100 mm, and the length is 4km. Zinc rich epoxy will be used as
coating, with 4 layers as shown table below.
Coat

Material

Primer
Barrier
Barrier
Finish

Epoxy Zinc Rich

Epoxy MIO
Epoxy MIO
Polyurethane

Thickness
(m)
40
150
150
50

Density
(Kg/l)
2.62
1.36
1.36
1.42

Total area that should be covered =

DL= x 100 mm x 4000000=1256000000 m m2

125600 d m

Material
Epoxy Zinc
Rich
Epoxy MIO
Epoxy MIO
Polyurethane

Thickness
(dm)
0.0004

Area (dm2)

Density (Kg/l)

Quantity (Kg)

125600

2.62

131.63

0.0015
0.0015
0.0005

125600
125600
125600

1.36
1.36
1.42

256.25
256.25
89.18

So,

The quantity of Epoxy zinc rich is 131.63 Kg or 33.47 Gallon

The quantity of Epoxy MIO is 512.5 Kg or 135.4 Gallon
The quantity of Polyurethane is 89.18 or 23.56 Gallon