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SURFACE PREPARATION
&
PAINTING PROCEDURE

Notes:

0
REV

Client Approval:
1. Approved
2. Approved
Submit Certified Final
3. Approved as Noted
Revise and Resubmit
4. Not Approved
Revise and Resubmit
5. Review Not Required /
For info only.
Approval does not relieve supplier from
full compliance with contractual
obligations
DATE:
SIGN:

210-09-2014
ISSUE DATE

IFA
DESCRIPTION

Sh.Yazdani
PREPARED BY

Add
Phone :
Fax :
Web :

V.Naderian
CHECKED BY

A.Heforezai
APPROVED BY

DEFINITION :

IFI : ISSUED FOR INFORMATION, IFA : ISSUED FOR APPROVAL, APP : ISSUED FOR FINAL

LIST OF CONTENT

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1.0

INTRODUCTION

2.0

REFERENCES

3.0

GENERAL
3.1
Equipment
3.2
Coating Material

4.0

SURFACE PREPARATION
4.1
General
4.2
Pre-Cleaning of Surfaces and Solvent Cleaning
4.3
Surface Preparation by Blast Cleaning
4.4
Blasting Abrasives
4.5
Techniques and Constraints
4.6
Surface Preparation by Hand and Power Tool Cleaning

5.0

PAINT APPLICATION
5.1
Pre Application Procedures
5.2
Scheduling
5.3
Application Methods
5.4
Repair of Defects

6.0

PAINTING AND COATING SYSTEM

7.0

FLOW CHART FOR INSPECTION OF BLASTING AND PAINTING ACTIVITIES


7.1
Before Blasting
7.2
After Blasting
7.3
Before coating
7.4
After coating

8.0

INSPECTION AND TESTING

9.0

DOCUMENTATION

10.0

SAFETY

11.0

ATTACHMENT
11.1
Attachment 1
11.2
Attachment 2

Blasting and Painting Inspection Report


Proposed Paint Technical Datasheet

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INTRODUCTION
1.1

Scope
This Procedure covers the requirement surface preparation and coating on steel
surface for

2.0

REFERENCES
2.1

Reference document shall be the specification herein and painting specification


a.
b.

3.0

GENERAL
3.1

Equipment
The compressed air supply for Blast Cleaning equipment shall be free of water
and oil. Adequate separators and traps shall be provided and these shall be kept
emptied regularly of water and oil. Accumulations of oil and moisture shall be
removed from the air receiver by regular purging. Air compressors shall not be
allowed to deliver air at a temperature in excess of 110 C. The grit shall normally
be discharged with a pressure of 7 bar measured at the nozzle using a
hypodermic pressure gauge and shall not under any circumstances fall below 5.6
bar for normal cleaning operations.
The coating spraying equipment to be used shall meet the recommendations and
instructions set forth by the paint manufacturer for each specific coating system.
Airless Spray is normally the choice of application method but if conventional air
spray is used, an adequate moisture trap shall be placed between the air supply
and the pressure pot feed to the gun. The trap shall continuously bleed off any
water or oil from the air supply.

3.2

Coating Material
Storage, thinning, mixing and handling of paint materials shall be in accordance
with the Paint Manufacturers recommendation. All paint materials and solvents
shall be supplied in the paint manufacturers original containers, durably and
legibly marked with clear description of the contents. This shall include the
specification number, the color reference number, the method of application for

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which it is intended, the batch number, date of manufacture, the shelf life expiry
date and the paint manufacturers name or recognized trademark.
Different brands or different make of paints shall not be inter-mixed. Similarly,
mixing of different brands or generic types of paint material is not permitted. The
Manufacturers pot-life requirements shall be strictly and diligently followed.
The same shall be said for the minimum and maximum over-coating time as
recommended by paint manufacturer

Only thinners as specified by the paint manufacturer shall be used. Mixing and
thinning directions as furnished by the paint manufacturer shall be followed.
Statutory requirements for levels of volatile organic compound are to be met.
4.0

SURFACE PREPARATION
4.1

General
For optimum paint performance, surfaces to be painted or coated shall be
completely dry and free from burrs, weld spatter, flux, rust, loose scale, dirt, dust,
grease, oil and other foreign matter deleterious and harmful to paint. After
preparation of substrate surface, any grit or dust shall be removed and a layer of
primer applied before any corrosion or recontamination occurs, normally within
four (4) hours after blasting. Surface preparation shall be subjected to inspection
before the primer coat is applied to ensure all traces of dust and foreign matter
have been removed by brushing, blowing with dry clean compressed air or
vacuum cleaning.

4.2

Pre-Cleaning of Surfaces and Solvent Cleaning


This cleaning process is mandatory before further cleaning or surface preparation.
Prior to the actual cleaning operation, surface contaminants such as oil, grease,
hydrocarbon etc. shall be removed preferably by degreasing with suitable
degreaser or solvent cleaning according to SSPC-SP1. The degreased surface
shall be further washed or rinsed down with fresh water to remove all traces of the
degreaser chemicals. The surface shall be allowed to dry thoroughly before
proceeding with any further coating work. This process also applies to all metal
surfaces to be coated that do not require blast cleaning or power tool cleaning.
Excessive rust scale shall be removed by impact cleaning tools or high pressure
water jetting. All edges shall be ground to a minimum radius of 2 mm. Flame cut
areas shall be ground flush.

4.3

Surface Preparation by Blast Cleaning


Blast cleaning shall be carried out through ISO 8504-2:1992 to the required visual
standard in accordance with ISO 8501-1:1988 or equivalents. All surfaces, where

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accessible shall be prepared by abrasive blast cleaning to a minimum of SA 2.5


ISO 8501-1(SSPC-SP10)
4.4

Blasting Abrasives
Blasting abrasives for use in blast cleaning carbon steel and low alloy steel are
specified in ISO 8504-2. Recommended blasting abrasives are as follows, but not
limited to:
a)
b)
c)
d)

Chilled iron grit or shot


Steel and malleable iron grit or shot
Natural mineral abrasives
Non metallic abrasives (aluminium oxide, garnet etc)

All blasting abrasives shall be tested and qualified in accordance with the
procedures described in SSPC-AB1 Abrasive Specification No.1; Mineral and Slag
Abrasives.
Abrasives that are classified as Scheduled Waste under the Environmental Quality
Act (EQA) 1974 shall not be used. Sand or other materials producing silica dust
shall not be used. The abrasives shall be free from oil, grease, moisture, salt, dust
etc. Re-used abrasives shall be clean, sharp and free from contaminants and requalified to SSPC-AB 1 requirements. The blast profile and angular anchor pattern
shall be that recommended by the paint manufacturer to suit the minimum
requirements of their respective primers. The acceptable peak-to-valley height
range shall be between 50 ~ 75 microns.
4.5

Techniques and Constraints


Blast cleaning shall not be carried out when the temperature of the surfaces to be
coated is less than 3 Celsius above the dew point or when th e relative humidity
of the air is greater than 85 %.
Abrasive blasting shall not be done in open areas close to painting operations or
wet coated surfaces to prevent dust and grit contamination. Normally grit blasting
shall be permitted only during daylight hours except that rough grit blasting will be
allowed during the night provided that the surface is subsequently blasted to the
specified standard under good light conditions. The illumination of the surface
during final blasting shall be at least 500 Lux and all environmental restrictions are
observed.
All welded areas and appurtenances shall be given special attention for removal of
welding flux in crevices. Welding spatters, slivers, laminations and underlying mill
scale not removed during fabrication and exposed before and during blast

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cleaning operations shall be removed by the best mechanical means and the
edges smoothed or rendered flush. Where rectification is necessary on abrasive
blast cleaned surfaces, the dressed areas shall be re-blasted to remove all rust,
slag and grit and to provide an adequate anchor pattern.
Blasting shall continue a minimum of 25 mm into any adjacent coated areas and
the edges shall be feathered. After dry blast cleaning, no acid washes, cleaning
solutions, solvents or other chemical treatment shall be used on metal surfaces.
This restriction includes inhibitive washes to prevent rusting. Any blast-cleaned
steelworks on which rust develops shall be re-blasted prior to being painted.
4.6

Surface Preparation by Hand and Power Tool Cleaning


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 eg. galvanize steel and stainless steel.
Manual cleaning shall be performed using hand wire brushes or mechanically
operated tools (grinders, chippers, wire brushes) in accordance with ISO 8504-3.
Where welds occur within these areas or when these areas cannot accommodate
a power disc, power impact tools shall be applied (vibratory and rotary hammers,
needle guns, chisels) followed by brush cleaning.
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 25
mm. The minimum requirement for successful coating application is St 3 ISO
8501-1 (SSPC-SP3) at the time of coating. Care shall be taken to ensure that the
substrate surface does not become polished during power tool cleaning.

5.0

PAINT APPLICATION
5.1

Pre Application Procedures


5.1.1

General
Any surfaces to be coated shall be dry and rendered dust free prior to
application of primer coat. This can be accomplished by blowing off the
surface with clean dry air or using an industrial vacuum cleaner together
with a clean dry stiff brush. The blasted surfaces shall be examined for
traces of smudge, oil, grease or other contamination and also tested for
the presence of soluble salts. If present they shall be removed by solvent
washing or for salts by water washing or steam cleaning and the areas
re-blasted.

5.1.2

Mixing and Thinning

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All coating materials shall be thoroughly stirred in a pressure pot with a


power mixer for a time sufficient to thoroughly remix the pigments and
vehicles. Sufficient agitation to maintain good mixing shall be applied until
the product is used. Coatings containing heavy or metallic pigments that
have a tendency to settle shall be kept in continuous suspension in the
pressure pot by a mechanical agitator or stirrer
If during mixing / stirring air is entrapped in the product, sufficient time
should be allowed for air bubbles to escape, before application is started.
This is to reduce the risk of pin-holing of the coating layer to be produced
Thinner shall not be added to primer or paints unless necessary for proper
application according to the paint manufacturers recommendation. The
type of thinner used must comply with same.
If the coating material requires the addition of a catalyst, the pot life under
application conditions shall be clearly stated on the label. The pot life shall
not be exceeded. When the pot life limit is reached, the spray pot shall be
emptied, the material discarded, the equipment cleaned and new material
catalyzed.
Hydrostatic and other testing of welds shall be completed prior to painting
weld lanes, ends of pipe and related components that will require
subsequent welding at site shall be masked off after blast cleaning and left
uncoated for a distance of 50 mm from all areas requiring welding.
5.1.3

Other Miscellaneous Requirements


For multi-coat system, a mist coat shall be applied over inorganic zinc
primer to avoid surface defects. Necessary care shall be exercised to
ensure a smooth and uniform coating is applied over inorganic zinc primer
Extra coats of paint shall be applied on areas where shape and/or plane
of application results in thinly applied coatings; example at edges, weld
behind angles, corners etc and areas not fully accessible by spray in order
to obtain the specified coverage and thickness. A stripe coat of paint shall
be brush applied before applying the subsequent coat.

5.2

Scheduling
Unless otherwise recommended by the paint manufacturer and accepted by the
Customer, paints shall NOT be applied when:
5.2.1
5.2.2
5.2.3
5.2.4

Incomplete surface preparation or oil, grease and dust still present on


substrate to be painted.
The surface temperature is less than 3C above Dew point.
The air or surface temperature is below 5C as it would adversely affect
curing of Paint.
The relative humidity of air is greater than 85% except for inorganic zinc
silicate up to 90%.

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5.2.5
5.2.6
5.2.7
5.2.8

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The metal substrate temperature is higher than that recommended by the


paint manufacturer for application
There is a likelihood of an adverse change in weather conditions within
two hours after application that would result in a drastic drop in air
temperature below those as specified above.
There is a deposition of moisture in the form of rain, condensation etc.
upon the surface.
The available light is less than 500 Lux

Blast cleaned or power disc grinded surfaces shall be coated with the primer
specified within four (4) hours after blasting or power grinding or within such other
limits as may be specified and before any visible rusting occurs. Each coat of paint
shall dry for a time period within the limits prescribed by the Paint Manufacturer
before the next coat is applied (minimum and maximum over-coating time).
5.3

Application Methods
5.3.1

General
Coatings shall be uniformly applied without runs, sags, solvent blisters,
dry spray or other blemishes. All blemishes and other irregularities shall
be repaired or completely removed and recoated. Special attention shall
be paid to crevices, corners, edges, weld lines, bolt heads, nuts and small
brackets to apply the specified minimum dry film thickness by brush
application if spray will not completely cover all surfaces.
Edges of existing coating shall be feathered towards the substrate prior to
over-coating Primers should not be over-coated with the second coat
paint until the specified minimum over-coating time is achieved

5.3.2

Inter-coat contamination shall be minimized by maintaining proper


cleanliness and by applying the intermediate and finish coats within the
over-coating time recommended by the paint manufacturer. If
contaminants are present, they shall be removed before applying
succeeding coats. Contrasting color shall be used for each coat of paint.
Spray Application
Paints shall be applied by Air Spray (Conventional) or Airless Spray
Hose and containers, lines and pots shall be thoroughly cleaned before
addition of new materials. The spray gun shall be held no closer than
200 mm (between 450 mm to 600 mm) from the surface to be coated at
right angles to the surface. Uniform parallel passes should be made with
the spray gun. Each spray pass shall overlap the previous pass by 50%.
Large surfaces should always receive passes in two directions at right
angles to each other.

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Each coat is to be applied uniformly and completely over the entire


surface. All runs and sags shall be brushed out immediately or the paint
removed and the surface re-sprayed. Before spraying each coat, all areas
such as corners, edges, welds, small brackets, bolts, nuts and interstices
shall be pre-coated, usually by brush to ensure that these areas have at
Least the minimum specified film thickness.
5.3.3

Brush Application
Brush application may be used under the following circumstances:
a)
b)

c)
d)
e)

When spraying for any reasons cannot properly coat areas


When spray application is deemed to be difficult, adverse to the
required quality finish, uneconomical or may affect other plant,
equipment property, personnel etc. due to location of work
accessibility
For the application of self-etching primers
For touch-up or repair to localized damaged paint areas or areas
of incorrectly applied paint
For application of initial stripe coat of paint to corners, edges,
crevices, holes, welds or other irregular surfaces

Paint brushes used shall be of a style and quality that will permit proper
and appropriate application of paint. Good quality hog bristle is preferred
and nylon or other synthetic bristle types are prohibited. Round or oval
brushes are considered most suitable for rivets, bolts, irregular surfaces
etc. Wide flat brushes are suitable for large flat areas but not to exceed
Width of 120 mm. Brushes shall be kept in good condition at all times and
discarded if damaged or excessively worn. The brushing shall be done so
that a smooth coat, as uniform in thickness as possible is obtained. There
should be no deep or detrimental brush marks.
Paint shall be worked into all crevices and corners. Runs and sags shall
be brushed out. During application of each coat, all areas such as
Corners, edges, welds, small brackets, bolts, nuts and interstices shall
receive additional coating material to ensure that these areas have at
least the minimum specified film thickness and to ensure continuity of
coating

5.3.4

Roller Application

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Roller application shall be discouraged and shall be subject to the specific


approval of customer. If allowed, it will only be used on relatively large
surface areas provide the first primer coat of paint is applied by brush and
its use in accordance to Paint Manufacturers instructions. Rollers shall be
manufactured from good quality carpet pile or lambs wool.
5.4

Repair of Defects
5.4.1

General
A specific paint system or scheme for the repair and/or touch-up painting
of each generic type shall be submitted for approval from customer
Before application of any further coat of material, all damages to previous
coats shall be repaired. All loose paint shall be removed to a firm edge. All
surface irregularities and contaminants shall be removed. Hard glossy
surfaces may require abrading to obtained suitable surface for painting.
If the surface being prepared lies adjacent to a sound coated surface
which is not to be repaired, the surface preparation shall overlap the
coated surface by at least 25 mm.

5.4.2

Inadequate Coating Thickness


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

5.4.3

Coating Damage not exposing steel surface substrate


The damaged area shall first be washed down to remove all
contamination, followed by rinsing with clean fresh potable water and left
to dry. The coating around the damaged area shall be feathered or
chamfered by sanding down to ensure continuity of the patch coating. The
full coating system shall then be re-applied strictly in accordance with
specification

5.4.4

Coating Damage exposing steel surface substrate


The damaged area shall be re-cleaned as originally specified for that item
and the full coating system re-applied in accordance with paint technical
data sheet. The re-cleaning shall carry over on to the secure surrounding
coating for not less than 25mm all round and the edges shall be feathered
or chamfered by sanding down to ensure continuity of the patch coating.

5.4.5

Repair of Zinc Silicate primer


Damaged surfaces of zinc primer shall be cleaned to remove all loose
materials and blast cleaned with a portable vacuum blast cleaning unit.

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The surfaces shall be coated with one coat of the primer which is the
same as the damaged primer. If blast cleaning is not possible, power tool
cleaning may be used subject to customer agreement.
5.4.6

Repair of Fully Cured Epoxy coatings


In case of repairing damage to fully cured epoxy coatings, the coating
work shall only be carried out after the surface of the fully cured epoxy to
be coated has been suitably abraded to provide an adequate tooth for the
coating to be applied. The repair coating shall be compatible with the
existing coating.

6.0

7.0

PAINTING AND COATING SYSTEM


6.1

Painting material will be applied according to the design temperature and services
condition. Selection of paint material is also confirmed by Paint Manufacturer.

6.2

Painting coating system shall be in accordance Table 2 & Table 3 in this


procedure.

FLOW CHART FOR INSPECTION OF BLASTING AND PAINTING ACTIVITIES


7.1

Before Blasting

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7.2

After Blasting

7.3

Before coating

7.4

After coating

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INSPECTION AND TESTING


8.1

The following inspection shall be carried out after in accordance with Table 1 in
this procedure. Surface shall be accessible until final inspection is carried out.

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Individual coat and completed coating shall be visually inspected for appearance.
Coatings shall be smooth and free from run, cracking, blistering, dry spray, over
spray, pinholes, crater and sagging.

8.3

During coating, the wet film thickness shall be spot-checked. Specified total
minimum DFT shall be spot-checked by thickness gauge. Dry film thickness shall
also be measured on individual coats. WFT and DFT measurements shall comply
with ASTM D 4414 and SSPC-PA2 respectively.
Temperature and relative humidity shall be measured by means of a temperature
gauge and hygrometer. Reading shall be taken at regular intervals, depending on
change in climatic condition

8.5

Coating shall be removed and repainted if the specification reveals the following:
a)
b)
c)
d)
e)
f)
e)

Coating not adhering to surface to which it is applied


Surface has not been properly blasted and/or clean
Loose or scaling paints remains
Foreign matter (contamination) embedded into coated surface.
Freshly coating surface is wet from rain, high humidity or low dew points.
Previously applied coating has not cured.
For other reason that will impair the coating performance.

DOCUMENTATION
9.1

10.0

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8.2

8.4

9.0

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Inspection results for surface preparation and coating shall be recorded in Painting
Inspection Report as per Attachment 2.

SAFETY
10.1

All safety and regulations of Malaysian and local laws and insurance underwriter
Regulations shall be adhered to in the storing, handling, use and application of
paints, thinners, solvents, etc.

10.2

Smoking, open fires, or sparks will not be permitted in confined areas that are
being or recently have been painted and are emitting flammable solvents.

10.3

All equipment recommended lifting up by using the lifting lug attached due the
painting work to avoid any damage or uneven distribution of paints on the
equipment main body.

10.4

The following documentation shall be provided and used when evaluating coating
systems:
a)
b)
c)

Chemical name of organic solvent, OAR number, and VOC content in g/l;
Percentage of low molecular epoxy (molecular weight < 700);
Content of hazardous substances;

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d)
e)
f)
10.5

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Specification of hazardous thermal degradation components;


Combustibility;
Special handling precautions and personal protection.

Use of Personal Protective Equipment (PPE) shall be mandatory to avoid any


incident / accident / health hazard during blasting and painting activities.

ATTACHMENT
11.1

Attachment 1

Blasting and Painting Inspection Report

11.2

Attachment 2

Proposed Paint Technical Datasheet

Table 1 - Inspection & Testing


Test Type
Environmental
conditions

Method
Ambient and steel
temperature,
relative humidity,
Dew point
Visual for sharp
edges weld
spatter, slivers,
rust grade etc
a) ISO 8501-1
b) ISO 8502-3

Frequency
Before start of
each shift and
minimum twice
per shift
100% of all
surface

Acceptance Criteria
In accordance with
specified
requirements

Consequence
No blasting or
coating

No defects, see
specified
requirements

Defects to be
repaired

a) 100% visual all


surfaces
b) Spot checks

Salt test

ISO 8502-6 and


ISO 8502-9

2 every 1m2

a) In accordance
with specified
requirements
b) Maximum quantity
& size is rating 2
Soluble salts (NaCl)
less than 3mg/cm3

Roughness

Comparator or
stylus instrument
ISO 8503
ASTM D4752

Each component
or once per 10m2

a) Re-blasting
b) Re-cleaning
and retesting
until
acceptable
Repeated
washing with
potable water and
retesting until
acceptable
Re-blasting until
acceptable

Visual
examination
Cleanliness

Curing test

Each component

In accordance with
specified paint
system
Rating 4-5

Allow to cure

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(for Zn silicate)
Visual
examination

Wet film
thickness (WFT)

Visual to
determine curing,
contamination,
solvent retention,
pinholes/popping,
sagging and
surface defects
SSPC-PA2

Dry film
thickness (DFT)

SSPC-PA2

Adhesion

ASTM D4541
(on test panel)

or once per
100m2
100% of surface
after each coat

Systematically
during any
application
Each coat, when
coating system
are cured
Spot checks
when coating
system are cured

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In accordance with
specified
requirements

Repair of defects
and retesting

In accordance with
specified paint
system
In accordance with
specified paint
system
Minimum value
3 Mpa

Repair or recoating as
appropriate
Repair or recoating as
appropriate
Coating to be
rejected

Table 2 Painting system for carbon steel substrate


Surface Material
Carbon Steel
Application
External
Painting System No
3.1
Paint Manufacturer
BAJAK
Coat No
Paint Type
1
Self-cured Inorganic Zinc
(Primer)
2
Epoxy High Build (Tie oat)
3
Aliphatic Polyurethane
(Top Coat)

Operating Temp
Part
Insulation
Surface Preparation
Paint Product

N/A
SA 2 and above
Color

BAJAPOX ZINC 15360L

Red-grey

BAJAPOX HI-BUILD 45200

grey
* White/Blue

BAJATHANE *
TOPCOAT 55210

Total DFT

DFT
75
100
50
225

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