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APPD

Standard Specification Committee


Based on new development & technology with the
consent of designated committee

Volume-1
01-GEMSS-M-01
Steam Turbine and Auxiliary Equipment

ORIGD

GEMSS-M-35
Revision No. 01
Painting and Coating Protection System

DESCRIPTION

VOLUME - 1

PROPRIETARY INFORMATION
This document contains proprietary information developed by and for exclusive use of
Saudi Electricity Company. Your acceptance of the document is an acknowledgement
that it must be used for the identified purpose/application and during the period indicated.
It cannot be used or copied for any other purposes nor released to others without prior
written authorization of Saudi Electricity Company. Saudi Electricity Company will not be
responsible for misuse and/or misapplication, and any harm resulting therefrom. Saudi
Electricity Company also reserves the right to take any necessary actions to protect its
interest against unauthorized use.

3.

2.

1.

DATE
NO.

GENERATION ENGINEERING & MATERIALS STANDARD SPECIFICATION

CERT.

REVISIONS

Document Responsibility:
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Originated By

Certified By

Approved By

Abdul Rahim Al Harbi

Khaled S. Al Rashed

Tariq M. Al Tahini

Division Manager
Generation Projects
Engineering & Design

Department Manager
Generation Projects
Engineering

Executive Director
Generation Engineering &
Projects

Date:-

Date:-

Date:-

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01-GEMSS-M-01
Steam Turbine and Auxiliary Equipment

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Generation Engineering & Materials


Standard Specifications
GEMSS-M-35 Rev 01
Painting and Coating Protection System
Document Responsibility:- Engineering and Design Division

Volume - 1

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Table of Contents
1.0

GENERAL DESCRIPTION---------------------------

2.0

SCOPE--------------------------------------------------

3.0

APPLICABLE CODES AND STANDARDS---------

4.0

DESIGN CRITERIA AND SYSTEMS


DETAILS------------------------------------------------

5.0

MATERIALS--------------------------------------------

6.0

GENERAL TECHNICAL REQUIREMENT----------

6.1

Painting and Coatings----------------------------------------------

6.1.1
6.1.2

Fuel oil tanks internal coatings---------------------------------Water tanks internal coatings------------------------------------

6.2

Galvanizing-----------------------------------------------------------

6.2.1
6.2.2
6.2.3
6.2.4
6.2.5

General---------------------------------------------------------------Preparation and repair--------------------------------------------Protection of galvanized surfaces------------------------------Sprayed metal coatings------------------------------------------Pipe service identification-----------------------------------------

6.3

Inspection and quality control------------------------------------

6.3.1
6.3.2
6.3.3
6.3.4
6.3.5
6.3.6
6.3.7

General---------------------------------------------------------------Inspection instruments--------------------------------------------Inspection stages---------------------------------------------------Measurement of thickness---------------------------------------Adhesion tests------------------------------------------------------Holiday detection---------------------------------------------------Rejection---------------------------------------------------------------

6.4

Warranty period------------------------------------------------------

6.5

Documentation and records--------------------------------------

7.0

MISCELLANEOUS REQUIREMENTS-------------

7.1

Instrumentation and Control System-------------------------

7.2

Electrical System--------------------------------------------------

7.3

Field Quality Control----------------------------------------------

8.0

TECHNICAL SCHEDULES/ DATA SHEETS


---------------------------------------------------------

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1.0

Volume - 1
GEMSS-M-35 Rev 01
Painting and Coating Protection System

GENERAL DESCRIPTION

All material and equipment shall be effectively protected against corrosion during transit and
while being stored at site. All materials and equipment shall be protected by the application of anti-corrosion
agents in a mineral-oil base.
The CONTRACTOR shall ensure that the design engineering, selection and supply of materials,
fabrication, construction, installation, inspection, testing, performance and operation of all the systems
comply with the latest rules, regulations, standards and codes.
2.0

SCOPE

This Specification provides for the design, manufacture, construction, supply, testing in works,
packaging for export, shipping, transport, delivery to Site, unloading at Site, complete erection, painting,
commissioning and putting into normal operation, performance and reliability testing on completion and
instruction of the Companys personnel for the Painting and coating Protection System, which are common to
all systems, plant and equipment being provided under the Mechanical Equipment and Material
specifications and all obligations during the defects liability period as stipulated in the Conditions of Contract.
All equipment, spare parts and materials used in the construction of the plant shall be new and unused.
This Specification describes the technical requirements for the design, manufacture, furnishing,
delivery, and testing of the painting and coating protection systems.
3.0

APPLICABLE CODES AND STANDARDS

For general requirements relating to codes and standards, please refer to Section 3 of GEMSSG-01 and other more specific codes and standards are listed within the text of this specification.
Material supplied from Europe shall be designed, manufactured and tested to MANUFACTURER
drawings, procedures and processes that are in general compliance with applicable sections of the European
industry codes and standards effective on the date of the proposal.
Where conformance to other supporting codes and standards is required in the above listed
documents, the latest editions (at the time of award) of these supporting codes shall apply. Other applicable
design codes and standards that are used by the manufacturer, such as International Organization for
Standardization (ISO), that govern the design and manufacture shall be subject to review by the COMPANY.
In the event of conflict between codes, or the technical specifications and codes, the more
stringent requirement shall apply.
4.0

DESIGN CRITERIA AND SYSTEMS DETAILS

Painting and coating systems shall be applied in the manner and sequence specified by
individual manufacturers and in alignment with relevant international standards.
Materials and equipment required for a complete and functional painting and coating protection
system shall be provided.

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GEMSS-M-35 Rev 01
Painting and Coating Protection System

The design, manufacture, inspection,testing of the painting & coating material and work shall
be in accordance with the requirements and recommendations of all appropriate internationally recognized
and accepted Codes and Standards.
The design and construction shall conform, in all respects, to the highest standards of
engineering design and workmanship. The system shall be designed, constructed and installed such that
every reasonable safeguard and provision for the safety of all personnel concerned with the construction,
commissioning, operation and maintenance of the equipment is incorporated.
The design, construction and installation of the system shall be carried out under the
consideration of maximizing the continuity of supply, availability of service and reliability.
5.0

MATERIALS

Materials shall only be sourced from reputable international manufacturers and shall be suitable
for the environment and substrate to and in which they are applied.
Reliability and simplicity of operation are of utmost importance. First class and new materials
shall be used, best workmanship applied, conservative stress levels employed, sufficient clearances
provided, and the latest proven design philosophy shall be applied.
All equipment and components shall be new and designed and manufactured for the specific
purpose for which they shall be used within the plant.
The design, manufacturer and application of the system shall be such as to minimize the risk
of the outbreak of fire and to minimize the potential and consequential injury to personnel and damage to
equipment.
Details of design and materials of the complete system are to be stated in the Tender.
A full list of proposed painting and coating materials shall be supplied to the Company / Engineer
for approval.
6.0

GENERAL TECHNICAL REQUIREMENT

6.1

Painting and Coatings

All surfaces to be protected shall be coated in accordance with the requirements


ISO 12944:2007. Preparation grade for surfaces shall be a minimum of Sa 2. Blast cleaned surfaces shall
be primed within a maximum period of 4 hours following blasting. Temperature of steel surface during dry
blast cleaning and until prime coat is applied shall be more than 3C above dew point of surrounding air.
All exterior surfaces, including aboveground pipework, shall be coated with a paint system of
high durability (>15 years) and appropriate to a C5-I (very high industry) or C5-M (very high marine)
environment as appropriate and applicable per scope of work as per site location. Interior surfaces shall be
coated with a system of high durability (>15 years) and appropriate to a C4 environment. Buried and
immersed steel surfaces (where coating is appropriate) shall be coated with a coating of high durability (>15
years) coating appropriate to Im2 or Im3 standard.
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Painting and Coating Protection System

Paint materials shall be stored at a temperature according to the manufacturers


recommendations and in no circumstances at more than 35C.
Temperature of surfaces to be painted shall not exceed 38C, relative humidity not more than
85 per cent. For two component epoxy paints, temperature of paint, surface and atmosphere shall be
between 15C and 30C at time of application and relative humidity shall be not more than 80 per cent.
Painting in general shall be according to the manufacturers instructions.
High temperature and intumescent coatings of hydrocarbon type fire shall be considered and in
accordance with manufacturers guidelines.
SEC logo shall be painted on all liquid storage (oil and water) tanks of capacity 10,000 litres and
larger.
The method of application shall be to the approval of the Company and shall be taken to ensure
mechanical and electrical compatibility with the factory applied coating and the cathodic protection system.
Contractor shall provide a full paint and coatings schedule to demonstrate the adequacy of the
provision. Contractor shall submit to the Company six (6) sample chips (100 150 mm size) of each colour
and finish on the type of surface specified. Colours shall be indicated on the paint and coatings schedule.
6.1.1

Fuel oil tanks internal coatings

The tank internals and associated access steelwork shall be painted in accordance with the
following painting requirements.
Following completion of hydrostatic tests and cleaning of tank internals, the base of the tank and
inside walls up to a height of 2.0 m shall be painted with corrosion resistant paint in accordance with the
following specified painting requirements:
a.

Blast clean to BS 7079 Second Quality (SA 2.5), ISO 12944:1998 equivalent or
technically equivalent USA Standard to a profile of 25-50 micron and thoroughly clean all
surfaces in preparation for the application of paint or sealer

b.

Apply one coat of inorganic zinc silicate primer by airless spray application, preferably
within 2 hours but not more than 4 hours after blasting to a dry film thickness of
65 micron

c.

After surface cleaning and priming apply two coats of glass flake reinforced epoxy to an
overall dry film thickness of 400 micron.

The roof members and plating etc, and internal walls down to 2.0 m below the roof, shall be
finished in white enamel which will help illumination for tank maintenance workers. Painting shall be in
accordance with the above specified requirements, except after surface cleaning and priming the final two
coats shall be white enamel to an overall dry film thickness of 200 microns.

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Painting and Coating Protection System

Similarly, after surface cleaning and priming, the inside walls (2.0 m above floor and 2.0 m below
the roof) shall be coated in accordance with the above specified requirements, except the final two coats
shall be a different shade of white enamel to an overall dry film thickness of 100 micron.
The Tenderer shall supply his intended painting schedule with the Tender.
6.1.2

Water tanks internal coatings

The tank internals and associated access steelwork shall be painted in accordance with the
following painting requirements.
Following completion of hydrostatic tests and cleaning of tank internals, the base of the tank,
inside walls and roof shall be painted with corrosion resistant paint in accordance with the specified painting
requirements.
a.

Blast clean to BS 7079 Second Quality (SA 2.5), ISO 12944:1998 equivalent or
technically equivalent USA Standard to a profile of 25-50 micron and thoroughly clean all
surfaces in preparation for the application of paint or sealer.

b.

Apply one coat of inorganic zinc silicate primer by airless spray application, preferably
within 2 hours but not more than 4 hours after blasting to a dry film thickness of
65 micron.

c.

After surface cleaning and priming apply two coats of glass flake reinforced epoxy to an
overall dry film thickness of 400 micron.

The Tenderer shall supply his intended painting schedule with the Tender.
6.2

Galvanizing

6.2.1

General

Where employed, galvanizing of surfaces shall be in accordance with the requirements of


BS EN ISO 1461 or ASTM A123/A123M-01a. Bolt fixings shall be galvanized in accordance with the
requirements of ASTM A153/A153M-01a.
Preparation grade for surfaces shall be SA 2.
Where the galvanized surface is rendered discontinuous for any reason, the un-galvanized
surface shall be thoroughly cleaned to bright metal and painted to the requirements of BS EN ISO 1461 or
ASTM A123/A123M-01a.
Surfaces, which are in contact with oil, shall not be galvanized or cadmium plated.
The identifying marks on any galvanized parts shall be stamped before galvanizing is applied
and shall be clearly legible afterwards.
Zinc coated fasteners such as nuts and bolts should be lubricated with bees wax or other
suitable lubricant prior to fitting and tightening.
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6.2.2

Volume - 1
GEMSS-M-35 Rev 01
Painting and Coating Protection System

Preparation and repair

The preparation for galvanizing and the galvanizing itself shall not adversely affect the
mechanical properties of the coated material.
All fastenings, which are used for regular inspection and maintenance, must be treated by a zinc
passivation process.
All possible welding, drilling, punching, cutting and bending of parts shall be completed and all
burrs removed before galvanizing is commenced. Small areas of galvanized coating damaged during transit
and erection or by cutting and welding at Site shall be removed and repaired to the satisfaction of the
Company. Such repairs to the coating will be made by use of either low melting point zinc alloy repair rods
or powders made specifically for this purpose, or, if the galvanized surface is to have paint finish, by the use
of at least two coats of good quality zinc-rich paint.
6.2.3

Protection of galvanized surfaces

If, on Site, any galvanized surfaces are to be externally visible, the Contractor shall take
precautions to avoid wet storage staining of freshly galvanized articles during transport or storage.
6.2.4

Sprayed metal coatings

Sprayed metal coatings shall comply with BS 2569 Part I Protection of Iron and Steel by
Aluminium and Zinc Against Atmospheric Corrosion for surfaces at Ambient Temperatures and with BS 2569
Part 2 Protection of Iron and Steel Against Corrosion and Oxidation at Elevated Temperature for Hot
Surfaces or alternative international equivalent standards.
6.2.5

Pipe service identification

A pipe service colour identification and banding scheme shall be used to identify pipework
included within this Contract. The identification requirements and colours employed for piping and
equipment shall be in accordance with the requirements of Saudi Electricity Company, BS 1710 and BS 4800
respectively.
Colour bands shall be painted on piping at reasonable intervals, on pipe bends at all changes in
direction and on each side of all valves and equipments on the piping systems. The use of adhesive-backed
colour bands is not permitted.
Pipework shall be provided with plentiful large painted arrows and/or other secure and durable
arrow markings to allow the flows of fluids around the plant to be readily understood.
6.3

Inspection and quality control

6.3.1

General

All surfaces that are to be painted shall be inspected by the Contractor before and after the work
is carried out.

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Painting and Coating Protection System

The Company shall have access at all times to the place where the work is being carried out and
to the records.
Contractor Inspector shall inform the Company of any deviations from the paint manufacturers
instructions or from this specification and the Company shall decide on the action to be taken.
All stages of preparation, application and repair shall be subject to the Companys approval.
Surface finish and condition prior to application of any protective, wet and dry film thickness checks and
continuity checks shall be carried out by Contractor. The Final Certificate will not be issued until all
paintwork, protection, finishes, surfaces etc satisfy the Company.
In addition to visual inspection it is expected that checks of paint dry film thickness, continuity
and uniformity will be carried out by Contractor, on all painted and protected surfaces and the equipment and
procedures proposed should be detailed and submitted to the Company for approval.
6.3.2

Inspection instruments
Contractor shall provide the following instruments for inspection purposes:
a.

Humidity gauges

b.

Surface thermometers

c.

Visual colour code standards in accordance with BS 1710 (BS 4800) or equivalent
international standard

d.

Visual standards in accordance with SIS 05 59 00 (BS 7079 substrate surface condition)

e.

Surface roughness gauges

f.

Dry and wet film thickness gauges

g.

Detector for film defects (such as pitting, cracks, lack of adhesion, etc)

h.

Viscosimeters

i.

Holiday detector (LV to ASTM G62 - 85 method A - Non Destructive).

Each test instrument shall be calibrated, be tagged with a series number and shall indicate the
data calibration.
6.3.3

Inspection stages

The inspection of coats, both in the workshop and at site, shall include all stages of work that
may affect the behaviour of paints. The following shall be inspected as a minimum:
a.

The means used for the preparation of surfaces and the storage, mixing, application and
curing of paints. This will include the cleaning conditions and suitability of all the tools
and instruments to be used to carry out this work
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Painting and Coating Protection System

b.

Reception of materials. This will include inspection of the containers, the documentation
that goes with them and the storage conditions

c.

Suitable ambient conditions both in the preparation of surfaces and the applications of
paints

d.

The substrate, before and after the preparation of the surfaces. If shall be inspected in
accordance with SIS 05 59 00 and the applicable SSPC. A record shall be made of the
surface condition before and after preparation

e.

Preparation, mixing and application of each of the specified paints and coats, in
accordance with the paint manufacturers instructions

f.

After a surface has been painted, a visual inspection of the state of the surface shall be
carried out with respect to:

g.

Pitting

h.

Blisters

i.

Uniformity of colour and gloss (finish paints only)

j.

Scratches and buckling

k.

Dry film thickness

l.

Film uniformity

m.

Surface contamination

n.

Mechanical damage

o.

Adhesion (if there is any fault or if the inspector finds it necessary)

No defects or changes in the specified paint thickness shall be permitted.


6.3.4

Measurement of thickness

Thicknesses shall be measured with suitable instruments (magnetic gauges) and in accordance
with that stipulated in SSPC-PA-2. In no case shall a measurement at any point (average of three readings)
be less than 80 per cent of the specified thickness. Coat thicknesses greater than 1.3 times that specified
shall be permitted only with the written approval of the paint manufacturer.
6.3.5

Adhesion tests

In accordance with ASTM D3359 method A, sample panels are required to carry out paint
adhesion tests for surface paints in contact with process fluids. An adhesion grade of 4A to 5A must be
obtained in accordance with the above standard.

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6.3.6

Volume - 1
GEMSS-M-35 Rev 01
Painting and Coating Protection System

Holiday detection

Coated surfaces intended for immersion or buried service shall be tested with a low-voltage
holiday detector to verify the absence of pin-holes and holidays and to assure the continuity of the film. Low
voltage to ASTM G 62-85 (Method A - Non Destructive).
6.3.7

Rejection

Surfaces whose coating and/or paint application do not comply with the requirements of this
specification and any applicable reference standards shall be rejected.
6.4

Warranty period

The warranty period for coatings with regard to defects and/or compliance with the specified
conditions shall be five (5) years.
The paint systems in this section are specified as High Durability (>15) years according to ISO
12944 for the relevant environment. ISO 12944 specifies that the >15 years high durability is indicative that
the coating system will last for >15 years before the first major maintenance for corrosion protection reasons
will be required. The first major maintenance occasion is defined as when the coating has deteriorated to
Ri3 according to ISO 4628-3 which is >1 per cent of the surface rusted. Because this period is extensive a
shorter warranty period based on a superior degradation performance is required as outlined below.
The warranty period shall begin as of the time of acceptance of a component by the Company.
A coat shall be considered as having passed the warranty period when at the end of such period,
the rust on the surface does not exceed grade Ri1 (<0.05 per cent of the rusted surfaced) of ISO 4628-3
Paints and Varnishes Evaluation of degradation of coatings Designation of quantity and size of defects
and of intensity of uniform changes in appearance Part 3: Assessment of degree of rusting.
If during the warranty period defects are detected which Contractor is obliged to repair, once the
repairs have been carried out the warranty period will begin again and shall be extended to a maximum of
one (1) year following expiry of the original warranty period defined above. Repairs shall not affect the
scheduling of other work to be carried out.
The reasons for premature failure of a coating system are numerous and are advised in ISO
12944-5 (2007). However, they can be categorized into two categories of failure the first being due to the
coating system and the second due to surface preparation and application. In order to better define the
quality of the paint system and if necessary identify the reason for premature failure the contractor may at his
discretion create one or more reference areas as defined in Annex B of ISO 12944-8. The reference areas
prepared with witnesses from interested parties as described in Annex B of ISO 12944-8 shall subsequently
be used to monitor the degradation of the paint system and more readily identify the reason for any failure.
The reference areas will not however absolve the contractor from his obligation to warranty total painted
areas as described earlier in this section.
6.5

Documentation and records

The Contractor is responsible for keeping a record of all the documentation required. This
documentation will include the following:
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7.0

a.

Surface Preparation and Painting

b.

Repairs

c.

Acceptance of Painting

d.

Daily record of work carried out

e.

Inspection record.

Volume - 1
GEMSS-M-35 Rev 01
Painting and Coating Protection System

MISCELLANEOUS REQUIREMENTS

One sets of Manufacturer's recommended special tools shall be provided with the package.
Local instruments for paint thickness measurement and set for holiday detection inspection shall be
provided.

7.1

Instrumentation and Control System


Not applicable in this case.

7.2

Electrical System
No special electrical facilities or requirements are anticipated for the painting and coating

systems.
7.3

Field Quality Control

The CONTRACTOR shall submit for approval a comprehensive quality control plan covering the
quality contrl inspection, testing activities . This document shall identify the degree of inspection and testing
to be carried out by his personnel.
Field Quality Control shall be managed in accordance with specification GEMSS-G-03 Factory
Inspection and Testing and specification GEMSS-G-05 - Quality Control and Quality Assurance.
8.0

TECHNICAL SCHEDULES/ DATA SHEETS

Technical Schedules and data sheets shall be filled and submitted along with the proposal for
COMPANY / Engineer review. (Please refer to Volume 2 )

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