IOCL Painting Manual & Colour Code - June - 2015

IOCL Painting Manual, Rev.
-1, June 2015
CHAPTER-1
1.0 INTRODUCTION
1.1 CORROSION AND ITS PREVENTION
Corrosion is natural phenomena of metals and alloys. It has highest

importance for safety, security and financial aspects of the country. Corrosion
costs heavily to our society. The financial impact of corrosion can be gauged
from the fact that the annual cost of corrosion world-wide, estimated at US $
2.2 trillion, is over 3% of the worlds GDP. If we calculate total corrosion cost
of India based on that data, it will be enormous. Corrosion also causes
industrial accidents. It is our responsibility to spread awareness about
importance of corrosion control in India and our industry in particular. Metallic
corrosion which is due to the metal-environment reaction involves
electrochemical reactions at the metal / environment interface. The most
effective cost economic method to hinder the metal-environment reaction and
thereby controlling the losses against corrosion is by painting, if adopted
efficiently. Corrosion prevention is very crucial for a plant/industry since it has
a bearing on the life expectancy of the equipments and consequently on the
general condition of the plant.
The mechanism of corrosion is explained on the basis of the operation of

micro-galvanic cells on the metal surface, leading to the oxidation (dissolution)
of metal at the sites having more negative potential sustained by the same
magnitude of a reduction (hydrogen evolution or oxygen reduction) at the sites
having less negative potential.
The origin of the micro-galvanic cells can be traced to such factors as metal
inclusion, presence of different phases, presence of grain boundaries, surface
defects, concentration cells, temperature differences, velocity changes and
stresses, both residual and applied.
Certain corrosive agents in petroleum products cause corrosion depending on

their concentrations in the products. Crude oil for example, can cause
extensive corrosion damage, especially when water separates from oil into
the bottom of the storage tanks. Micro biological corrosion in circulating water
systems can cause severe corrosion at water side of coolers/ condensers and
piping. Atmospheric corrosion depends on temperature, relative humidity,
solar radiation / sunshine hour, amount of rainfall, wind direction, velocity and
Developed by M&I, RHQ, New Delhi Page 1 of 133

IOCL Painting Manual, Rev.-1, June 2015
other pollutants like chloride, sulphur-dioxide etc, in the atmosphere. The

major factors influencing underground corrosion of buried equipments and
piping are porosity, electrical resistance, dissolved substances, moisture,
stray current and bacteria present in the soil.
Corrosion can be mitigated through a number of ways like proper designing,

use of corrosion resistant materials, use of cathodic protection system,
corrosion inhibitors and surface painting / coatings. Among the corrosion
control techniques, the application of painting/ coating remains the most
convenient and widely used technique for mitigation of corrosion.
The broad category includes all types of coatings such as metallic, organic
and inorganic coatings intended for corrosion protection. The use of
organic/surface/protective coatings to isolate the metal from a corrosive
atmosphere has long been used successfully for reasons of their low cost,
ease of application, suitability to almost all structures and all environments
and to some extent its aesthetic appeal.
1.2 ATMOSPHERIC CORROSIVITY MAP OF INDIA
Figure 1.1: Atmospheric Corrosivity Map of India
The paint system for protection of equipment and piping from atmospheric
corrosion largely depends on the atmospheric corrosivity of the location. The
atmospheric corrosivity map of India as shown in Figure 1.1 denotes the
location of the refineries of IOCL and subsidiaries with respect to the extent of
atmospheric corrosion. The map shows Haldia, Paradeep and CPCL
Refineries are located in the extremely severe atmospheric corrosion zone
and hence, require special protection considerations. Guwahati, Digboi,
BRPL, Barauni and Koyali (Gujarat) Refineries fall in the severe/ moderate

atmospheric corrosion zone while Mathura and Panipat Refineries fall in the
moderate/ mild zone.
Similarly, the pumps stations of Pipelines and Marketing installations also are
spread over the length & breadth of the country and fall in different corrosive
zones. Accordingly, a city wise classification of two zones namely extremely
severe corrosive and moderately corrosive has been prepared and enclosed
at Sl. No. 1.4, for ready reference.
1.3 SELECTION OF PAINT SYSTEM
Application-wise the paint system can be classified into the following types:
i) Paints for protection against external environment

ii) Paints for protection against internal environment
iii) Paints for protection against soil side corrosion
The paints/ coating systems for protection against external environment

largely depend on the atmospheric corrosivity of the zone and the location of
the equipment to be protected. Increased external corrosion has been
observed in the vicinity of the cooling towers, in the handling areas of toxic
chemicals and acids etc.
The paints/ coating systems for protection against internal environment like
petroleum products, circulating water, chemicals depends mainly on the type
of the material which is stored or transported, the amount of impurities and
other constituents, velocity, process conditions etc.
The coatings systems for protection against soil side corrosion of

underground lines, buried/ mounded vessels etc are wrapping and coating/
coal tar, tape coatings, cement lining, fusion bonded epoxy coatings, three
layer polyolefin coatings etc.
The continuous research and development in the field of paint and coatings
have lead to commercialization of specialized paint systems with improved
service life, reliability and resistance to degradation. Selection of coating for
protection of equipment and piping is of prime importance and should be
continuously updated and revised based on field performance and newer
developments. Apart from the basic function of protection against corrosion,
paints/ coatings are now being developed for specific purposes like fire
protection, warning tool etc. Specialized thermo indicative paints are being
used not only for corrosion protection but also indicates the possible internal
refractory damage causing increase in skin temperature of critical cold wall
equipments.
1.4 CLASSIFICATION OF ZONES
Based on the corrosion rates collected by CECRI and the field experience of
IOC Engineers, the different stations are divided into two zones as follows:

ZONE - A
EXTREMELY SEVERE CORROSIVE ZONE
Calcutta Haldia Visakhapatnam
Kandla Chennai Tuticorin
Narimanam Cochin Cannanore
Feroke Quilon Trivandrum
West Hill Calicut Mangalore
Karwar Berhampur Paradip
A&N islands Mumbai Goa
Okha Jamshedpur Durgapur
Dhanbad Tatanagar Rourkela
Surat Jamnagar Porbandar
Sambalpur
ZONE - B
MODERATELY CORROSIVE ZONE
Siliguri Bongaigaon Malda
Cuttack Jorhat Guwahati
Bhubaneshwar Panbari Missamari
Duliajan Chabua Tinsukhia
North Lakhimpur Tezpur Doom Dooma
Agartala Arunachal Pradesh Mohanbari
Khumbigram Sikkim Rangpo Manipur
Tripura dharmanagar Dhula Loni
Nagaland dimapur Renigunta Manmad
Aurangabad Belgaum Triunelveli
Rajamundry Neyveli Hubli
Allahabad Kanpur Mugalsarai
Mathura Bhavnagar Bareilly
Gorakpur Jhansi Lucknow
Meerut Moradabad Varanasi
Delhi Jaipur Ajmeer
Bharatpur Kota Udaipur
Basti Gonda, Hiskar Patna
Bhagalpur Ranchi Akola
Bhitoni Sholapur Jadali
Nagpur Baroda Ahmedabad
Rajkot Bhilai Bilaspur
Bishrampur Gwalior Itarsi
Jayant Mangaliagaon Nishatpura
Bhopal Ratlam Salna
Indore Cuddapah Coimbatore
Erode Salem Sankari
Trichy Vilangudi Madurai
Pune Pimpri Nasik
Palghat Bangalore Bijapur
Mysore Shimoga Yellahanka

ZONE - B
MODERATELY CORROSIVE ZONE
Jammu Srinagar Awantipur
Ambala Rajpura Bhatinda
Jalandhar Amritsar Patiala
Pathankot Chandigarh Jodhpur
Bikaner Jaisalmar Nal
Shimla Hanumangarh Kargil
Kotkapura Guntakal Nizamabad
Hyderabad Raichur Bidar
Baddi Warangal Tadepalli
Agra Digboi Barauni
Panipat Mathura

CHAPTER-2
2.0 BASICS OF PAINTS AND COATINGS

2.1 CORROSION PROTECTION THROUGH PAINTS/ COATINGS
There are various methods practiced for mitigation of corrosion, of which, the
most effective, economic and very widely practiced technique is protection by
coatings or paints which can be very easily adopted, repaired and properly
maintained compared to other techniques practiced in industrial applications.
About 80% of corrosion protection achieved worldwide is through application
of paints / coatings. The history of painting dates back to about 15000 BC as
evident from the cave paintings. Late 18th century saw the emergence of paint
and varnish industry. In 19th century, mechanization of the paint
manufacturing process was started. The beginning of 20 th century saw the
industrial production of synthetic resin. Since then, more sophisticated coating
materials and systems have been developed and today a number of useful
and high performance coating systems are available for corrosion protection.
2.2 MECHANISM OF PROTECTION
The mechanism of protection through paints / coatings can be different for

different paint systems. The protective mechanism of the coatings can be
explained by the following:
2.2.1 Barrier Mechanism
This is the most general and popular mechanism of protection by paints,

which is achieved by applying a barrier film of very high electrical (ionic)
resistance between the metal and the corrosive environment.
Figure 2.1 : Mechanism of Barrier Protection

The barrier film impedes the movement of ions thereby preventing flow of
corrosion currents. The ions cannot pass between anodic and cathodic areas
and hence corrosion is prevented. Highly cross-linked polymer films have the
highest ionic resistance, e.g., epoxy, polyester, polyurethane, phenolics etc.
Obviously ionic resistance increases with paint film thickness. Figure 2.1
shows the mechanism of barrier protection by organic coatings. The main
barrier effect is provided by the thick undercoat which reduces the quantity of
moisture that penetrates through the coating and also being a thick barrier
suppresses reaction between oxygen and the substrate called the cathodic
reaction. By being a cross linked polymer material, it offers resistance to the
flow of corrosive ions like chlorides and sulphates to the substrate and
reduces the penetration of moisture through the film.
2.2.2 Inhibitive / Passivation mechanism
The inhibitive / passivation mechanism uses anti-corrosive / inhibitive

pigments which offer inhibition to corrosion at the coating-metal interface.
There are many known inhibitive pigments e.g. red lead, lead silico-chromate,
calcium chromate and zinc phosphate. They leach or dissolve in the moisture
and produce a passive layer over the steel surface which retards the anodic
reaction, thus inhibiting the corrosion process. But today only the zinc
chromate and zinc phosphate pigments are in use, the others being phased
out due to environmental considerations. Figure 2.2 shows the mechanism of
protection by inhibitive primers.
Figure 2.2 : Mechanism of Protection by Inhibitive Primers
2.2.3 Sacrificial mechanism
The sacrificial mechanism works by use of metallic pigments for sacrificial

type cathodic protection in primers. The primer is of a sacrificial nature,
containing fine zinc powder as pigment in an organic or inorganic medium
(called organic or inorganic zinc rich). The zinc present at the interface being
anodic to steel becomes the anode and dissolves itself preferentially and

protects the steel. This is the sacrificial cathodic protection. The popular
primers for such uses are zinc ethyl silicate primer (inorganic zinc rich) and
organic zinc rich primers based on epoxies, polyurethanes and chlorinated
rubbers. The two processes of working of inhibitive and sacrificial primers at
the coating-metal interface can be termed as suppression of anodic reaction.
The zinc rich primer may be an organic or inorganic type. Zinc, being anodic
to steel protects the steel by sacrificing itself. Zinc supplies electrons and
suppresses the anodic reaction of steel thus protecting steel. The inorganic
system, due to higher conductivity, is more effective in getting sacrificial
protection and also it can withstand higher temperatures compared to organic
systems. Figure 2.3 shows the mechanism of protection by sacrificial
mechanism.
Figure 2.3 : Mechanism of Sacrificial Protection
2.2.4 Working of a Multi-coat Protective Coating System
A multi-coat protective coating system predominantly consists of:
i) An anticorrosive primer containing either an inhibitive or a sacrificial

pigment
ii) A thick undercoat of a cross linked polymer system optionally with a
pigment
iii) An UV resistant topcoat.
A paint scheme consisting of a primer, undercoat/s and topcoat, utilizes the

advantages of all the three types of mechanisms of protection described
above and provides protection in a corrosive environment.

2.3 PAINT CONSTITUENTS
Paint is a complex liquid coating material composed of pigments, binders and

other additives. When applied to a surface, the liquid is changed to an
adherent solid coating over the substrate. The main constituents of a liquid
paint can be grouped in to four broad categories:
i) Binders
ii) Pigments
iii) Solvents
iv) Additives.
2.3.1 Binders
Binders otherwise called film formers are the resinous materials of complex
organic polymers. They hold together the other ingredients and form the
continuous film adherent to the substrate. They are usually modified with
plasticizers and catalysts to improve film properties such as gloss, durability,
adhesion, corrosion resistance, weather - resistance, flexibility etc.
The commonly employed generic types of resins along with the resistance
characteristics in different atmospheric conditions are alkyd resins, vinyls,
chlorinated rubber, epoxies, coar tar epoxies, phenolic linings, urethane
coatings and polyesters.
2.3.2 Pigments
Pigments are finely divided, insoluble solid particles that are dispersed in the
binder and remain suspended in the binder after film formation. The role of
pigments in the paint coatings is:
i) to provide color and reinforcement

ii) to hide the surface
iii) to decrease the permeability of the film
iv) to provide rust inhibiting characteristics
v) to protect the film from the effect of ultraviolet light and weathering.
Pigments used in the paint industry may be divided into two broad groups:
i) Main pigments
ii) Extenders.
Main pigments determine the function of the coating (primer, undercoat,

topcoat etc.). They once again may be divided into three categories:
i) Inhibitive pigments e.g. red lead, zinc chromate, zincs phosphate etc.
ii) Inert pigments e.g. micacious iron oxide, titanium dioxide etc
iii) Metallic pigments e.g. aluminum, zinc dust etc

Extenders are inert pigments usually inexpensive and of low refractive index,
that are added to the paint to modify its properties and to reduce costs. The
extenders may be used for lowering the paint cost, increasing pigment
volume, better brushing, consistency control, increasing toughness and
reducing permeability, settling tendency etc. Most widely used extenders are
silica, mica, talc, china clay etc.
2.3.3 Solvents
Solvents are organic liquids which dissolve or disperse the film former.
Solvents reduce the solution to the proper solids and proper viscosity. For
different binders, different solvents are used. Normally a mixture of solvents is
used. In addition to the solvents already in the paint, so called diluent solvents
(thinners) are also used to give the paint a viscosity that makes it easier to
apply.
2.3.4 Alkyd Resins
Alkyd resins are the reaction products of polyfunctional alcohol with polybasic
acids. The function of acid is to link the polyol units into a linear structure.
Obviously the characteristics like hardness, solubility etc. are introduced as a
result of molecular structure. The function of polyol appears mainly to provide
site for further chemical or physical modifications to the system.
Colour and exterior durability contribute greatly to the extensive use of alkyd
resin through their resistance to water and alkali is not very high.
2.3.5 Vinyls
Vinyls are lacquer type coatings that could be readily touched up or recoated
after weathering. They are resistant to acid and alkali and have good weather
resistance properties.
2.3.6 Chlorinated rubber
These coating form fairly high build coatings and like vinyls could be easily
repaired. They have good low temperature application. They are resistance to
acid, alkali, water and have good Weather - resistant properties. They exhibit
poor solvent resistance.
2.3.7 Epoxies
Chemically cross - linked epoxies usually come in two packages: the first
usually consists of epoxy resin, pigments, and solvents and the second is the
copolymer curing agent. The two packages are mixed immediately before
application and upon curing, develop the large macromolecular structure. The
properties of the epoxy coating derive both from the type and molecular weight
of the epoxy resin and from the copolymer curing agent that is used to

crosslink with it.
2.3.8 Epoxy Resins
For industrial maintenance coatings, the most common epoxy resin is the di -
glycidyl ether type particularly that is derived from bisphenol - A and
epichlorohydrin. The molecular structure of this type of epoxy resin is shown in
figure 4.
Cycloaliphatic epoxides have been developed that offer improvements in light

stability and resistance to ultra violet degradation, but do not exhibit the
adhesion, chemical resistance and flexibility of the resins derived from
epichlorohydrin and bisphenol - A. Epoxy - cresol - novolacs have also been
introduced and they are said to provide greater high - temperature resistance
and chemical resistance at the expense of brittleness and a lack of flexibility.
2.3.9 Co-polymer curing agents
Although epoxies are generally considered as catalyzed, the crosslinking

reaction is in fact a copolymerisation. The reaction occurs primarily through the
epoxy ring endgroups or the mid - chain hydroxyls of the epoxy resin. The
curing agent is usually an amine or polyamide, with crosslinking derived
through the active hydrogen atoms attached to the amine nitrogen. The
reaction of epoxy group with amine group is shown in figure 5.
Figure-5 Reaction of Epoxy group with Amine groups
Although a variety of cross linking agents can be used (including mercaptans,

polybasic acids, anhydrides, phenol - formaldehyde and phenol resins), the

most common are the polyamines, the amine adducts, and the polyamides.
The polymines (for example diethylene - triamine, hydroxyethyl diethylene

triamine, bishydroxydiethylene triamine) are relatively small molecules with a
low molecular weight compared to the epoxy resin. As a consequence, when
reacted they lead to tight cross linking and high chemical and moisture
resistance. However, during the cross linking reaction, any unreacted amine
may be squeezed out of the cross linked film to the surface, developing the so-
called amine blush, a hazy white coloration on the coating surface. The blush
is not detrimental in atmospheric service and can be allowed to remain on the
surface.
However, for immersion service, it is a good practice to wipe it from the

surface (it is water soluble ) before application of a subsequent epoxy coat. To
minimize the formation of the amine blush, many formulators will specify a 15-
30 min. induction period after mixing but prior to application. This allows the
reaction to begin and initial crosslinking to occur before the paint is applied.
Some of the small amine molecules will partially crosslink with epoxy resin
molecules, reducing the tendency toward squeezing out of the smaller
molecules and minimizing amine blush.
Recognizing this problem, many coating manufacturers supply the amine as a

prereacted amine adduct. In this case, the epoxy resin, pigments and
solvents are packed as before in one container, but an excess of the amine is
prereacted with some of the epoxy resin to increase its molecular size. The
pre - reacted amine adduct is then packed in a separate container, sometimes
with additional pigments and solvents. Chemical crosslinking of the resultant
applied film is not considered to be quite as good as that provided by a non -
prereacted amine and the chemical resistance is said to be somewhat lower.
However, application is much easier and not nearly as dependent on through
mixing and induction time of the reactants.
Polymide curing agents are the condensation products of a dimerized fatty

acid (usually tung oil fatty acid) with a polyamine. Terminal amine functionality
allows cross linking to occur as with a straight amine, although the polyamide
molecule is much larger. The cross - linked film has improved flexibility,
improved gloss and flow, excellent water resistance and good chemical
resistance. Polyamide cured coatings, however, have somewhat less solvent
and alkali resistance than amine and amine adduct cured epoxies do.
2.3.10 Coal - tar - Epoxies
Coal tar epoxies are a combination of coal tar combined with an epoxy resin
packed separately in one container. The curing agent is an amine, amine
adduct, or polyamide (as described above) packed in a separate container.
The cross-linking reaction is the same as described above. The coal tar acts
as a filler within the cross - linked epoxy matrix and the resulting film has the
good toughness, adhesion, ultraviolet resistance and thermal stability of the
epoxies, combined with the extremely high moisture resistance afforded by

coal tar. As might be expected, the amine - cured coal tar epoxies generally
have greater chemical and moisture resistance, but are more brittle and harder
to apply and to topcoat than the amine adduct and polyamide cured coal tar
epoxies. On the other hand the polyamide cured coal tar epoxies are more
flexible, easier to top coat, and more tolerant of application variables.
2.3.11 Epoxy - Phenolic Coatings
Phenolic cross - linked epoxy coatings are extremely resistant to acids,

alkalies and solvents and they are widely used as linings for tank cars, drums,
cans, process tanks and equipment. High molecular weight epoxies with a
high proportion of hydroxyl functional groups available for reaction are used.
During manufacture, the epoxy is packed with a phenolic resin (commonly a
phenol - formaldehyde resin), pigment and an acid catalyst. After mixing, the
coating is applied by spraying and it must be baked at temperature from 150 to
2050C in order for cross -linking to occur. Multiple - coat systems require brief
intermediate baking between coats; longer baking times are commonly used
after application of the final coat.
The resulting coatings have excellent acid and solvent resistance associated
with the phenolics as well as the flexibility, adhesion and toughness of
epoxies. Epoxy phenolics have the good alkali resistance of the epoxy
constituent, but straight phenolic linings have very poor alkali resistance.
The crosslinking that occurs is between the hydroxyl groups along the epoxy
chain and the methylol groups present in the phenolic resin. A possible
secondary reaction is the reaction between the terminal epoxide groups of the
epoxy resin and the hydroxyl groups of the phenolic resin.
2.3.12 Phenolic Linings
Phenolic resins are formed by the reaction of phenol with formaldehyde to

form phenol - formaldehyde. The methylol group can react on the two ortho
positions and the preposition on the benzene ring to form phenol -
formaldehydes with functionality (Possible reaction sites) upto 3. Upon
heating, a condensation reaction occurs between methylol groups on adjacent
molecules that crosslink the film and liberate water.
The phenol - formaldehyde resins are usually disolved in alcohol and applied
by spray, dip or roller. The fact that water is liberated during the crosslinking
reaction is important. The coatings must be applied in multiple - coat systems;
each coat approximately 25 m (1 mil thick and must be baked for a few
minutes at 120 to 205 0C between coats. This partially crosslinks the coating,
but more importantly, it volatilizes the water formed during the cross linking
reaction. Subsequent coats are applied and baked until, after the final
application, a postbake at higher temperatures and longer durations is
performed. It is easy to determine when the coating has been baked
sufficiently to ensure proper curing and crosslinking. The phenolic resin
darkens upon heat exposure, and a thoroughly cured coating is relatively

uniform, light chocolate brown in colour.
Because they are odorless, tasteless and non - toxic after full curing, phenolics
are often applied as linings for vessels and tanks used for the processing and
storage of food products. They also have excellent resistance to boiling water
and hot aqueous solutions of mild acids. Thus, they often find application as
linings for steel subject to high temperature freshwater and salt water as well
as acid. A major weakness, however, is the lack of alkali resistance, and
unless phenolic coatings are modified with epoxies, they should not be used
for alkaline service.
2.3.13 Urethane Coatings
Urethane coatings have chemical and moisture resistant properties similar to

those of the epoxies, but they can also be formulated in a variety of light -
stable colors that maintain their gloss upon prolonged exposure. The
chemistry involved in urethane coating curing typically consists essentially of
the reaction of an isocyanate - containing (-N =C= O) material with a
polyhydroxylated (-OH containing) co-reactant (Figure 6) Crosslinking occurs
because of the high reactivity and affinity of the isocyanate group for the active
hydrogen of the polyol hydroxyl or any active hydrogen atom attached to a
nitrogen or oxygen atom. The rate of this cross-linking reaction depends on a
number of factors such as the type and configuration of both the isocyanate
and polyol materials and the temperature. Polyurethanes can cure at
temperatures as below as -180C (00 F).
Figure 6 Urethane Formation
2.3.14 Isocyanate Polyol Urethane
A number of different types of isocyanate materials are used in urethane

coatings. The molecular weight and structure as well as isocyanate
functionality (the number of isocyanate groups available for reaction) can
affect the final properties of the coating. Similarly, different polyol structures,
such as acrylics, epoxies, polyesters, polyethers, and vinyls, when reacted
with a given isocyanate to form a cross - linked polyurethane coating, will
result in variations of physico-chemical properties. Some of the general
properties of the isocyanate and polyol constituents that are coreacted to form
urethane coatings are given below.
The isocyanates are commonly categorized as either aromatic (containing the

benzene ring) or aliphatic (straight - chain or cyclical) hydrocarbons. The first
aromatic isocyanate used in urethane coatings toluene disocyanate (TDI) is

toxic in monomeric form. Hence as such, TDI cannot be used in

polyurethanes. To form a safer, more suitable coreactant, TDI is further
reacted with a trial like glycerol, trimethylol propane to provide a higher
molecular weight polyisocyanate prepolymer with terminal active isocyanate
groups.
These higher molecular weight aromatic isocyanates, when reacted with a

polyol (usually a polyester, polyether, or acrylic), form useful chemical -
resistant coatings that could be cured at low temperatures. However, the
urthanes so formed tend to chalk, yellow, and darken upon exposure to
sunlight.
In the early 1970s, aliphatic isocyanates were commercially developed.

Although they are considerably more expensive than the aromatic
isocyanates, they allow the formulation of non - yellowing, light stable, high
gloss finish coats.
An important aliphatic isocyanate is hexamethylene diisocyanate (HDI). In its

monomeric form, HDI is an irritant, like TDI, however, HDI can be reacted
(commonly with water) to form a larger molecule, called isocyanurate.
Various combinations of aromatic and aliphatic isocyanates can be produced,

including specialty isocyanates, to make high solids or solvent free coatings,
elastomeric coatings, or coatings designed for baking or curing at elevated
temperatures. Specially isocyanates can be either aromatic or aliphatic;
If aromatic, they will discolor. Both straight - chain and cyclical aliphatic
isocyanates, although non-yellowing, are much slower to react and crosslink
than aromatic isocyanates, which can be overcome with the use of catalysts
like dibutyl tin dilaurate, zirconium oxychloride etc.
2.3.15 Polyols
As stated previously, polyols coreact with isocyanates in order to form the

polyurethane film. Accordingly, the polyol is packed separately from the
isocyanate, and the polyol package always contains the pigments, most of the
solvent and any additives used for flow, thixotrophy, anti - setting properties,
and so on. The major properties of the crosslinked urethane film, such as
chemical resistance, toughness, lightfastness, and flexibility, derive principally
from the polyol constituent. Long repeating carbon - to - carbon backbone
chains with little branching (for example, vinyl) result in tough, flexible resins.
Aromatic groups add rigidity to the chain, as does cross - linking. The
presence of numerous ester, ether, and urethane groups reduces chemical
and moisture resistance.
For corrosion protective coatings, the polyol co-reactant is usually one of the
following: acrylic, polyester, polyether, epoxy, vinyl, or alkyd. Asphalts and coal
tars can also be added with any of the polyols. Because they are essentially
non - reactive, however, it is felt the bitumen acts predominantly as a filler in

the urethane matrix, providing the cured coating with the attendant properties
of good chemical resistance, high moisture resistance, and high film build at a
relatively low cost.
Acrylic urethanes are perhaps the most widely used urethanes for corrosion
protection in atmospheric service. These coatings, when properly formulated,
have excellent weather ability, gloss, and color retention and have good
chemical and moisture resistance. They can be readily tinted and pigmented to
provide a variety of deep and pastel colors at a lower cost per kg than the next
most popular class, the polyester urethaness.
Acrylic urethanes are not used for immersion service, and for the most part,
they do not have the chemical resistance of the polyester urethanes. However,
they do have excellent weathering properties when an aliphatic isocyanate is
used.
Because of their high isocyanate demand when co-reacted, polyesters result

in relatively hard chemical resistant polymer films. Impact resistance is not as
great as with the acrylic urethanes, but as a rule, chemical and moisture
resistance are better. However, because ester linkages occur in the molecular
backbone, alkaline attack and water sensitivity may occur at locations where
the ester group is exposed, i.e. at areas of low cross-link density or where less
branching of adjacent molecules occurs. Accordingly, polyester urethanes like
acrylic urethanes are not normally used for immersion service.
2.3.16 Epoxy - Urethanes
The reaction of an epoxy with an isocyanate would seem to be a natural one,

because of the mid - chain hydroxyl functionality of the epoxy molecule.
However, there are very few epoxy - urethanes on the market, and those being
promoted are used predominantly as primers or intermediate coats. This is
due to:
i) The tendency of the epoxy and the epoxy-urethane to chalk
ii) The lower moisture resistance resulting from the urethane link, which
gives a less chemical and moisture resistant polymer than a straight
epoxy coating
iii) The greater expense of a epoxy - urethane compared to a conventional

amine or polyamide crosslinked epoxy.
As a result, most epoxy - urethanes are formulated with the less expensive
aromatic isocyanate and are promoted primarily as low - temperature curing
epoxies or fast curing chemically resistant urethanes for interior use.
2.3.17 Vinyl - urethanes
Vinyl - urethanes use a long - chain linear, hydroxyl - bearing PVC / PVA resin

reacted with a poly functional isocyanate prepolymer. Urethane coatings using

vinyl polyols combine the abrasion resistance of the urethane with the
toughness, flexibility, and chemical resistance of the vinyl polymers. Such
urethane coatings are promoted for use where flexibility and abrasion,
resistance are important. Vinyl urethane coatings, however, are subject to
some chalking or fading upon exterior exposure and do not have the color,
gloss, weather - ability, or solvent resistance of the acrylics and polyesters.
Because the vinyl is thermoplastic and is attacked / softened by solvents, re -
coatability after extended times is not a problem and is a major advantage of
vinyl - urethane systems.
2.3.18 Moisture - Cured Urethanes
Isocyanates can also react with the hydroxyl group in water to form a class of
coatings known as moisture - cured urethanes. single - package moisture
cured urethanes use an isocyanate prepolymer that, when applied, reacts with
the moisture in the air to form a hard, tough, resinous film. Because of their
rapid rate of reaction, aromatic isocyanates are used almost exclusively in
moisture - cured urethanes. The pigments must be essentially non -reactive
with the isocyanate; although it is possible to use a number of pigments,
aluminium leaf is most common. It should be noted that the isocyanate / water
reaction produces gaseous carbon dioxide. In fact, some carbon dioxide is
evolved in the curing of all urethane coatings, because moisture (humidity)
present in the atmosphere reacts with isocyanate rapidly during curing.
In areas where the relative humidity is expected to be low or where assurance

of a more complete cure is necessary, a small amount of tertiary amine
catalyst, such as dimethyl ethanolamine, can be added. This catalyst is
packaged separately from the isocyanate and added just before use. Although
it comes as a two - package system, this type of catalyzed urethane can be
considered to be an extension of a single package moisture cured urethane.
2.3.19 Polyesters
Polyester coating are frequently used with fibre glass reinforcement to impart
strength and rigidity. High build polyester incorporated with glass fibres
produce a tough, durable and abrasion - resistant coating.
2.3.20 Pigments
Pigments are finely divided, insoluble solid particles that are dispersed in the
binder and remain suspended in the binder after film formation. The role of
pigments in the paint coatings is
i) to provide color and reinforcement

ii) to hide the surface
iii) to decrease the permeability of the film
iv) to provide rust inhibiting characteristics and
v) to protect the film from the effect of ultraviolet light and weathering.

Pigments used in the paint industry may be divided into two broad groups viz.
i. main pigments and ii. extenders. Main pigments determine the function of
the coating (primer, undercoat, topcoat etc.) They once again may be divided
in to three categories viz. i. inhibitive pigments ii. inert pigments and iii. Metallic
pigments.
Inhibitive Pigments
The main inhibitive pigments used in paints are red lead, lead silicochromate.
zinc chromate, zinc phosphate, calcium plumbate etc. They are mainly used in
primers. The mechanism of inhibition of corrosion differs from one pigment to
another.
Inert Pigments
The main inert pigments used in the paint industry are red iron oxide,
micacious iron oxide, titanium dioxide etc. They have very good hiding
property.
Metallic Pigments
Metallic pigments normally used are aluminum pigment and zinc dust.
Aluminum pigments are used because of their excellent properties such as
brilliance, durability, high covering and hiding power and high resistance to
atmospheric corrosion. Aluminum pigments are mainly produced by wet milling
in white spirit. There are two major classes of aluminum pigments used in
coatings: leafing and non - leafing pigments.
Leafing aluminum pigments have been surface treated (e.g. with stearic acid)
so that they have a very low surface tension. When a coating containing
leafing aluminum pigment is applied as a result of their low surface tension,
flakes orient at the surface. This gives a bright metallic appearance and,
furthermore, acts as a barrier to permeation of oxygen and water vapour
through the film. As a result of this barrier development, leafing aluminum
pigments are used in corrosion protection topcoats for steel structures.
Non leafing aluminum pigments are used more to produce aesthetic metallic
effects in paints, particularly automobile finishes.
Zinc dust is used as a pigment in anticorrosive primers. Zinc rich primers can
provide an effective longer life to a paint system when applied over well
prepared surface. It is used with organic as well as inorganic binder.
Extenders
Extenders are inert pigments usually inexpensive and of low refractive index,
that are added to the paint to modify its properties and to reduce costs. As
most of them being white in colour extenders may be used for any one of

several reasons outlined here, lowering the paint cost, increasing pigment
volume, flattening, tooth for primers, better brushing, consistency control and
better suspension. Most widely used extenders are silica, mica, talc; china clay
etc. and their specific purposes are as follows:
i) China clay increases the toughness of a paint film because of its plate
like structure.
ii) Talc reduces the settling tendency of pigment because of its acicular
nature.
iii) Mica reduces the permeability of a paint film to moisture because of its
lamellar nature.
2.3.21 Additives
Additives are the ingredients that are added to the paint in small quantities in
order to improve certain properties to a desired level e.g. driers to improve
drying; plasticizers to give flexibility to the film; anti - skinning agents to
prevent skinning during storage; wetting agents to permit easier grinding and
to improve wetting ability of the surface to which the paint is applied, anti
flooding agents to reduce flooding and floating of some pigments etc.
2.4 TYPES OF PAINT AND PAINT SYSTEM
Depending on the function of paint, it is classified into three types: Primer,

Undercoat & top coat
2.4.1 Primer
The primary function of a primer over steel is to provide corrosion protection.

The primer is in direct contact with the metal surface and must therefore
provide a firm bond between the metal and the subsequent coats of paint. The
primers may well be classified as follows:
i) Inert primer (primer containing only inert pigments)

ii) Inhibitive primer (Primer containing inhibitive pigments)
iii) Galvanic primer (Primers containing zinc or aluminum pigment)
2.4.2 Undercoat
Undercoats are highly pigmented high build paints possessing high

impermeability which follow the primer, provide necessary ground for the
finishing coat and should possess the following properties:
i) Fairly rapid set to avoid sagging and pulling away from sharp edges
ii) Very high impermeability to ions, moisture and air
iii) Good adhesion to primer and topcoat

2.4.3 Top Coat
The topcoat completes a paint scheme and serves as the first line of defense
against the corrosive environment whilst providing decoration. At the same
time, a good finish coat should offer adequate protection and be capable of
retaining its decorative effect (measured in terms of color and gloss) for a long
period. The top coat also protects the entire paint scheme from UV
degradation. Normally for corrosive environments, paints are seldom used in
a single coat. Multi coat protective schemes are designed comprising one /
two coats of primer, one / two coats of undercoat with one / two coats of top
coat or dispensing with undercoats according to the severity of the
environment encountered.
Paints can be divided into three groups according to their drying or curing
mechanism:
Physically drying paints. The drying process consists exclusively of the

evaporation of solvents.
Oxidative drying paints. The drying process combines evaporation of
solvents with a chemical reaction between the oil in the paint and the
oxygen in the air.
Chemically curing paints. The drying process involves a chemical reaction
between the base and a hardener. Before use the two components must
be mixed properly.

CHAPTER-3
3.0 TYPES OF PAINTS AND COATINGS

A variety of industrial paints and coating products are available in the market
catering to the different needs. The most common type of products used in
refinery applications are listed below. The properties of the generic primers,
intermediates and finish paints listed here are only indicative and the
manufacturers product catalogue is to be referred for all purposes.
3.1 PRIMERS
3.1.1 Zinc Ethyl Silicate Primer:
The zinc ethyl silicate consists of two packs. One pack contains the ethyl
silicate binder with suitable solvents. The other pack contains zinc dust with
additives. They have to be mixed in suitable proportions before application as
recommended by manufacturer.
Binder Ethyl silicate

Pigment Zinc dust (As per the ASTM D520, Type -II)
Application Spray (airless /air)
Dry film thickness/ coat 70 microns
Theoretical coverage 8.5 sq. m / litre
Drying time 4 hours
Re-coating time 24 hours
Volume solids 60-65 %
Storage life 6 months under sealed conditions
3.1.2 Two Pack Epoxy Polyamide Zinc Phosphate Primer:
These coatings are corrosion resistant inhibitive primers based on cold cured
epoxy polyamide two pack system, over which subsequent coatings can be
applied.
Binder Condensation product of bisphenol A &

epichlorohydrin with terminal epoxides with
epoxide equivalent 450-500
Pigment Mixture of iron oxide with zinc phosphate.
Application By brush or spray
Theoretical coverage 8.5 sq. m / litre
Drying time Surface dry in four hours
Re-coating time 24-48 hours
Volume solids 50-54%
Storage life 18 months under sealed conditions or as per
manufacturers recommendation

3.1.3 Red Oxide Zinc Phosphate Primer
This primer is based on single pack air drying type with water resisting
phenolic resin medium pigmented with zinc phosphate red oxide.
Binder Phenolic resin

Pigment zinc phosphate and red oxide
Application Brush or spray
Dry film thickness/ coat 25-30 microns
Theoretical coverage 10 - 12 sq. m / litre
Drying time 6 hours
Volume solids As per IS:2074
3.1.4 Mastic Coating
This is a two pack high build, modified aluminum epoxy mastic coating
possessing self priming properties and good adhesion to even rusted steel or
aged paints. The coating is tolerable to under prepared surfaces.
Binder Condensation product of bisphenol A &

epoxide equivalent of 180-200
Application by brush / air less spray
Theoretical coverage 6 sq. m / litre
Drying time Touch dry- 2 hours, Hard dry- 24 hours
Re-coating time 24-48 hrs
Volume solids 80%
3.1.5 Glass Flake Epoxy Coating
This is a two pack high performance surface tolerant glass flake reinforced
coating for excellent corrosion resistance to humid and saline environment.
Binder Epoxy resin with catalyst

Application by brush / conventional/ air less spray
Theoretical coverage 3 sq. m / litre
Drying time Touch dry- 4 hours, Hard dry- overnight
Re-coating time Overnight

3.2 INTERMEDIATE PAINTS
3.2.1 Two Pack Epoxy Polyamide Mio Undercoat
These coatings are high build paints based on cold cured epoxy polyamide
system pigmented with chemically inert pigments and extenders formulated to
permit application at a DFT higher than 100 microns per coat.
Binder Bisphenol A and epichlorohydrin with terminal

epoxides with polyamide as curing agent
Pigment Micaceous iron oxide (MIOlamellar)
Application By brush or airless spray
Dry film thickness/ coat 110-120 microns.
Theoretical coverage 5 - 5.5 sq.m/l
Drying time Touch dry in 2 hours, hard dry in 48 hours
Re-coating time 24-48 hours.
Storage life 12 months under sealed conditions.
3.3 FINISH PAINTS
3.3.1 Two Pack Aliphatic Acrylic Polyurethane Finish Paint
Part A and Part B are to be mixed together to form a pigmented polyurethane

paint in suitable proportions as recommended by manufacturer. Part A
consists of polyacrylate polyol with appropriate pigments, extenders, solvents
and additives. Part B consists of an aliphatic polyisocyanate with appropriate
solvents and additives.
Binder Aliphatic polyisocyanate and Polyacrylate polyol

Pigment Rutile TiO2 and extenders
Theoretical coverage 11-13 sqm/ litre
Drying time Surface dry 1 hr., Full cure 7 days.
Re-coating time Overnight to 5 days
Storage life 3 months under sealed conditions. To be verified
with manufacturers catalogue.
Colour As desired
3.3.2 Aluminum Finish Paint
It is a two pack system based on oleo-resinous binder and leafing aluminum

pigment given separately in paste form. Both are mixed at the time of
application.

Binder Oleo-resinous binder

Pigment Aluminum (ASTM 962)
Dry film thickness/ coat 15-20 m
Theoretical coverage 13-15 sq. m/liter
Drying time Surface dry /1 hr., Hard Dry / 8 hrs.
Re-coating time Min 24 hours
Storage life 6 months under sealed conditions.
Colour Metallic Aluminum
3.3.3 Coal Tar Epoxy
A high build two component epoxy coal-tar product meant for excellent
performance under total / partial / intermittent immersion conditions in salt or
fresh water. It is a blend of epoxy and coal-tar pitch in suitable ratios.
Binder Condensation product of bisphenol A and

polyamide as curing agent.
Pigment Suitable pigment
Theoretical coverage 4 - 5 sq.m/l.
Drying time Touch dry overnight, Hard dry in 48 hours.
Re-coating time 24-48 hours.
Storage life Up to 9 months under sealed conditions
Colour Black/ brown
3.3.4 Synthetic Enamel
High quality enamel based on synthetic resin vehicle stable weather resistant
pigment designed for both protection and decoration.
Binder Alkyd resin

Pigment Suitable pigment
Application By brush or conventional spray
Theoretical coverage 15 sq.m/l.
Drying time Surface dry - 4 hrs. , Hard dry in 18 hrs.
Re-coating time Minimum overnight
Colour As desired

3.3.5 High Build Bituminous Black
A single pack bituminous based coating for application at high thickness. The
product forms a hard film having excellent water and chemical resistance.
Binder Bituminous medium

Application By brush or conventional spray
Dry film thickness/ coat 75 - 100 microns
Theoretical coverage 5 6 sq.m/l.
Drying time Surface dry in 6 hrs. , Hard dry in 24 - 48 hrs.
Volume solids 50%
Colour Black
3.3.6 Solvent less Epoxies
A two pack solvent less coating suitable for sustained immersion in

hydrocarbons and water.
Binder Catalyzed epoxy resins

Dry film thickness/ coat 200 500 microns
Theoretical coverage 2 3 sq. m / litre
Drying time Overnight
Re-coating time 24 48 hours
Volume solids 100%
Colour White/ grey
3.3.7 Epoxy Putty
A two pack solvent less epoxy filler which cures with minimum shrinkage and
can be used for filling irregularities in substrate surface.
Binder Catalyzed solvent less epoxy

Application Trowel
Dry film thickness/ coat 300 500 microns
Theoretical coverage 1 sq. m / Kg
Drying time Overnight
Re-coating time Minimum : overnight , maximum : 5 days
Volume solids 100%
Storage life 6 months under sealed condition
Colour Off white
3.3.8 Compatibility of Different Paints
While applying multi coat system of paint it is always desirable to have a

firsthand knowledge of compatibility of different coating systems with one

another. A general view of such information is given in the following tables.
This is only a general view. In some cases, specific recommendations may
differ due to some special reasons.
Top Coat
Oleo Phen-
Sili- Chlori- Coal
resin olic Epoxy Ureth
Primer Alkyd cone Vinyl nated tar
ous oleoresi 2 ane
alkyd rubber epoxy
nous
Oleore- C C C C NR NR NR NR NR
sinous
Alkyd C C C C NR NR NR NR NR
Silicone C C C C NR NR NR NR NR
alkyd
Phenolic C C C C NR NR NR NR NR
resin
Vinyl C C NR NR C C C C NR
Chlorinated C C C C C C NR NR NR
rubber
Epoxy NR NR NR NR C C C C C
Coal tar NR NR NR NR NR NR C C NR
epoxy
Zinc - rich NR NR NR NR NR C C C NR
epoxy
Inorganic NR NR NR NR C C C NR NR
Zinc
Urethane NR NR NR NR NR NR NR NR C

CHAPTER-4
4.0 SURFACE PREPARATION

The adhesive bond between the metallic substrate and the coating plays a
key role in the success of the coating. More the adhesion, greater would be
the protection. Surface preparation is a crucial step in that direction.
Investigations have earlier shown that the best system applied over an
unprepared surface performs poorly than a moderate system applied over a
well prepared surface. A proper surface preparation i.e. the removal of visible
elements like rust, oil, grease, dust, dirt etc. and invisible contaminants like
weld-flux and ions of chloride and sulfate ensures the maximum polymeric
adhesion.
The clean surface will enhance the polymeric adhesion of the coating to the
metal, in addition to the mechanical bonding. A well cleaned surface will
provide a good anchorage to the paint film. The performance and durability of
any coating is largely decided by the complete cleanliness of the surface , and
the extent of thoroughness. As an average, nearly 90% of coating failure
results because of the insufficient preparation. Surface contaminants such as
rust, oil, grease, dust, dirt etc. will reduce the anchorage either physically or
chemically. In addition to these visible elements, invisible contaminants such
as weld - flux, ions like chloride, sulphate etc., from atmosphere, hand marks
etc. are also influencing the adhesion. These foreign elements are to be
completely eliminated before painting, so as to ensure proper adhesion
leading to better performance.
In the case of surface preparation, wherever blasting to SA 2 is

recommended, a surface profile of 15-20% of the total DFT of the paint
scheme has to be maintained. In view of variations in the formulations of
paints manufactured by different companies and other market factors which
are inevitable the expected life of the recommended paint systems is 5 years.
4.1 METHODS OF SURFACE PREPARATION
Virtually, no steel work is painted without some form of preparation. Many

surface preparation methods are available, but the treatment chosen must be
compatible with the specific protective system to be used. The general
methods of surface preparation can be classified as 1- Mechanical methods
2- Chemical methods.
4.1.1 Mechanical Methods
The various mechanical methods employed are:
i) Hand cleaning
ii) Power tool cleaning
iii) Dry abrasive blasting

iv) Wet blast cleaning
Hand Cleaning
Hand cleaning removes loose rust, loose mill-scale, dirt and non adherent oil
paint. This is generally done with wire brushes, scrappers, scrubbing with
bristle brush and in some instances emery and sand paper.
Before hand cleaning is undertaken the surface should be examined to

determine the amount and nature of the contaminants. If detrimental amount
of oil or grease are present, solvent cleaning must be carried out before hand
cleaning operation.
The limitations of hand tool cleaning are:
i) Properly shaped tools may be necessary

ii) Tough mill scale cannot be removed
iii) Very slow and impracticable for large areas
Power Tool Cleaning
It does not remove the tight mill scale or all traces of rust on pitted steel. It is
employed in places where blast cleaning is impracticable. Power driven tools
include pneumatic chippers, chisels, descaling tools and needle hammers,
rotary scalers, rotary wire brushes and abrasive wheels. Auxiliary equipment
includes the air or electric power supply, dust brushes and safety equipment
as required.
Power tool cleaning operation implies the removal of loose rust, mill scale,
paint by power tool chipping, descaling, wire brushing etc. without excess
roughening leading to the formation of ridges and burrs.
Abrasive Blast Cleaning
Abrasive blast cleaning is one of the best methods available for surface
preparation. Many varieties of abrasives are used, the most common being
a. Metallic
Iron grit or shot; Malleable iron grit or shot, hardened steel shot; chopped
steel wire.
b. Non Metallic
Aluminum Oxide, slags from iron and steel making plants.
All blast abrasives can be classified into three categories based on their
shape.

i) Shot: It is spherical or near spherical in shape
ii) Grit: It has irregular shape

iii) Semi sharp abrasives: It incorporates some sharp as well as round
edges in one particle.
Factors influencing blast cleaning
The following important factors are to be considered while doing abrasive

blast cleaning
a. Grit: Size of grain , type, freedom from dust

b. Hose: Size and length of hose
c. Blast nozzle: Size and type
d. Air spray: Pressure
Abrasives commonly used for white quality
For fastest cleaning, iron grit or iron shot of 16 - 30 mesh to be used i.e. zero
percent of abrasive to be retained on 16 mesh screen and 100% retained on
30 mesh screen. The shape of abrasive can be sharp, semi-sharp, spherical
or near spherical.
Abrasives commonly used for white blasting of steel are synthetic abrasives,
steel or cast iron grit. Generally a stream of compressed air in combination
with a blasting unit is the means of driving the abrasive on to the surface. The
blasting unit places the abrasive on the air stream in measured quantity.
List of Abrasives:
Metallic Non Metallic

Chilled cast iron, cast steel, malleable Silicon carbide, aluminium oxide,
iron, crushed steel, cut steel wire, refractory slag, rock wool bi-product
aluminum / brass / copper shots etc.
Air and blast hose
At least 1 internal diameter hose has to be used if the distance from the air
compressor to blaster is about 50 feet long.
Blast Nozzles
The three common sizes of blast nozzles for general maintenance painting
are 1/4, 5/16, 3/8. The larger size nozzles are preferable to smaller ones
because more area can be cleaned per hour with same labour cost.
The nozzles made up of Tungsten carbide are superior to the other types of
nozzles. These hard nozzles have a life of 800 hrs of continuous blasting.
Nozzle should be discarded when the crevice is worn to a diameter 50%

greater than the original i.e. 1/4 nozzle should be discarded when the crevice
is worn to 3/8 diameter.
Air Supply Pressure and Volume

Usually 100 pounds per sq. inch is considered to be the ideal working
pressure. It is assumed that there is 100 psi at the nozzle if the gauge reading
is 100 psi before starting the job. This however is not necessarily the case.
Compressor capacity for each nozzle should be at least 25 to 30% above the
rated amount of air required for that size nozzle. The pressure at the nozzle
should be maintained at 100 psi for blast cleaning irrespective of the length or
diameter of the hose used and the angle between the nozzle and the surface
to be cleaned could be approximately 40 450 inclination. By choosing
appropriate compressor with standard HP motor and air capacity tank, the
100 psi at nozzle could be achieved, considering the length and diameter of
the hose. Allowance may be made for the expected pressure drop across the
hose. The compressor capacity required for the type of nozzle used to
achieve 100 psi at the receiver is as follows:
Nozzle size cfm of free air

1/4 150
5/16 240
3/8 393
Before the start of job, the hoppers shall be pressure tested to check its
integrity.
Wet Blast Cleaning
Water blasting or wet blasting (when water is used along with additives and
inhibitors) is used principally for maintenance paint work when dry abrasive
blast cleaning is not convenient or prohibited. Wet blasting is effective and in
many cases economical alternative of surface preparation methods. This is
comparatively new form of cleaning for steel work and includes a number of
different methods. Basically water is used, generally with abrasives, at various
pressures, to clean off rust and to remove soluble deposits and dampen down
the dust. It enables inclusion of an inhibitor as part of the process to prevent
rusting for several hours so that the primer can be applied to clean steel. A
water-tolerant primer can be applied before the drying of steel.
4.1.2 Chemical Methods
Chemical or solvent cleaning is normally employed to remove soluble

deposits etc. The chemical cleaning method is normally practiced along with
mechanical cleaning. The cleaning should be done with proper precautions in
a well-ventilated area.

4.2 SURFACE PREPARATION STANDARDS
For the purpose of inspecting the prepared steel surface with abrasive, the
respective Visual standards can be utilized.
The standards commonly used in industry to describe surface preparation are:
i) National Association of Corrosion Engineers (NACE)

ii) Steel Structural Painting Council (SSPC)
iii) Swedish Pictorial Standards
The Swedish Pictorial Standard for surface preparation is enclosed as

Annexure-II.
The designation codes for the different surface preparation methods are as
follows:
4.3 INSPECTION OF SURFACE PREPARATION
Inspection of the prepared surface is carried out by visual comparison with the
original standards. Surface profile gauge can be used to measure surface
profiles obtained during surface preparation. Some of the surface preparation
system described as below:
4.3.1 White Metal Blast ( SSPC 5, NACE No. 1, SA - 3)
This is defined as removing all rust, scale, paint etc. to a clean white metal
which has uniform grey white appearance. Streaks and stains of rust or other
contaminants are not allowed.
4.3.2 Near White Metal (SSPC 10, NACE NO. 2, SA - 2 1/2)
This provides a surface of about 95 % as clean as white metal. Light shades

and streaks are not allowed.

4.3.3 Commercial Blast (SSPC 6, NACE No. 3, SA - 2)
This type of blast is more difficult to describe. It essentially amounts to about

2/3 of a white metal blast which allows for very slight residues of rust and
paint in the form of staining.
4.3.4 Brush off Blast (SSPC 7, NACE No. 4, SA - 1)
This preparation calls for removal of loose rust, paint scales, etc. Tightly
adherent paint, rust and scale are permitted to remain.
4.3.5 Precautions required during Blast Cleaning
Normally, the blast cleaning apparatus and pressure containing air vessels
are not fabricated or tested as per pressure vessel codes. Therefore,
adequate precautions to be exercised to ensure safety during blasting
operations, based on the learning following to be ensured:
A trained compressor operator has to be at work spot and carry out checks
as specified in operating manual such as Manually pop up the pressure
relief valve when the compressor is operating, at least weekly. The
operator to ensure the compliance of following and maintain records:
- Loading and unloading of compressor used for grit blasting operation,

shall be checked on daily basis before starting the grit blasting
operation. The loading of the compressor takes place as per the
MAWP of the compressed air receiver.
- The blow off valve is set at 1 kg/cm2g more than the MAWP (or as per
OEM recommendations) and is functioning.
- The engine idling has to be set so as not to switch off during nil load
operation (i.e.) when there is no air off take from the receiver.
- The safety relief valve installed on air receiver of the compressor

should be set at design pressure of compressor air receiver and bench
tested.

CHAPTER-5
5.0 PAINT APPLICATION

The manufacturer can produce high performance liquid coatings, yet the
products usefulness lies in the hands of the applicator. That is the reason
why stress is given for proper and careful application as a key to the success
of any coating.
Protection by coating mainly depends upon three factors:
i) Material
ii) Surface preparation
iii) Application
If any one of the three is weak, protection value is affected to large extent.
In order to obtain the desired paint life of coating, proper application is just as
important as proper surface preparation and correct choice of paint. The
primary objective of industrial paint coating is to provide a film which will give
protection to the surface on which it is being applied. The requirement is to
apply a continuous film, free from defects, at the correct dry film thickness,
under suitable environmental conditions. All difficult to approach areas and
sharp edges must be provided with stripe coating for ensuring complete
coverage of paint. Apart from proper surface preparation, the variables which
govern the success of any paint/ coating application are:
i) Mixing
ii) Thinning
iii) Pot life
iv) General conditions during application
v) Film thickness and spreading rates
vi) Method of application
5.1 MIXING
In general, all paints show some separation of the lighter and heavier
components during storage. Some pigments settle to a hard cake and some
to a soft sludge. This property determines the shelf life of the paint. The shelf
life of some paints is further limited by the tendency of certain binders to
curdle or gel upon prolonged storage. If the paint cannot be made
homogeneous by stirring, it must be discarded.
Hard mixing should be avoided. The best method for mixing the paint is by
mechanical stirring. Mechanical mixing should always be employed for more
than 5 litres volume of paint and also for mixing two component paints. When
paint drums are opened, care should be taken to avoid contamination with grit
or any other contaminants. Mixing operations should not be carried out in the
vicinity of blasting operations. The mixing should be done by propeller, screw

or paddle type agitator, driven by compressed air or electrical motor. Both

components should be thoroughly stirred separately after which, the hardener/
curing agent should be added slowly to the base component under continuous
stirring. The mixed paint should be stirred till a homogeneous mixture is
obtained. For mixing of any two component paint system, the instructions of
product data sheet must be strictly adhered to.
5.2 THINNING
Addition of thinners should be done with proper care and precautions. Most
paints are supplied in the proper viscosity for brush or roller applications. For
conventional spraying, a somewhat lower viscosity is desired for which a
minimum amount of specified thinner may be required. However, as thinning
reduces the volume solids of the paint, it is necessary to apply extra wet film
thickness of paint in order to achieve the specified dry film thickness (DFT).
Only specified thinner is to be used as wrong thinners can cause film defects.
Excessive thinner may result in solvent entrapment and blistering.
5.3 POT LIFE
Pot life is the time period between mixing and curing when the paint is
workable and can be applied. All two pack materials have pot life. The
polymerization reaction gets triggered when the two components are mixed
together and the viscosity of the mixture starts increasing rapidly. At one point
of time, the mixture becomes too viscous for application, which marks the end
of the pot life of the paint. The pot life of paint is a function of temperature and
is generally lower at higher temperatures. Mixing of more paint than what can
be applied before expiry of pot life is to be strictly avoided. Thinners should
not be applied for the purpose of extending the pot life. If the pot life is
expired, the paint should be discarded immediately. The paint manufacturers
data sheet information must be strictly followed during application.
5.4 GENERAL CONDITIONS DURING APPLICATION
All paint applications should be properly planned and allowances to be kept

for drying time, weather conditions, temperature, sunshine etc. In general, the
paint should be applied only to surfaces that are thoroughly dry and under
such conditions of humidity and temperature that will promote evaporation
rather than condensation. This means that the temperature of the surface
must be above the dew point of the air. Strong hot sunlight falling on surfaces
being painted may result in porosity, cratering or blistering. Low temperatures
are not suitable for curing of the two component paints. Wind or strong drafts
can cause application difficulties because of too rapid evaporation of solvents.
5.5 FILM THICKNESS AND SPREADING RATES
Most paints consist of two portions, the non-volatile part referred to as

volume solids and volatile part referred as solvents. In order to obtain good
performance from any coating system, an adequate thickness of dry paint

(non-volatile part) must be present. Measurement of film thickness is therefore

most important, at the time of application as wet thickness and subsequently
as dry thickness.
5.6 METHOD OF APPLICATION
The liquid coating material is a highly technical product which has to be

applied with utmost care by a skilled applicator. There are a number of
application methods by which coating can be applied. Though there are other
methods such as electrostatic spray, electro-deposition, curtain coatings,
roller coatings and dip coatings, the two principal and popular methods widely
used for field application are by brush and spray application.
5.6.1 Brush Application
Brushing should be used mainly for small areas and edges around rivets, in
corners, along welds and similar areas, prior to the application of a general
spray coat. Brushing is also useful to improve wetting of primers, particularly
on the surfaces which are difficult to coat.
The two general designs of brush which may be used for steel are
conventional wall type brush and flat brush made of nylon or hog bristles. The
proper application of a coating by brush depends on the proper handling of
the brush. The brush should be held with the fingers, like holding a pencil.
Brushes should not be dipped deep into the paint. Dipping into the paint to a
depth of approximately 2.5 cm is adequate. This keeps the paint out of the
heels of the brush and prevents dripping of the paint on to the handle. The
coating should be spread over the surface holding the brush at an angle
approximately 45 degrees to the work.
The coating should be spread evenly and quickly over the surface by a
number of light strokes using the wrist and aim to spread even coating. Once
the coating is evenly spread, the coating should be smoothed by light parallel
stripes of the brush over the surface to eliminate any irregularities in the
coating. During brushing the brush should not be pushed down, this will not
improve the brushing procedure. Pushing the brush too hard, especially on
the finish coats, can create brush marks which act as a focal point to lead to
premature coating failure.
When the next brush load of coating is applied the final smoothing stroke
should be from the latest applied coating into the previous brush load so as to
spread the overlap between the two areas of coating. The final strokes of the
brush should be always from the last application into the previous one
sweeping the coating into the wet edge of the previous application to prevent
lap marks. The coating can be best smoothened and spread uniformly by
using cross strokes. The final strokes should be parallel and in one direction.
The brush is constructed by cementing the bristling ends on a setting up
compound then adding a handle. The setting compound and flat end of the
handle are fastened together with a metal ferrule. Strips or felling are inserted

inside and at the bottom of the bristling. Cavity formed in this way help to hold
more paint and reduce the volume of bristling.
5.6.2 Spray Application
The large volume of all maintenance and high performance coating is applied
in the fastest way by spray. This is illustrated by relative efficiency of different
methods of application in the table given below:
Method of application Sq. meters covered in one day

Brush 60-100
Air spray 350 - 750
Airless spray 750 - 1100
By adopting this techniques coating films with uniform thickness and fewer
imperfections than other methods can be obtained. The spray method of
coating utilizes a stream. Highly atomized coating particles are directed to the
surface in a uniform pattern. The particle flows together to form a continuous
and even film. The time duration per day comes to 8 hours and the number of
workers to be deployed can be three. Spray application can be done
essentially by two types of equipments:
i) Air Spray Conventional

ii) Air Less Spray
Air Spray Application
Air spray is a process in which compressed air and the coating liquid are
brought together in a way that forms a fine spray. The spray gun is the
important component in the spray system as is the machine which brings the
air and liquid together. The spray principle is shown in Figure 5.1.
Figure 5.1 : Air spray principle
Compressed air is used to atomize the coating liquid at the tip of the gun and
also to apply pressure to the liquid coating material and force it through the
nozzle on the gun. The pressure of air passing through the gun as well as the
pressure on the liquid, have a great influence on the type of air spray and the
type of fan developed. If there is only too little air pressure at the gun the
stream will not be broken satisfactorily, resulting in unsatisfactory coating film.

The same thing can occur if the air pressure in the liquid is too high in
comparison with the air pressure at the gun.
Spray guns are available to fit any requirement. An air cap at the front of the
gun atomizes the paint and forms the desired spray pattern. Air caps may be
interchanged to meet the requirements of different applications. A fluid tip of
nozzle, located directly behind the air cap directs the paint into the air stream.
These tips vary in material and size according to the value of viscosity of the
paint being applied with the speed and volume requirements of the
application. Large orificed nozzles are required for heavy coarse, or fibrous
paints. Smaller orifices are used for thin paints. Because atomization of the
paint improves as the nozzle size decreases abrasive materials contained in
the paint require tips made of materials with resistance to wear.
Air compressor should be capable of supplying 25 cft/min of free air at 100 psi
for each gun. If an air mask is used for spraying on the interim tanks and
similar vessels an additional 5 10 cft/min should be added for each operator.
Air compressor provides the force for atomized spray painting. A fluctuating
air pressure at the gun usually caused by inadequate compressor capacity,
can result in improper atomization of the paint and defective paint films. Air
regulator regulates the air pressure as required. Air filters and moisture traps
remove moisture from the compressed air. These should be installed in the air
supply lines between compressor and the paint container and between
compressor and the spray gun. These regulators and filters should be as
close to the tanks and guns as possible.
Pipes and hoses that distribute the compressed air or paints must be
adequate in size to handle peak loads and must be able to withstand any
abrasive or chemical effects of the paint. For best results, the gun should be
equipped with 1.27cm ID fluid hose and 0.75 cm air hose. Smaller hoses
should be avoided since they cause excessive pressure losses.
Basic equipments for atomized spray paints consist of:
i) Spray gun (Typical spray gun shown in Figure 5.2)

ii) Container for the paint
iii) Air compressor
iv) Air regulator or transformer.
v) Connections for pipes and hoses
vi) Air felts and moisture trap

The proper spraying technique is essential to the success of the coating. The
following points should be observed:
i) Hold the guns not more than 25 cm away from the surface.
ii) Use a normal spray pattern. It is possible to check this by holding the
gun in the proper distance from the surface and pulling the trigger
quickly. With normal spray pattern, the spray will be an even, smooth
oblong with no heavy centre or dry spray at the ends. The spray patterns
are shown in Figure 5.3.
iii) The gun should be pointed perpendicular to the surface.
Airless Spray Application
The word airless is used in connection with this type of spray equipment since
there is no air used in the atomization of the liquid coating. The liquid is forced
through a very fine orifice by hydraulic pressure and forms a spray pattern as
it loses pressure and expands into the atmosphere. The combination of the
pressure and the small orifice breaks the liquid coating into a very fine mist
which is forced onto the surface to be coated.
Airless spray is more advantageous than air spray methods as can be seen
from the comparison given below:
Conventional Airless
Coverage sq.m/day 350-750 750-1100
Overspray 10 to 30 % Below10%
Pin holing Possible Unusual
Thickness Min 20-25 50 - 60
Max 100 - 110 200 - 220
Material loss on application Considerable Up to 35 % less
Penetration of corners and voids Fair Good
Paint clogging problems Slight Considerable
Safety during cleaning Excellent Fair
Coating contamination from air Possible None
Wind loss Considerable Negligible

Gun distance from surface 15 -25 cm 35 - 40 cm

Film build per coat Lower Higher
Versatility More Less
Thinning before spray Usual Sometimes
Hoses to spray gun 2 1
Compressors Large Small
Portability Fair Excellent
5.7 PAINT CALCULATIONS
5.7.1 Theoretical Spreading Rate (Coverage)
The theoretical spreading rate or coverage for paint is calculated from the %
volume solids of the particular paint and the dry film thickness (DFT) required.
Theoretical spreading rate (m2/ litre) = (Volume solids x 10)/ Required DFT
(microns)
5.7.2 Practical Spreading Rate (Coverage)
The practical spreading rate or coverage for paint is calculated from the
volume solids of the particular paint, the actual dry film thickness (DFT) and
the transfer efficiency (TE).
Practical spreading rate (m2/ litre) = (Volume solids x 10 x TE)/ Actual

DFT(microns)
Where Transfer Efficiency (TE) = (100- % Loss factor) / 100
The loss factor for general applications is normally in the range of 30 40 %

and grossly depends on the method of application, type of surface and
method of surface preparation.
5.7.3 Cost of paint per sq. metre
The material cost of paint per sq. metre is calculated from price per litre of
paint, theoretical spreading rate (depending on % volume solids and dry film
thickness) and Transfer Efficiency (TE).
Material cost/ m2 = Price per litre / (Theoretical spreading rate x TE)
5.7.4 Estimation of paint quantity
Quantity of paint required (litres) = Area (m2)/ (Theoretical spreading rate x

TE)
5.8 HEALTH AND SAFETY FACTORS
Most of the volatile organic solvents used in paints cause health and fire
hazards. They are harmful for the respiratory system, eyes and skin and also

are potentially explosive. Hence, apart from the general safety rules, the
following general precautions are necessary while handling and application of
paints:
i) Inhalation of solvent vapors or paint mist, contact with liquid paint with
skin and eyes should be avoided.
ii) Suitable approved respirators or face masks should be used during paint
application and handling.
iii) Appropriate gloves and clothing should be worn during painting and
handling of paint materials.
iv) Solvent should not be used for cleaning/ washing etc.
v) Since solvent vapors are heavier than air, they tend to accumulate at the
bottom of tanks or of confined spaces. Care should be exercised while
entering areas where this might have happened.
vi) Food and drink should not be stored or consumed where paints are
stored or applied and the painting areas should be properly ventilated.
vii) All fire/ safety precautions are to be followed in areas where paints are
stored and where paint application is done.
viii) Cans holding liquid paints are to be handled carefully and should not be
kept near or above any hot surface or object.

CHAPTER-6
6.0 FACTORS AFFECTING COATING PERFORMANCE

The principal factors involved in the successful performance of surface
coatings depend on the type of coating and the conditions of service. Failure
to a coating system may be due to the neglect of any one of the following
factors:
6.1 PAINT FORMULATION
The combination of correct ingredients in correct proportions must be used to

give the desired performance characteristics to the finished product.
Combination of resin, solvent, pigment used in making the paint dispersion is
called a mill base. The formulator must design a mill base for dispersing a
pigment in the most appropriate dispersion equipment at the optimum
efficiency.
Higher pigment loading means more efficient production; high loading are
possible when the viscosity of the vehicle to be used in the mill base in low.
6.2 PAINT MANUFACTURE
The raw materials must be mixed properly to produce the paint, which meets
all the requirements from batch to batch. The function of the manufacturing
unit is to produce satisfactory paints on specified schedules and at the lowest
possible cost. Paint preparation consists of a number of steps like mixing the
pigment with sufficient vehicle, grinding the paste on a mill, tinting the batch to
the required color, testing to determine physical properties and performance
requirements and finally storing, filling and packaging. The packaged material
must be delivered to the customer in proper condition for use. The quality
control procedure must be adhered to by the manufacturer at all stages of
manufacturing.
A coating cannot be expected to develop good adhesion to a surface which is

contaminated with oil, grease or other foreign materials. Grease not only
affects adhesion, but it may be absorbed into the coating thereby preventing
the development of maximum hardness and resistance to abrasion and
making the film liable for attack by chemicals. Different substrates on which
coatings are applied require different methods of preparation. Also for the
surface preparation a wide variety of surface treatments for metals is available
not only for cleaning the metals but also for removing rust and mill scales.
Correct application is one of the fine fundamental requirements in the

production of satisfactory protective and decorative coatings. Various

methods of application for which coating are designed, their advantages,

limitations and their correct film thickness are taken into the consideration for
the performance of successful coating systems in different environments.
Non-uniformity of thickness must be avoided because it may cause premature
failure of a coating or lowering of its resistance to service conditions. Coatings
which are brushed must be properly flowed out and sprayed. Coating should
be atomized correctly and not applied too wet or too dry i.e. very low viscosity
or very high viscosity.
6.5 DRYING
The transition of a surface coating from liquid or paste into solids is called
drying. Drying operation have been classified as air -drying, force - drying
and baking, Surface coatings dried under normal weather conditions are said
to be air dried. Drying within a temperature range of 38 - 930C is called force
drying and the operation carried out at more than 930C is called baking.
During the application and drying of paint films many kind of defects or
imperfections can develop in the film. The defects are mainly related to
surface tension phenomena. For example when a wet coating is applied to a
vertical surface, the force of gravity causes it to flow downwards to some
extent. Difference in film thickness at various places lead to different degrees
of sagging resulting in curtains or draper of paint. In spray applied solvent
based coatings, sagging can generally be minimized. Latex paints i.e. paints
based on the dispersion of polymer particles in water in general are less likely
to exhibit sagging when compared to solvent based paints, since they are
always thioxotropic i.e. getting good flow characteristic when stirred.
The common defects of films at the time of application and drying is listed as
follows:
i) Sagging
ii) Crawling
iii) Floating and flooding
iv) Wrinkling
v) Popping
vi) Foaming
These defects are overcome by adding suitable additives in the formulation or

modification in the application methods followed by proper drying of the
coating system.
6.6 ENVIRONMENTAL FACTORS
The basic cause of degradation of an organic coating is the chemical

breakdown of the organic matrix of the coating. UV radiation is a powerful
source of energy contributing to paint film break down. The rate of binder
degradation will be related to the absorption coefficient of the binder for the
damaging radiation and generally absorption is greater for lower wavelengths.

The degradation of resin will cause loss of gloss in a pigmented system, as

pigment particles are exposed at the surface of the film. As the pigment
particles are released from the binder surrounding them, the effect is known
as chalking. Normally bisphenol a based epoxy coatings are susceptible to
this type of failure and hence they are not used as top coats in atmospheres
open to direct sun light. Acrylic polymers possess good weather resistance.
Polymers like polyvinyl acetate, polyesters and alkyd resins hydrolyse in the
presence of strong base or acid. This type of effect occurs through
environment. If the atmosphere contains sulphur dioxide, Chlorine or
carbondioxide, it will combine with rain water to form corresponding acids,
which leads to the degradation of the coating by acid hydrolysis process. If the
atmosphere contains ammonia gas, it will combine with the rain water to form
ammonium hydroxide base, which also leads to the coating degradation by
base hydrolysis reaction.
Pigments such as calcium carbonate will also be affected by acid rain causing
calcium sulphate blooming on exterior exposure. Sea water environment is
aggressive than the rain water because of the greater electrolytic conductivity
afforded by increased ionization from dissolved salts. In this solution, more
soluble ferrous hydroxyl chloride complex will be formed which ultimately will
be converted to the more insoluble rust. Corrosion maximizes as salt
concentration increases to 3% and thereafter the electrolyte becomes less
corrosive, probably because the solubility of oxygen is reduced as the salt
concentration increases.
6.7 PAINT DEFECTS
The following are the common paint/ coating defects and their probable
causes:
6.7.1 Blistering
Description:
Hollow bubbles appearing in paint film.
Probable reasons:
Excessive moisture in air supply

Primer not allowed to dry thoroughly
Improper curing
Topcoat immersed in water for extended periods of time

6.7.2 Chipping
Description:
Paint breaking away in small pieces.
Probable reasons:
Surface impact
Improper surface preparation
Exposure to harsh conditions
6.7.3 Cracking
Description:
Splitting of paint throughout its thickness.
Probable reasons:
Non uniform mixing of paint components

Exposure to higher temperatures
Excessive paint film thickness
Coating applied over improper substrate
6.7.4 Cratering
Description:
Paint film marked with round surface depressions or bowl-like craters. Usually
occurs while spraying or immediately after.
Probable reasons:
Surface contamination (grease/ oil etc)

Surface not dried properly
Contaminated air
6.7.5 Crawling
Description:
Recession of wet paint creating non-uniform

distribution of film.
Probable reasons:
Surface contamination

Non uniform mixing of paint components

Excess paint volume
6.7.6 De-lamination
Description:
Separation of layers of paint film.
Probable reasons:
Surface contamination
Incompatible primer
Improper over-coating interval
Incorrect spray technique
6.7.7 Dissolution
Description:
Metallic flakes of base coat surfacing at top

coat in case of metallic primers.
Probable reasons:
Improper over coating interval
6.7.8 Dry spray
Description:
Areas of paint film lacking gloss.
Probable reasons:
Improper gun setting

Gun air pressure too high
Wrong thinner used
Viscosity too high
Incorrect spraying technique
6.7.9 Mottling
Description:
Non homogeneous concentration of metallic

flakes in the paint film.

Probable reasons:
Improper gun setting

Improper mixing of paint components
Wrong thinner used
Holding spray gun too close to the surface
6.7.10 Wrinkling/ Orange peel
Description:
Dimpled surface of dry paint film.
Probable reasons:
Gun air pressure low
Paint viscosity high
Primer applied not smooth
6.7.11 Runs or sags
Description:
Heavy paint film collects and moves

downwards. Usually occurs on vertical
surfaces.
Probable reasons:
Gun air pressure too low

Incorrect solvent
Wrong amount of thinner
6.7.12 Solvent popping
Description:
Small blisters or bumps on the paint surface.
Probable reasons:
Improper drying/ curing

Incorrect thinner used
Incorrect DFT Figure 6.12 : Solvent popping

6.7.13 Water spotting
Description:
Patches of whitish coloration on the paint

surface.
Probable reasons:
Coating exposed to moisture before hard dry.

Excess moisture Figure 6.13 : Water spotting
6.7.14 Slow drying
Description:
Coating does not cure within usual time.
Probable reasons:
Incorrect composition of paint components

Poor drying conditions Figure 6.14 : Slow drying
6.8 GOOD PRACTICES IN PAINTING
The following points need to be taken care during application of a coating

system for enhancing the useful life of a coating:
6.8.1 During Surface Preparation
i) The surface imperfections shall be removed as far as practicable. The

weld spatters should be completely removed.
ii) All sharp edges shall be removed/ smoothened.
iii) Pitting/ grooving on the surface to be thoroughly cleaned and preferably
filled.
iv) Water washing of surface should be done for removal of salts and other
contaminants and dried completely before paint application.
6.8.2 During Paint Application
i) Paint of different shade to be used during over coating.

ii) Stripe coat to be applied at all edges and other difficult to approach
locations.
iii) Use of dehumidifier is recommended during internal painting if the
relative humidity level is high.
iv) Paint application should be stopped during storms etc.
v) Mechanical agitators to be used for mixing the two-component paints.

vi) For mixing two component paints, mix the individual components into
uniform state before mixing the components together.
vii) Components to be mixed in correct ratio and combination as per paint
data sheet.
viii) Mix full packs wherever possible.
ix) Thinners to be used only when necessary.
x) Never mix more paint together than can be used before the pot life
expires.
xi) Primer to be applied immediately after surface preparation.
xii) Sufficient curing time must be allowed before placing into service.

CHAPTER-7
7.0 PAINT/ COATINGS INSPECTION

Inspection techniques have to be applied at various stages. i.e. from purchase
of coating materials to paint application and evaluation of performance during
service. Inspection procedures at various stages before and after the
application of coating systems over the oil installations have been described
below:
7.1 PAINT COMPOSITION
The type of paint system has to be selected depending upon the

environmental conditions.
Generally primer, undercoat and finish coats are used in protective coating
system. The purchased paint materials are to be tested for the following
properties to ascertain whether the supplied paint conforms to the
specifications:
i) Type of film formers present

ii) Types of pigments present
iii) Thickness per coat
iv) Volume solids
v) Pigment volume concentration
vi) Area coverage per liter of the paint
vii) Specific gravity
viii) Drying time
ix) Main pigment content in total pigmentation
The painting operation is to be started only after the values obtained coincides
with the required specification of the paint system. It is essential to see that
the surface is not wet during the application of the paint. Moreover paints
should not be applied when the humidity of environment is above 80%. The
atmospheric temperature should not be below 100C during the operation.
7.1.1 Procedure for Testing Paint Samples
The following laboratory test procedures are adopted for the characterization
of the film - formers, pigments and studying the properties of the paint.
a) Type of film - formers present
The film former has to be separated out of the paint by means of

centrifuging. It is then to be analyzed using infra red spactroscopy for
identifying the functional group i.e. the type of film formers.

b) Type of Pigments Present
After separating the pigment from the paint, it has to be subjected to x-

rays diffraction for identifying the pigment.
c) Thickness per coat
Magnetic thickness gauges are used to measure the thickness of the

paint film applied over the iron - substrate. The thickness is measured in
micrometer (m). Thickness gauges operating on eddy current principle
are used to measure coating thickness over metals other than steel /
magnetic substrates.
d) Volume solids
Paint is a mixture of three major components such as pigment, binder

and thinner. The pigment and film - former will remain in the paint film
after the evaporation of the solvent. The pigment and film former
together are called as solids. The volume of these together in the liquid
paint is called as volume solids.
e) Area coverage per litre of the paint
This is determined by taking a known volume of the paint and applying it

over a surface. The area covered by the known volume of the paint is
determined. From this value, area covered by one litre of the paint is
calculated.
f) Specific gravity
For determining specific gravity, a cup of known volume is taken. The

difference in weight of the cup filled with paint and the empty cup gives
the weight of paint of known volume. From this, we can calculate specific
gravity.
g) Drying time
i) Touch Dry
In this case, if the coated surface is touched with finger, no finger

mark should be found on the coating.
ii) Hard Dry
It is the condition of coating drying very hard. Unless the coating

itself is damaged with force, no pressure could mar the coating in
this condition.

h) Flow properties of the paint ( Ford cup method)
Ford cup is the mostly used instrument for studying the flow properties of
the paint. Ford cups having different orifice sizes are available in the
market. The varying orifice sizes are meant for measuring the flow time
of different viscosities.
7.1.2 Spot Testing Procedures
The following spot tests will be useful to identify the binders (film -formers)
qualitatively.
Before carrying out the test, the binder is to be separated from the pigment by
means of centrifuging.
a) Epoxy Resin
i. Filter paper test
This test can be carried out even with paint itself. 0.5 gms . of the
paint (binder part) / binder is taken in a 100 ml beaker . and treated
with 1ml of concentrated sulfuric acid (con. H2SO4). . The beaker is
slightly heated at 600C for a few minutes. It is then diluted with 5ml
of con. H2SO4. A drop of the solution is taken in a glass rod and
spread over a filter paper. The development of purple color within
one minute on the filter paper will indicate the presence of
Bisphenol - A type of epoxy resin.
ii. Formaldehyde test
0.5 gm of the paint (binder part) or binder obtained after the

separation of the pigment is taken in a 100 ml. beaker. 2 ml. of
concentrated Sulphuric acid is added into it and slightly warmed.
One to Two drops of formaldehyde Solution (formalin) is added into
it with stirring. If epoxy resin is present, an orange color will
develop. This on dilution with water will change the color from violet
to blue.
b) Chlorinated rubber resin
0.5 gm of the paint or binder obtained after the separation of the pigment
is taken in a 100 ml beaker. 5ml. of pyridine is added in to it and stirred
well. 1 ml of methanolic potassium hydroxide solution (potassium
hydroxide pellet dissolved in methanol) is added into it. If chlorinated
rubber resin is present, a yellow precipitate will be formed. This
precipitate will slowly darken to a yellow brown color.

c) Polyurethane
1 ml. of the sample containing the binder part is taken in a 50 ml. of

beaker. 0.2 gm of paradimethylamino benzaldehyde dissolved in 2 ml. of
xylene is added into it. The contents are slightly warmed. If an yellow
colour is developed it indicates the presence of free isocyanate group in
the binder.
d) Phosphate in pigment
The pigment part separated as described earlier from the paint is

dissolved in dil. HNO3. It is then treated with a 10% by wt. aqueous
solution of ammonium molybdate. The development of yellow precipitate
or colouration indicates the presence of phosphate in the pigment
contents.
e) MEK / MIBK test (solvent resistant test)
Select areas on the coated surface at least 150 mm long and 25 mm

width. Clean the surface with tap water to remove any loose materials
and allow drying. Measure the dry film thickness. Fold a cotton cloth into
a pad of double thickness and saturate it to a dripping wet condition with
MEK / MiBK or any other solvent. Rub the rectangular area with
moderate pressure first away from the operator and then back towards
the operator. One forward and back motion is one double rub, and
complete at the rate of approximately 1 /sec. Continue rubbing the test
area for a total of 25 double rubs. Take care to stay within the
rectangular test area. Immediately inspect the middle 125 mm of the
rubbed area for finger nail hardness and visual changes in appearance.
If numerical values or ratings are desired, gloss may be measured and
pencil hardness test may be conducted. Measure the film thickness of
the rubbed area. Visually examine the cloth for indications of coating
removal. There should not be reduction in thickness after rubbing and
also coating material should not be found in the cloth.
Surface preparation of the metal is essential to provide better adhesion of a

coating over the substrate. Mechanical or solvent cleaning methods are
adopted for obtaining good surface condition. In solvent cleaning method,
solvent is utilized to remove oils, waxes, greases and other lubricants from the
surface. In mechanical methods, mechanical means such as hand cleaning
and power tool cleaning are employed. In the case of abrasive blast cleaning
the size of the abrasives have to be assessed. The size of the abrasive
should be such that it passes through 16 mesh screen and 100 % retained in
30 mesh screen. In the case of iron girt / iron shot blasting, the prepared
surface should correspond to a surface with grey white uniform metallic colour
(SA 3 or NACE 1) or 95 % of the surface shall have the appearance of a
surface blast cleaned to a white metal surface ( SA 2 or NACE 2). The

surface should not be contaminated with oil or grease. Solvent cleaning is to

be effected before painting.
Inspection has to be carried out by visually comparing the different standards

available with that of the surface to be painted whether they conform to the
specification. Surface profile has also to be checked simultaneously using a
surface profile gauge. Moreover in high humid atmosphere, the primer coating
is to be applied within a very short duration; otherwise corrosion of blasted
surface would occur.
7.3 ENVIRONMENT CONDITION
In order to select paint system and the time of painting, environmental studies
relating to humidity, rainfall, salinity and sulphur dioxide in atmosphere have
to be carried out.
Application of the paint over metallic surfaces can be carried out using brush,
air spray or airless spray. Extreme care should be taken to see that no oily or
greasy material is present on the surface. If such things are present, they
have to be removed before starting paint application. Moreover moisture
should not be present on the surface as it would lead to poor adhesion of the
coating. Generally, the edges of the material being painted will not be properly
covered with paint. Care should be taken to see that edges are covered with
paint.
The thickness of dry film in each coat i.e. primer, undercoat and finishing coat
has to be determined separately using thickness meters. They can be found
out even during application using a wet film thickness gauge. After the
application of the primer, the subsequent coatings have to be applied within
the time limit prescribed in the specification.
The painted materials can be put to service only after completion of full cure
period. In view of the inflammable and hazardous nature of solvents used in
paint, precautions are to be taken to avoid possible fire accidents and workers
should be provided with safety masks, gloves and goggles. A detailed Quality
Assurance Plan (QAP) for ensuring quality application of paints is enclosed as
Annexure-III for ready reference.
7.5 PAINT PERFORMANCE EVALUATION
The performance evaluation has to be done by observing the defects that may
arise on the film and metal surfaces periodically. The defects that may arise
include chalking, blistering, cracking, fading, rusting etc.

7.5.1 Chalking
Chalking is a deterioration of the hard paint film by the attack of the UV

radiation and other contamination of the atmosphere. The formation of a
powdery mass over the surface is the indication which could be identified by
rubbing with a silk cloth wrapped around the index finger with the medium
pressure turning 1800 and observing the powdery mass absorbed in the cloth.
The standard marking of the chalking level could be judged with ASTM 659.
7.5.2 Checking
The formation of short, shallow cracks in an exposed glossy film is defined

checking. Visual observation of the extent of checking could be compared as
per standard ASTM 660.
7.5.3 Blistering
The uplifting of the film from the surface, due to the pressure developed
underneath because of moisture permeation through the film will lead to
blister formation on prolonged duration which will lead to rusting underneath
as well. The visual observation of the extent of blistering can be recorded as
per ASTM 714.
7.5.4 Rusting
The formation of rust spots on the painted surface due to penetration of

moisture, ions and other contaminants of the atmosphere is called rusting and
the extension of such rust spots over the surface is called spreading of rust.
The extent of rusting can be assessed as per ASTM grading D 610 - 85.
7.5.5 Flaking / Cracking
The defects mainly associated with the coatings which lift from the surface or
from the film underneath in the form of plates or at times in the form of bulk
layers are called flaking. The extent of flaking or cracking could be visually
compared with ASTM 661 / 772.
7.6 PAINT INSPECTION GUIDELINES
Proper inspection of the paint materials, surface preparation and paint

application greatly increases the reliability of the applied paint/ coating. The
following parameters need to be cross checked at the different painting
stages.
7.6.1 Paint Materials
Manufacturer Certification
Manufacturing date and Expiry date
General health of the packing

Correctness of specification
7.6.2 Surface Preparation
Cleanliness of the subject surface

Surrounding area to ensure non-contamination during or just after
application
Surface cleaning equipment and procedure with due consideration to
safety
Proper surfaces after preparation free from all loose particles
Proper cleaning of nooks & corners and difficult to access location
7.6.3 Application
Proper time lag from surface preparation to application

Proper mixing (for two pack system)
Correct application tools, procedure and skill
Uniformity of wet film thickness per coat
Proper inter-coat time interval
Adequate post drying hardness
7.6.4 Final Inspection
DFT
Adhesion
Holiday Detection
Check of finish and workmanship
Hardness test
The inspection results shall be noted in checklist as per sample given

Annexure-I.
7.7 PAINT INSPECTION INSTRUMENTS
The field painting inspection kit level consists of:
a) Dry film thickness meter

b) Wet film thickness meter
c) Paint film inspection gauge
d) Holiday detector
e) Break down voltage tester
f) Field adhesion tester
g) Surface thermometer
h) SSPC VISI 89
i) Calibration standards etc.
j) Surface profile gauge
k) Surface comparator
l) Consistency/ viscosity cups

m) Weight per gallon cup
7.8 SUGGESTED VOLTAGES FOR HIGH VOLTAGE SPARK TESTING AS

PER ASTM D5162
Also the equation given in ASTM D5162, for calculating the test voltage.

CHAPTER-8
8.0 APPLICATION WISE PAINT/ COATING SYSTEMS

The specific paint schemes recommended to be applied for different areas are
given in tabular form in this Chapter. The paint systems include both
construction and maintenance painting. Selection of suitable paint system for
maintenance painting, especially where blast cleaning is not feasible, is a
challenge since the quality of prepared surface for painting has direct impact
on the expected life of the paint.
The locations where it is difficult to do the blasting operation in a running

plant, an alternate route is always looked for, like power tool cleaning or
manual cleaning. The problem with these types of alternatives is that they
cannot remove the old paints and also the well adherent rust from the surface
thoroughly or at least to a satisfactory level for the two-pack epoxy or
polyurethane paint systems which does not adhere to the residual old paints.
In such cases, the mastics and other surface tolerant coatings are generally
preferred.
The tables for application-wise paint systems have been classified into:
i) Paints/ coatings for external surfaces

j) Paints / coatings for internal protection
k) Paints / coating for protection against soil side corrosion
The paint/ coating systems for external protection of equipments, piping and
structures include external painting of Columns, vessels, heater casing,
exchangers, tanks, stacks, pumps, structures etc for protection against
atmospheric corrosion, equipments and piping under insulation for protection
against corrosion under insulation (CUI), equipment, piping and structures for
protection against toxic gases and fumes, acid/ alkali/ salt spillage etc. The
choice of the external paint systems largely depend on atmospheric
corrosivity of the zone and the location of the equipment to be protected. The
paint/ coating systems for protection against internal environment include
internal painting of hydrocarbon/ water storage tanks, vessels etc. The choice
of the internal paint systems largely depend on the type of the material which
is stored or transported, the amount of impurities and other constituents,
velocity, process conditions etc. The paint/ coating systems for protection
against soil side corrosion are applied to underground piping, mounded
bullets etc. The preferred paint systems for protection against soil side
corrosion are wrapping and coating/ coal tar, tape coatings, cement lining,
fusion bonded epoxy coatings, three layer polyolefin coatings etc.
The suggested paint systems in this Chapter are intended to be a guideline in

selecting the proper paint system for different services. The location features,
type of crude handled, the maintenance practices, intended life of paint etc
are some of the factors which needs to be considered during selection of paint
system.

8.1 PAINTS/ COATINGS FOR NEW CONSTRUCTION
Primer Intermediate Coat Finish Coat Total Min

Surface
Service Generic Generic Generic DFT
Preparation DFT DFT DFT
name name name micron
External surface of un- Sa 2 Inorganic 65-75 HB Epoxy 100-150 Two pack 40-50 215
insulated equipment, tank, Zinc MIO Acrylic Poly-
piping and structures (up to Silicate Urethane (PU)
0
120 C)
External surface of insulated Sa 2 Two pack 300 (2 - - - - 300
equipment, tank and piping (up epoxy coats
0
to 120 C) phenolic of 150
each)
External surface of un- Sa 2 Inorganic 65-75 - - HR Aluminum/ 15-20 (2 100
insulated equipment and Zinc Silicone coats of 40 )
0 0
piping (120 C to 200 C) Silicate Aluminum
External surface of insulated Sa 2 Inorganic 65-75 - - Two pack 300 (2 coats 350
0
equipment and piping (120 C Zinc epoxy of 150 )
0
to 200 C) Silicate phenolic
External surface of un- Sa 2 - - HR Aluminum/ 15-20 (2 40
insulated equipment and Silicone coats of
piping (above 200 deg C) Aluminum 40 )
External surface of insulated Sa 2 - - HR Aluminum/ 15-20 (2 40
equipment and piping (above Silicone coats of
200 deg C) Aluminum 40 )
External surface of equipment, Sa 2 HB 200 (2 Two pack 40-50 300
piping and structures at highly Polyamide coats of Acrylic Poly- (2 coats of
corrosive atmospheres like cured 100 Urethane (PU) 100 )
immersion service, acid epoxy each)
handling and splash zones primer
External surface of equipment/ Sa 2 - - Aluminum 40 (2 coats of 40
piping with intermittent Finish Paint 15-20 )
temperature rise (e.g. flare (IS-2339)
lines)
External surface of pontoon Sa 2 HB 200 (2 Two pack 40-50 300
top and roof decks of floating Polyamide coats of Acrylic Poly- (2 coats of

Primer Intermediate Coat Finish Coat Total Min

Surface
Service Generic Generic Generic DFT
Preparation DFT DFT DFT
roof tanks cured 100 Urethane (PU) 100 )
epoxy each)
primer
Internal surface of tanks in Sa 2 Inorganic 65-75 HB Epoxy 35 - 40 High build 150-200 (2 250
hydrocarbon service (Note-iv) Zinc based Zinc Epoxy finish coats of
Silicate Phosphate 75 - 100 )
Internal surface of tanks in Sa 2 Polyamide 75 High solids 500 575
water service (Fire water, cured amine cured (2 coats of
Industrial Water) epoxy epoxy 250 )
primer
Internal surface of bottom Sa 2 Aliphatic 75-125 Amine cured 400-500 (2 500
plates and first shell course of amine solvent free coats of
crude oil tanks cured high build 200-250 )
epoxy zinc epoxy liner
phosphate
Underside of tank and external Sa 2 Inorganic 65-75 - - High build 150-200 (2 265
surfaces of buried vessels/ Zinc Epoxy finish coats of
piping Silicate 75 - 100 )
Notes:
i) Moisture barrier (Up to 1700C Aluminum, above 1700C Aus. SS foils) to be provided for all insulated piping/
equipment after paint curing and before application of insulation.
ii) HR Aluminum / Silicone Aluminum paints are available for different temperature ranges and hence should be selected
for appropriate temperature range.
iii) Before finalizing the paint specification, the catalogue of manufacturer to be referred for temperature limit and DFT.
iv) For ATF service, in case of QC requirement Polyamide cured epoxy zinc phosphate primer may be used in place of
inorganic zinc silicate primer.
v) In case of steel structural 2 coats of Synthetic Enamel finish coat can be applied in place of Acrylic Poly-Urethane
finish paint (2 x 20-25 microns).
vi) Tanks external in mild corrosive zone Two coats of synthetic enamel or aluminum paint may be used in place of PU
paint.

8.2 PAINT/ COATINGS DURING MAINTENANCE (EXTREMELY SEVERE ATMOSPHERIC CORROSION ZONE)
Primer Intermediate Coat Finish Coat Total

Surface
Service Generic Min DFT
Preparation Generic Name DFT DFT Generic name DFT
Name micron
External surface of un- Sa 2 HB zinc 30-35 HB Epoxy 100-150 Two pack 40-50 200
insulated equipment, tank, phosphate MIO Acrylic Poly-
piping and structures (up to coating Urethane (PU)
0
120 C)
External surface of insulated Sa 2 Two pack epoxy 300 (2 - - - - 300
equipment, tank and piping phenolic coats
0
(up to 120 C) of 150 )
External surface of un- Sa 2 Inorganic Zinc 65-75 - - HR Aluminum/ 40 (2 100
insulated equipment and Silicate Silicone coats of
0
piping (120 to 200 C) Aluminum 15-20 )
External surface of insulated Sa 2 Inorganic Zinc 65-75 - - Two pack 300 (2 350
0
equipment and piping (120 C Silicate epoxy phenolic coats of
0
to 200 C) 150 )
External surface of un- St-3 HR Aluminum/ 15-20 (2 40
insulated equipment and Silicone coats of 40
0
piping (above 200 C) Aluminum )
External surface of insulated St-3 HR Aluminum/ 15-20 (2 40
equipment and piping (above Silicone coats of
0
200 C) Aluminum 40 )
External surface of Sa 2 HB Polyamide 200 (2 Two pack 40-50 300
equipment, piping and cured epoxy coats of Acrylic Poly- (2 coats of
structures at highly corrosive primer 100 Urethane (PU) 100 )
atmospheres like immersion each)
service, acid handling and
splash zones
External surface of St-3 - - Aluminum 40 (2 coats 40
equipment/ piping with Finish Paint of 15-20 )
intermittent temperature rise (IS-2339)
(e.g. flare lines)
External surface of pontoon Sa 2 HB Polyamide 200 (2 Two pack 40-50 300
top and roof decks of floating cured epoxy coats of Acrylic Poly- (2 coats of
roof tanks primer 100 Urethane (PU) 100 )

Primer Intermediate Coat Finish Coat Total

Surface
Service Generic Min DFT
Preparation Generic Name DFT DFT Generic name DFT
Name micron
each)
Internal surface of tanks in Sa 2 Inorganic Zinc 65-75 HB Epoxy 35 - 40 High build 150-200 (2 250
hydrocarbon service (Note-iv) Silicate based Zinc Epoxy finish coats of
Phosphate 75 - 100 )
Internal surface of tanks in Sa 2 Polyamide cured 75 High solids 500 575
water service (Fire water, epoxy primer amine cured (2 coats of
Industrial Water) epoxy 250 )
Internal surface of bottom Sa 2 Aliphatic amine 75-125 Amine cured 400-500 (2 475
plates and first shell course of cured epoxy zinc solvent free coats of
crude oil tanks phosphate high build 200-250 )
epoxy liner
External surfaces of buried Sa 2 Inorganic Zinc 65-75 - - High build 150-200 (2 250
piping (e.g. CBD lines) and Silicate Epoxy finish coats of
underside of tank bottom 75 - 100 )
plates
Notes:
i) Moisture barrier (Up to 1700C Aluminum, above 1700C Aus.SS foils) to be provided for all insulated piping/ equipment
after paint curing and before application of insulation.
ii) Washing with fresh water to be done as part of surface preparation to remove soluble salts and contaminants.
iii) Stripe coat of primer paint to be applied at all edges, welds and other difficult to apply areas.
v) Before finalizing the paint specification, the catalogue of manufacturer to be referred for temperature limit and DFT.
vi) In case of steel structural 2 coats of Synthetic Enamel finish coat can be applied in place of Acrylic Poly-Urethane
* These are special application paint system with high cost. However, in case of non availability, suitable system is to be
selected from guidelines given in section 8.5

8.3 PAINT/ COATINGS DURING MAINTENANCE (SEVERE / MODERATE ATMOSPHERIC CORROSION ZONE)
Surface Primer Intermediate coat Finish Coat Total Min

Service Preparation Generic Generic Generic DFT
DFT DFT DFT
External surface of un- St-2 HB zinc 30-35 Two pack 40-50 70
insulated equipment, tank, phosphate Acrylic Poly-
piping and structures (up to Urethane (PU)
0
120 C)
External surface of Sa 2 Two pack 300 (2 - - - - 300
insulated equipment and epoxy coats
0
piping (up to 120 C) phenolic of 150 )
External surface of un- St-2 - - - - HR Aluminum/ 40 (2 coats 40
insulated equipment and Silicone of 15-20 )
0
piping (120 deg C to 200 C) Aluminum
External surface of Sa 2 - - - - Two pack 300 (2 300
insulated equipment and epoxy coats
0
piping (120 to 200 C) phenolic of 150 )
External surface of un- St-2 HR Aluminum/ 40 (2 coats 40
0
piping (above 200 C) Aluminum
External surface of St-2 HR Aluminum/ 40 (2 coats 40
0
piping (above 200 C) Aluminum
External surface of St-3 Solvent free/ 350-500 - - - - 350
equipment, piping and high solids
structures at highly surface
corrosive atmospheres like tolerant epoxy
immersion service, acid coating *
handling and splash zones
External surface of St.2 Aluminium 40 (2 coats 40
equipment / piping with Finish Paint of 15-20 )
intermittent temperature (IS-2339)
rise (e.g. flare lines)
External surface of pontoon Sa 2 HB Polyamide 200 (2 coats Two pack 40-50 300
top and roof decks of cured epoxy of 100 Acrylic Poly- (2 coats of
floating roof tanks primer each) Urethane (PU) 100 )

Surface Primer Intermediate coat Finish Coat Total Min

Service Preparation Generic Generic Generic DFT
DFT DFT DFT
Internal surface of tanks in Sa 2 Inorganic Zinc 65-75 HB Epoxy 35 - 40 High build 150-200 (2 250
hydrocarbon service (Note- Silicate based Zinc Epoxy finish coats of
iv) Phosphate 75 - 100 )
Internal surface of tanks in Sa 2 Polyamide 75 High solids 500 575
water service (Fire water, cured epoxy amine cured (2 coats of
Industrial Water) primer epoxy 250 )
Internal surface of bottom Sa 2 Aliphatic 75-125 Amine cured 400-500 (2 475
plates and first shell course amine cured solvent free coats of
of crude oil tanks epoxy zinc high build 200-250 )
phosphate epoxy liner
External surfaces of buried Sa 2 Inorganic Zinc 65-75 - - High build 150-200 (2 250
piping (e.g. CBD lines) and Silicate Epoxy finish coats of
underside of tank bottom 75 - 100 )
plates
Notes:
i) Moisture barrier (Up to 1700C Aluminum, above 1700C Aus.SS foils) to be provided for all insulated piping/
ii) Stripe coat of primer paint to be applied at all edges, welds and other difficult to apply areas.
v) In case of steel structural 2 coats of Synthetic Enamel finish coat can be applied in place of Acrylic Poly-Urethane
vi) Tanks external in mild corrosive zone Two coats of synthetic enamel or aluminum paint may be used in place of PU
paint.
* These are special application paint system with high cost. However, in case of non availability, suitable system is to be
selected from guidelines given in section 8.5.

8.4 PAINT/ COATINGS DURING MAINTENANCE (MILD ATMOSPHERIC CORROSION ZONE)
Primer Intermediate coat Finish Coat Total

Surface
Service Min DFT
Preparation Generic name DFT Generic name DFT Generic name DFT
micron
External surface of un- St-2 HB zinc 30-35 - - Aluminum Finish 30 (2 coats of 60
insulated equipment phosphate Paint (IS-2339) 15-20)
piping, tank and coating
0
structures (up to 120 C)
External surface of Sa 2 - - - - Phenolic epoxy 250 (2 coats 250
insulated equipment, of 125 )
tank and piping (up to
0
120 C)
External surface of un- St-2 - - - - HR Aluminum/ 40 (2 coats 40
insulated equipment Silicone of 15-20 )
and piping (120 to Aluminum
0
200 C)
External surface of St-2 - - - - HR Aluminum/ 40 (2 coats 40
and piping (120 to 200 Aluminum
0
C)
External surface of un- St-2 HR Aluminum/ 40 (2 coats 40
and piping (above 200 Aluminum
0
C)
External surface of St-2 HR Aluminum/ 40 (2 coats 40
and piping (above 200 Aluminum
0
C)
External surface of St-3 Solvent free/ 350-500 - - - - 350
equipment, piping and high solids
structures at highly surface tolerant
corrosive atmospheres epoxy coating *
like immersion service,
acid handling and
splash zones

Primer Intermediate coat Finish Coat Total

Surface
Service Min DFT
Preparation Generic name DFT Generic name DFT Generic name DFT
micron
External surface of St-3 - - Aluminum Finish 30 (2 coats of 30
equipment / piping with Paint (IS-2339) 15-20)
intermittent temperature
rise (e.g. flare lines)
External surface of St-2 Self priming HB 100-125 - - 100
pontoon top and roof coating
decks of floating roof
tanks
Internal surface of Sa 2 Inorganic Zinc 65-75 HB Epoxy based 35 - 40 High build Epoxy 150-200 (2 250
tanks in hydrocarbon Silicate Zinc Phosphate finish coats of
service(Note-iv) 75 - 100 )
Internal surface of Sa 2 Polyamide 75 High solids amine 500 575
tanks in water service cured epoxy cured epoxy (2 coats of
(Fire water, Industrial primer 250 )
Water)
Internal surface of Sa 2 Aliphatic amine 75-125 Amine cured 400-500 (2 475
bottom plates and first cured epoxy solvent free high coats of
shell course of crude oil zinc phosphate build epoxy liner 200-250 )
tanks
External surfaces of Sa 2 Inorganic Zinc 65-75 - - High build Epoxy 150-200 (2 200
buried piping (e.g. CBD Silicate finish coats of
lines) and underside of 75 - 100 )
tank bottom plates
Note:
i) Moisture barrier (Up to 1700C Aluminum, above 1700C Aus.SS foils) to be provided for all insulated piping/
ii) Stripe coat of primer paint to be applied at all edges, welds and other difficult to apply areas.
v) In case of steel structural 2 coats of Synthetic Enamel finish coat can be applied in place of aluminum finish paint (2
x 15-20 microns).

8.5 GUIDELINES FOR SELECTION OF PAINT/ COATING SYSTEMS
8.5.1 Commonly used Paint/ Coatings Systems
The following table provides the advantages, disadvantages, typical uses and mechanism of protection of the common paint
systems. This table can be used as a general guideline for selection of a paint system for a particular service.
Primers
Min. Surface Mechanism of

Generic Name Advantages Disadvantages Typical Uses
Preparation Protection
Inorganic Zinc Silicate (IZS) Sa 2 Galvanic- Widely used anticorrosive 1) Requires blast clean Project stage-any
Sacrificial primer surface substrate except
2) Only one coat can be crude tank-internal
applied
Two pack epoxy phenolic Sa 2 Barrier Excellent chemical 1) Chalking may result Pipe external; tank
resistance up to 150 deg 2) Requires blast clean internal
C surface
Polyamide cured epoxy primer Sa 2 Inhibitive Good chemical Less DFT / coat Tank internal;
resistance, can be used structure; pipe
over Inorganic Zinc
Silicate
Aliphatic amine cured HB epoxy Sa 2 Inhibitive Excellent chemical Nil Tank internal;
Zn phosphate resistance structure; pipe
Single component HB self priming St-3 Barrier, Heat Excellent HR coating; Very high cost High temperature,
coating with inert polymeric matrix resistance suitable for wet heat under insulation
(e.g. Hi-Temp 1027) service; no blast cleaning
required.
Solvent free/ High solids surface St-3 Barrier High DFT in single coat; High cost Equipment and piping
tolerant epoxy coating good chemical resistance; in corrosive external
no blast cleaning required. environment
Two component HB self priming St-2 Barrier Excellent chemical Not suitable in Tank external;
micaceous iron oxide modified resistance up to 150 deg immersion service structure; pipe; flare
epoxy coating C; no blast cleaning line
required.

Min. Surface Mechanism of

Generic Name Advantages Disadvantages Typical Uses
Preparation Protection
Self priming HB coating St-2 Barrier Good chemical Not suitable in Tank internal;
resistance; no blast immersion service structure; pipe
cleaning required.
Surface tolerant HB epoxy with St-2 Barrier Good chemical & Not suitable in Tank internal;
MIO and Aluminum temperature resistance; immersion service structure; pipe
no blast cleaning required.
Intermediate Paint
Generic Name Mechanism of Protection Advantages Disadvantages Typical Uses

HB Epoxy MIO Barrier Excellent moisture Not suitable in Structure; pipe
barrier immersion service, tank
internal
Finish Paint Systems
Generic Name Mechanism of Advantages Disadvantages Typical Uses

Protection
Two pack Acrylic Poly-Urethane Barrier Excellent UV resistance Not suitable for tank floating External surface (top coat) of
(PU) roof, Cooling Tower area equipment, structure; pipe
Silicone Aluminum/ HR Aluminum Heat Excellent temperature Commonly used as high
resistance resistance temperature coating
Solvent -free / High Solids amine Barrier Excellent liner for product Not suitable for external use Internal paint for product
cured epoxy / Amine cured tanks Requires specialized tanks
solvent free high build epoxy liner application
High build Epoxy finish Barrier Good chemical resistance Not suitable for highly Tank roof top, external and
corrosive zones internal surface of equipment
Glass flake epoxy Barrier Excellent moisture/ chemical/ Not suitable for tank internal Underground piping/
anti-bacterial resistance equipments
Epoxy Aluminum Barrier Good top coat as under Chalking effect Any external surface below
0
insulation 120 C.
Low VOC Epoxy siloxane coating Barrier, Heat Excellent temperature and Chalking effect Flare lines
resistance corrosion resistance

8.5.2 Advantages / Disadvantages of types of Epoxy Coatings
Different kinds of epoxy coatings are available in the market. The curing agents react with the epoxy resins and form a
cross-linked network that converts the epoxy resin to a suitable protective coating for different applications. Various types of
curing agents are used to obtain different performing characteristics of an epoxy coating. Selection criteria for curing agents,
sometimes called as hardener is very important to get better paint service life. There are so many variants of each of these
that it is very difficult to judge comparable values from just the product data sheet information alone.
From a practical standpoint, amine based curing agents are considered to more durable and chemical resistant than amide
based curing agents but most have a tendency to blush' in moist conditions. Blushing produces a waxy surface layer on
actively curing epoxy, the result a reaction with the curing agent and moisture in the air. Other potentially toxic chemicals
within the curing agent can also be released in the same manner, thus amines are often viewed in light of these potential
shortcomings. Amides, on the other hand, are more surfaces tolerant and less troubled by moisture.
Although there are many overlapping properties but some basic differences among some commonly used epoxies are
furnished as under:
Polyamine Polyamide Phenolic Siloxane Coal Tar

D Polyamine-cured epoxies are Polyamide is used in Phenolic epoxy has been Siloxane epoxies are Coal tar epoxies are a
E
S
normally used to improve film primers for recoatability, typically referred to as a relatively fast curing combination of a basic
C hardness, abrasion flexibility, adhesion, better system where the epoxy coatings with excellent epoxy resin and coal tar.
R resistance, adherent film and wetting characteristics, resin is heat-cured with a stain and mar The coal tar is in the form
I excellent chemical and and improved corrosion phenolic resin. resistance. They have of a semi-liquid pitch and
P
T
corrosion resistance. Amine resistance. Polyamide Sometimes combination excellent color and blended with the epoxy
I cured epoxies are often used epoxies generally offer the of phenol and gloss stability. Siloxane resin. The curing agents
O as protective coatings and widest latitude in coating formaldehyde are used epoxies are typically for coal tar epoxies are
N linings in highly corrosive formulation. They are for higher and / or higher used in high usually either mines or
environments. Amine considered more resilient temp. resistance. performance industrial polyamides. Coal tar
epoxies require care in and flexible, and have Increasing the level of and architectural epoxies offer excellent
handling since the amines better weathering phenolic increases the applications. resistance to fresh and
can be moderately irritating resistance and a longer chemical and solvent salt water and are highly
to the skin, and may cause pot life than amine cured resistance, but the resistant to cathodic
allergic reactions. epoxies. Polyamide coating loses flexibility. disbondment.
epoxies generally have

Polyamine Polyamide Phenolic Siloxane Coal Tar

less solvent and acid
resistance than amine
cured epoxies.
A Excellent alkali and water Good alkali and water High heat resistance Very good High film build with
D
V
resistance resistance Excellent chemical weathering one coat
A Very good acid resistance Good acid resistance resistance resistance Excellent salt water
N Excellent solvent Longer pot life than Excellent solvent Hard, abrasion resistance
T resistance amines resistance resistant film Excellent water
A
G Hard, abrasion resistant Easy to apply Excellent corrosion Very good acid resistance
E film Cures more quickly resistance resistance Excellent resistance to
S Excellent corrosion than amines Hard, abrasion Excellent color and cathodic disbondment
resistance Good weathering resistant film gloss retention Economical
Excellent wetting of characteristics Relatively fast dry
substrate Good film flexibility
Chemical/moisture barrier Excellent adhesion
L Amines can be irritating/ Faster dry than amines Some may require Solvent resistant Not for potable water
I
M
toxic Chalks heat cure Heat resistant Black color
I Relatively short recoat High viscosity Relatively slow air Critical recoat time/
T time Temperature cure difficult to recoat
A Relatively short pot life dependent Chalks/may discolor Fair solvent resistance
T
I Slower dry than normal Slow cure Relatively brittle Chalks/browns
O polyamides
N Chalks/ may discolor
S
A Severe chemical resistant Water immersion Severe chemical Bridges Liner for sewage
P
P
coating General industrial resistance Marine treatment tanks
L Barrier coating Offshore structures Tank linings High performance Not-potable water
I Offshore structures Storage tanks, Secondary finish coating tanks Pipe coating
C
Storage tanks, structural steel containment Kennels, Penstocks, dam gates
A
T structural steel Water/wastewater General industrial Schools, jails, Offshore rigs
I Bridges, power plants plants Tank linings Refineries hospitals Paper mills
O
Tank linings Bridges, power plants Bridges, power plants High moisture areas Chemical Plants
N
S Secondary containment Secondary Stain resistant Secondary
containment coating containment

8.6 PROTECTION OF UNDERGROUND PIPING
8.6.1 Coaltar enamel coating
The coaltar enamel coating involves the following operations
i) Surface preparation
ii) Priming
iii) Coating of pipeline
iv) Wrapping of pipeline by glass fibre felt
v) Outer wrapping by coaltar saturated asbestos felt
The coating and wrapping of the pipeline is done as per AWWA/ ANSI C-203-
86.
The coating operation calls for materials e.g. Type B (fast drying, synthetic)
Primer, Coaltar Enamel, Fibre glass felt inner wrap, Coaltar saturated
asbestos felt outer wrap. The equipment needed are coal tar Enamel heating
dope kettles, Primer containers, Priming & Coating machines for mechanical
operation and / or coating application felts, priming brushes for manual
coating.
Material & equipment
i. The primer should be type B (fast drying and synthetic) conforming to

AWWA C-203-86. Fast-drying, synthetic primer shall consist of
chlorinated rubber, synthetic plasticizer, and solvents. These
constituents shall be suitably compounded to produce a liquid coating
that can be readily applied cold by brushing or spraying and that will
produce a suitable and effective bond between the metal and a
subsequent coating of coal-tar enamel. And it should have a minimal
tendency to produce bubbles during application.
ii. Coaltar Enamel should be Type II conforming to AWWA-C-203- 86,

Coaltar Enamel is composed of specially processed coaltar pitch
combined with an inert mineral filler. It should not contain asphalt of
either Natural or Petroleum base. The coaltar primer and coaltar enamel
should be obtained from same manufacturer in order to have
compatibility.
iii. Glass fibre felt inner wrap shall have a minimum thickness of 0.76mm
conforming to AWWA C-203-86 Section 2.10. The glass fibre
reinforcement material shall be reinforced in the longitudinal direction.
iv. The outer wrap material should be coaltar saturated asbestos felt of
minimum thickness 0.6 mm and shall conform to AWWA C- 203-86
Section 2.10.

v. Primer containers of capacity approx. 20 litres or so shall be filled from

main primer drums capacity 200 liters or so and be used during hand
priming operation of pipeline. Primer containers should be cleaned
before filling the primer and their lids should be closed after use to avoid
evaporation of volatile solvents in primer. The primer shall be thoroughly
agitated in the drum / container before use.
vi. Coaltar enamel in solidified form is normally made available by

manufacturer, in 200 kg/ 50kg capacity drums. Suitable dope kettles
should be used for heating the enamel. Coaltar enamel cut pieces to be
charged in kettle for heating should not weight more than 5-6 kg.
Surface preparation
The pipeline surface should be free of oil and grease, prior to cleaning
operation. The oil and grease should be wiped with clean rags saturated in a
suitable solvent e.g. xylene or Trichloroethylene. The pipe surface should be
cleaned using mechanical machine/ blasting, of all dirt, mud, oil paint, rust,
scale and other impurities exposing base metal overall presenting a greyish
metal appearance equivalent to requirements as specified in SA 2 in the
case of new pipes. In the case of existing lines and where abrasive blasting is
not possible, mechanical machines, buffing wheels, wire brushes, files emery
paper may be used for cleaning the pipe surface to SA2. Cleaning by
mechanical means should be controlled to prevent burnishing or injurious
abrasion of the pipe metal.
Priming
The primer should be applied on a thoroughly cleaned pipe as an uniform thin

film which shall be free from runs, bubbles, dust, grass or foreign matter.
Primer should completely cover the circumference of the pipe and all surfaces
which are to be enamel coated. The missed spots or areas covered with
insufficient primer should be touched up immediately. The primer which has
been applied too heavily, for example at base of weld joints, should be
brushed out before the primer sets. Any runs and sags which have been dried
shall be scrapped off and painted. Only good quality paint brushes should be
used for priming. Care should be taken to prevent damage to primer film prior
to enamel application. The pipe should be reprimed in case the deterioration
of the primer has taken place before the application of coaltar enamel. Only
two applications of primer are permitted. If the enamel is not applied before
the second coat of primer gets dead (that is to say that primer looses its
effectiveness), the pipe shall be cleaned to base metal and then reprimed
afresh.
The primer coat shall be exposed for curing and only after that coaltar enamel
should be applied. The time of curing of prime is given by manufacturer. The
manufacturer also prescribes the time limit within which the coaltar enamel
should be applied on the primed pipe failing which the primer gets dead and
looses its effectiveness and bonding property. The cleaned pipe having

moisture ladden or wet surface should be primed only after the moisture dries
off.
8.6.2 Coaltar tape application
This coaltar tape protective coating system consists of a cold applied liquid
primer and heated coal tar base tape used in conjunction with coal tar and
other type of coatings. Primer and tape shall be either shop or field applied to
the exterior surfaces of steel pipes. Primer and tape shall be furnished by the
same manufactures.
The pipe surface is cleaned and a primer is applied. The primer used shall be
supplied by the tape manufacturer so as to be compatible to the system. A
polyethylene butyl-laminate or pressure sensitive pipeline coating tape is
applied over the primer which acts as the corrosion protective layer. A
polyethylene film is applied over that which is only an outer wrap whose main
function is to provide mechanical protection. Polyethylene in the form of a
heat sealing ribbon is extruded during the coating process. This ribbon forms
a weld or heat seal at the overlap of the polyethylene outer wrap. It is also
possible that multiple layers of tape and outer wrap rather than just one of
each can be applied by the above plant coating process if the specification for
the particular environment or operating conditions warrant.
8.6.3 Three layer polyolefin coatings (3LPO)
Recently, new 3 layer pipe coating systems, based on an epoxy primer,

polymeric intermediate layer and polyethylene top coat have been introduced
which combine the chemical resistance and interfacial properties of epoxy
coatings with the thick film mechanical properties afforded by polyethylene.
Before application, the surface is blast cleaned to Sa 2 . The prepared pipe

is preheated to 150 2000C after which the powder epoxy primer layer,
polymer intercoat layer and polyolefin top coat is applied and water cooled.
8.6.4 Cement lining
The cement lining for protection of steel pipe is popular in view of its
economy, durability and outstanding corrosion resistance.
The unique mechanism of protection by cement linings is different and

superior to that of other lining systems used for interior of pipelines. The lining
is permeable and permits the corrosive water to migrate through the cross
section of the lining wetting the steel surface. During the process, water
absorbs the product of hydration process calcium hydroxide raising the pH
to an alkaline value of 11 or more thus passivating the steel surface and
inhibiting corrosion. In addition, the lining possesses an inherent ability of self
repairing the hair line cracks that may occur.

A good adhesion of the lining is obtained by spinning the cement mixture

slurry at high speed. Also a very smooth low friction surface can be obtained
in the process. The normal thickness of the lining is 25mm. There are a
number of compositions of cement lining mortars and slurries used by
different applicators. But the most successful composition for oil field
applications is a cement / fly ash (artificial pozzolan) slurry consisting of 60%
API class C cement with high early strength and high sulfate resistance
containing zero tricalcium and 40% fly ash.
8.7 COATING & WRAPPING
8.7.1 Preparation of Coaltar Enamel
The coaltar enamel is usually supplied by manufacts in sheet metal drum of

200 kg capacity. The enamel shall be cut into pieces of 5-6kg. wt. the enamel
cut pieces shall be prevented from coming into contact with dirt, weed,
cinders, grass and other contaminants.
The enamel cut pieces shall be charged into dope kettle and slowly heated to
the temperature recommended by manufacturer for application. During
heating of enamel in kettle, the enamel charge shall be continuously agitated.
The molten enamel shall be passed through the screen fitted in the draw-out
nozzle to exclude particles of foreign matter or other deleterious materials that
could cause flaws in finished coating.
The enamel heated in excess of the maximum temperature specified by

manufacturer shall be rejected and dumped.
In case of an interruption or short shutdown due to weather conditions or

other unavoidable circumstances, the temperature of the enamel charge shall
be reduced approximately 550C lower than application temperature until
coating operations resume.
8.7.2 Application of Coating and Wrapping
Molten coaltar Enamel at application temperature shall be withdrawn from

dope kettle and poured over the slowly rotating pipe to coat the pipe uniformly
with an even film of coaltar enamel. The minimum thickness of coating of
enamel shall be 2.4mm (+0.8mm tolerance).
The pouring of coaltar enamel over the pipe can be done by mechanical
means or manually through buckets. In mechanical coating machines coaltar
enamel is drawn from kettle by pump in a trough. The molten enamel from
trough is again drawn by pumps and discharged through a enamel pouring lip
over the pipes. In manual coating, coaltar enamel in molten stage is drawn
from the kettles in the buckets and immediately poured over the pipe by
experienced coating mechanics called insulators in an even and uniform
manner. Care should be taken in not allowing molten enamel to cool below

lowest application temperature in buckets. Hot enamel in application

temperature range, should be applied over the pipe.
Immediately after application of the first layer of coaltar enamel, before the
enamel cools appreciably, the glass fibre felt reinforcement should be pulled
over the enamel in an uniform spiral wrap, so that fibre glass wrap is drawn
into hot enamel. The enamel should penetrate through fibre glass wrap,
sufficiently soaking it, and furnish a proper bond with next layer of enamel.
A second layer application of hot coaltar enamel shall then be applied to such
thickness as may result in composite enamel thickness of 4.75mm inclusive of
the two layers of enamel and reinforcement.
The coating of enamel over the pipe should be free from bubbles, foaming
and foreign matters.
A second layer of glass fibre reinforcement wrap should then be applied

immediately behind second layer of enamel coating in uniform spiral wrap so
that enamel penetrates through it and soaks the same. The coal tar
impregnated asbestos outer wrap shall thereafter be applied behind glass
fibre reinforcement wrap in a tight uniform spiral. The outer wrap should be
completely bonded with enamel.
No wrinkling should be allowed in wrapping. The overlap at the edges of all

wrapping should not be less than 12mm and also not more than 25mm. Care
should be taken so that there are no air pockets or bubbles between the outer
wrap and inner glass fibre felt wrap.
8.7.3 Field joint coating
In some projects of pipeline, the pipes are centrally coated at a yard. About 1
ft. length on both edges of pipes is left uncoated. Such pipes are sent to site
where pipes are welded. Thus all about 2 to 3 ft. length of pipeline field joint is
coated at site.
Uncoated length should be thoroughly cleaned by wire brushes, buffing

wheels etc. to the same specifications of cleaning as given in these
specifications. The cleaned length should be primed. The edges of exiting
coating on pipe should be slightly chamfered to about 4 inch length. In that
length outer wrap should be removed.
Field joint uncoated length, after priming should be coated with coaltar enamel
and wrapped with fibre glass felt wrap as given herein specifications.
The next layer of coaltar enamel should be poured on field joint coating patch
and on adjacent chamfered patch. The final outer wrap should then be
wrapped over second layer of coating. The entire coating thus should be
checked for any holidays by Holiday detector and repair should be done and
rechecked for holidays.

8.8 QUALITY CONTROL & TEST PROCEDURES
The coating thickness of selected location should be checked by pit gauge.

After checking the thickness spots where thickness readings have been taken
should be repaired. The coating of pipes should be checked by high voltage
holiday detector (beep tester) for any voids/ holidays in coating, according to
AWWA C-203-86. The operating voltage of Holiday Detector should not
exceed 15 kV. Voids/ holiday in coating is indicated in form of spark / beeping
sound when holiday detectors Ring / Brush electrode moves over the coating.
8.8.1 Electrical Test Equipment
The electrical equipment used to test the enamel and tape systems in the
shop, yard, or field shall be a portable, low-amperage, adjustable voltage,
pulse-type holiday detector employing an audible signaling device. The
holiday detector shall be furnished with a coil-spring electrode or suitable
brush type electrode.
Input Power
The primary input wattage shall be no higher than 20W, and the minimum
number of pulses at crest voltage shall be 20/s.
Operating voltage
For electrical inspection of coal-tar-enamel protective pipe coatings, the

operating voltage of the detector shall be established according to the
following procedure, but in no case shall the operating voltage exceed 15,000
V.
A portion of the coated pipe that includes an overlap of the outer wrap and is
located approximately 380 mm from one end of the pipe section shall be
selected for inspection. (This location represents the maximum thickness of
the coating and wrapping on the pipe).
To establish the operating voltage the detector the following steps shall be
taken:
i) Puncture the coating and wrapping with a sharp knife, awl, ice, pick, or
similar sharply pointed tool.
ii) Move the detector electrode back and forth over the puncture, reducing
the voltage until the detector ceases to register the known holiday.
iii) Place a strip of the same outer wrap used to coat the pipe over the
known holiday and move the detector electrode back and forth over the
strip of outer wrap.
iv) Slowly increase the equipment voltage until the detector begins to
register the known holiday under the outer wrap.

8.8.2 Marking and Repair of Holiday
Holidays will be indicated by an electric spark between the electrodes and the
metal surface, and by an audible signal. All holidays so indicated shall be
marked by chalk or crayon and repaired as follows:
8.8.3 Coal- tar enamel coatings
To repair holidays in coal-tar enamel coatings, first cut the outer wrap of lining
from around the holiday. Then recoat the bared area with the same system of
materials as used for the original coating or lining. After the repairs are
completed, the repaired areas shall be retested with the electric holiday
detector.
8.9 SHOP OR FIELD PEEL TEST PROCEDURE
The bond test to be conducted in the shop or field for the primer and coal-tar
adhesion shall be performed using a knife. The test shall be conducted at
10C - 27C, and shall be applicable without modification to both the interior
lining and exterior coating with or without reinforcement. If the penetration of
the enamel after application is less than 10, the peel test shall be evaluated at
no lower than 18C. Not more than one test each of interior lining and exterior
coating shall be performed on each pipe section unless either test fails.
If the coating or lining temperature measured with a surface thermometer is

above 27C or below 10C, pour sufficient hot or cold water over the test area
to adjust the enamel and substrate temperature within this range. Unless the
temperatures of the steel pipe and the enamel system at the peel test location
are within 3C of each other and also within temperature limits set forth
herein, incorrect peel test results will be obtained.
Using a knife heated if necessary (but not so much as to cause the enamel to
fume) and ensuring knife-blade-to-pipe contact, make two parallel cuts
through the coating or lining, approximately 102 mm long and 16mm to 19mm
apart. Place the cutting edge of the knife blade, beveled edge up, on the
enamel between, and at the beginning of, the parallel cuts. Push the knife at
an approximate 450 angle into the enamel and after ensuring knife-to-pipe
contact exists over the full width of the enamel between the parallel cuts,
apply an even pressure and loosen the enamel from the pipe for a length of
about 13mm.
Applying an even, steady pressure is necessary to avoid imparting shock

stresses within the enamel between the parallel cuts, thereby causing a
shattering separation of the enamel from the pipe that may be erroneously
interpreted as bond failure. With the knife blade placed under the loosened
end of the enamel, grasp the strip of loosened enamel between the knife
blade and the thumb. Apply a slow, steady upward pull. The bond is
satisfactory if the length of peel is no greater than the width of cut before the
enamel breaks.

If the peel length exceeds the cut width, the test is a failure and two additional
tests shall be made at two different locations on the same pipe section, a
minimum of 0.9m from the point of test failure. If both tests are satisfactory,
the pipe section shall be approved. If either additional test fails, the pipe
section shall be rejected.
8.9.1 Measuring coating thickness
The thickness shall be measured by pushing the point of an approved pit

depth gauge through the coating and wrappers until metal is reached. The
plate of the gauges shall then be lowered until it just touches the outer surface
of the outer wrap, always being placed parallel to the axis of the pipe and kept
normal to the surface. The thickness of any felt shall be deducted from the
figure indicated in order to obtain the thickness of the enamel. After the
checks, the holes made by the gauge shall be closed again by pressing down
the surrounding enamel. The specified minimum thickness shall be present
both at the pipe weld or any other point.
Coaltar enamel coating is quite common and salutary for short length
pipelines as used by the marketing division of IOC. Coaltar enamel coating
materials are also available in India made by indigenous manufacturers. The
quality of coating, dielectric strength, insulation resistance and protective
characteristics, obtained from coaltar enamel coating are also satisfactory.
This is the recommended system of coating for underground service in IOCs
marketing installations.
8.10 COATED PIPELINE LAYING
8.10.1 Handling and Transporting Enameled Pipe
Handling
Protected pipe shall be handled with equipment such as wide belts and wide
padded skids designed to prevent damage to the coating. Bare cables,
chains, hooks, metal bars, or narrow skids shall not be permitted to come in
contact with the coating.
Rail shipments
When shipped by rail, all pipe shall be loaded on properly padded saddles or
bolsters. All bearing surfaces and loading stakes shall be property padded.
Pipe sections shall be separated so that they do not bear against each other,
and the whole load shall be fastened together to prevent movement in transit.
Truck shipments
The pipe shall be supported in wide cradles of suitably padded timbers with
supporting surface shaped to fit curvature of the pipe. Chains, cables, or other
equipment used for fastening the load shall be padded. For smaller

diameter pipe, sand or sawdust-filled bags may be used instead of shaped

timers.
8.10.2 Laying of Pipelines
Precautions
During laying of the pipeline, worker shall exercise reasonable care and shall
reduce to minimum damage done to the protective coating or the pipe. Metal
tools or heavy objects shall not be permitted to come into contact
unnecessarily with the finished coating. Workers will be permitted to walk on
the coating only when necessary, in which case they shall wear shoes with
rubber or composition soles and heels. This rule shall apply to all surfaces,
whether bare, primed, or enameled. Damage to the pipe or the coating on any
cause during the installation of the pipeline shall be repaired.
Trench-side placement and storage
Pipe stored along the trench side shall be suitably supported off the ground to
avoid damage to the coating.
Hoisting
Pipe shall be hoisted from the trench side to the trench by means of wide belt
slings. Chains, cables, tongs, or other equipment likely to cause damage to
the enamel coating will not be permitted, nor will dragging or skidding of the
pipe. Inspection of the coating on the underside of the pipe shall be done
while it is suspended from the slings. Damage shall be repaired before the
pipe is lowered into the trench.
Bedding
Unless otherwise specified, where the trench traverses rocky ground

containing hard objects that could penetrate the protective coating, a layer of
screened earth or sand not less than 76 mm thick shall be placed in the
bottom of the trench prior to installation of the pipe. Other suitable bedding
materials may be used in lieu of earth or sand.
Trench Backfilling
Backfilling shall be conducted in such a manner as to avoid abrasion or other

damage to the coating or the pipe. The following requirements shall be
adhered to unless otherwise specified.
Installation and type of backfill
Immediately after the pipe is placed and aligned in the trench and before the
joint is completed, loose backfill shall be placed about the pipe, except at field

joints, to a depth of about 152 mm above the pipe. This backfill shall be free
from large stones, frozen lumps, trash, or material that may decay.
Rocks and Hard Objects
If rocks or other hard objects occur in the backfill along any section of the
pipeline, such backfill shall be screened before being placed about the pipe,
suitable waste backfill from other parts of the line may be transported to and
placed about, the pipe in such sections or the coated pipe may be wrapped
with rock shield to avoid such damages.
8.11 COALTAR TAPE APPLICATION
This coaltar tape protective coating system is meant for special sections,
connections and fittings. It consists of a cold applied liquid primer and heated
coal tar base tape used in conjunction with coal tar and other type of coatings.
Primer and tape shall be either shop or field applied to the exterior surfaces of
steel pipes. Primer and tape shall be furnished by the same manufactures.
The coating materials shall consist of cold-applied liquid primer and tape
meeting the following requirements:
Prime shall be cold-applied liquid that shall comply with pollution control
requirements in effect at the location of use. Primer shall not settle in the
container to form a cake that cannot be mixed easily by hand stirring. Primer
shall have satisfactory brushing or spraying properties and a minimum
tendency to produce bubbles during application.
Tapes shall be composed of coal-tar base coating material supported on a

fabric of organic or inorganic fibers. The tape shall comply with the physical
properties listed in table 3.2.1. The fabric shall be covered on both sides by
the coating material. Tape shall be furnished in standard widths as
recommended by the manufacturer. Rolls shall be wound on hollow cores
having a minimum inside diameter of 37.5 mm. Tape shall have sufficient
pliability at a temperature of 25C to unwind from the roll without disbonding
the coating from the fabric.
Coaltar tapes are available in roll of 9M, 15M, 23M length and 30 cm width.
The thickness of coaltar tape at the minimum is 1.27mm.
The tape application should be done as per recommendations of

manufacturer. The tape should be wrapped over the pipe with minimum of
12.5mm overlap per single wrap. Manufacturer may specify either single or
double wrap. In application care should be taken that there are no air pockets
and bubbles beneath the tape. The tape should remain in intimate contact of
primed pipe.

The electrical inspection of coaltar tape coating should be done by running the
holiday detector on coaltar tape coating for any voids / holidays.
8.11.1 Physical Properties of Coaltar Tape
ASTM Requirement
Property
Method Min. Max.
Tape thickness (microns) coalter component 1270 -
Softening point (0C) D36 65 121
Penetration at 250C / 100 gm 3 20
Filter % D2415 20 30
Film separator (If used and if of the type that is 6.4 12.7
not removed prior to primer application) microns
8.12 P.E TAPE COATING
P.E tape system consists of one primer, one inner wrap coating and one outer
wrap coating. P.E tape coatings are done as per recommendations of
manufacturer.
8.12.1 Primer
Several types of primers are available. Normally they are made of a solution
of rubber and unsaponifiable resins in petroleum spirit. It must be compatible
with the tape and it is applied by hand / machine. Drying time of primer varies
between 10-30 mts. depending upon the type of primer and atmosphere. The
primer must be over wrapped with tape within 6 hours after application.
8.12.2 Tapes inner wrap
This consists of a three ply plastic tape stabilized polyethylene backing with
rubber compound as adhesive on both sides. The consistency of the
compound on one side is such that under tension it flows on uneven steel
surfaces and provides good bonding. The total thickness of the inner wrap is
0.50mm or 0.80mm. This can be applied by
i. Hand operated machines

ii. Machine application in yards and
iii. Machine application over the ditch.
8.12.3 Tapes Outer Wrap
This consists of a two ply plastic tape with the same type of adhesive on one
side only. It is applied over the inner wrap using the same type of machines
as above. The outer wrap should be fully compatible with the properties of
inner wrap. The outer wrap must fully self amalgamate with the inner wrap
tape at contact area. The total thickness of outer wrap is 0.5mm or 0.75mm.
Service temperatures of these tape are between -60C and +75C.

P.E tape coating entails the following operations.
a. Surface preparation to the norms as given in the case of coaltar enamel.

b. Priming by a suitable primer as recommended by manufacturer according
to the type of tape and compatibility.
c. Application of PE tape
P.E. tapes are usually available in lengths of 15M, 25M, 80M, 100M and
200M and width of 5cm, 15cm, 25cm, & 30cm. Total thickness is between
1.00 mm to 1.55 m. Overlapping can be as per manufacturers
recommendations. But the inner wrap when applied over primer, should have
a minimum overlap of 12.5mm per single wrap. Manufacturer may specify
either single or double wrap, care should be taken to eliminate air pockets /
bubbles beneath the tape coating; sometimes manufacturers recommend a
white PE tape with low adhesive to wrap over main PE tape coating to protect
the tape coat over pipeline from heat and excessive sun rays. Heat shrinkable
polyethylene tapes are also offered for consideration.
The tapes are applied as follows:
Step 1
The pipe surface is cleaned and a primer is applied. The primer used shall be
supplied by the tape manufacturer so as to be compatible to the system.
Step 2
A polyethylene butyl-laminate or pressure sensitive pipeline coating tape is

applied over the primer which acts as the corrosion protective layer;
Step 3
A polyethylene film is applied over that which is only an outerwrap whose

main function is to provide mechanical protection;
Step 4
Polyethylene in the form of a heat sealing ribbon is extruded during the

coating process.
This ribbon forms a weld or heat seal at the overlap of the polyethylene outer
wrap.
All the above four steps are in a single and simultaneous operation. It is also
possible that multiple layers of tape (Step 2) and outer wrap (Step 3) rather
than just one of each can be applied by the above plant coating process if the
specification for the particular environment or operating conditions warrant.

8.12.4 PE Tape specification
PE Tape, primer specifications are obtainable from manufacturer depending

upon the service desired from the tape. The following table presents the
various parameters of P.E Tapes used for tape coating of pipeline. The values
indicated can be used as a guideline. Final selection of parameters of tape
coating depends upon service required from pipeline, environmental condition
etc.
PE Tape
Backing Polyethelyne, slow density

Adhesive Synthetic rubber, synthetic resin
pressure sensitive
Physical Properties
Total thickness 1.00 to 1.55mm
Backing thickness 0.52 to 0.60mm
Adhesive thickness 0.40 to 1.00mm
Tensile Strength at 23C N/10mm >40
Elongation at break at 23C% >400
Dielectric strength kV/mm >30
Water vapour transmission g/m2-24 hr 0.2
Water absorption at 23C < 0.1
Adhesion strength
Water / primer / tape at 23C >15
Minimum overlap 50%
The tape must comply with DIN 30 672, DIN 53 481, DIN 53 455, DIN53 122.
8.13 ADVANTAGES
The outer wrap layer completely covers and protects the corrosion protective
layer from UV, cold, heat and moisture during outdoor storage and
transportation to site. The PE based tape and outer wrap remain ductile and
flexible down to - transportation and handling under
extremely cold weather conditions without much damage. The manufacturers
claim that coated pipes can be bent in the field without damage to the
coatings. The tapes made by reputed manufacturers do posses this property.
Pipes coated with the above multi-layered PE tape coating system can be
coated with concrete if specified so as the outer wrap is capable of
mechanically protecting the inner corrosion protective layer during concrete
coating process.
8.14 PVC TAPES
These tapes are similar to PE tapes in construction and application. The

adhesive used in this case is a bituminous rubber compound for bonding to
steel and also for bonding to self. Thickness of a single layer of tape is
1.65mm. These tapes are to be applied as follows.

The pipe surface is to be thoroughly cleaned to remove rust, millscale, weld

spatter, dirt and other loose or deleterious matter. A primer is to be applied by
brush to the dry, clean, prepared surface in one thin continuous coat without
runs or sags. The primer dries within 2-10 mts. depending on the atmosphere.
The tape should be wrapped over a dry primer. The primer shall be furnished
by the tape manufacturer in order to have compatibility.
8.14.1 Some typical properties of PVC tapes
Test method Value Unit

Adhesion to steel ASTM-D-1000 2.75 N/mm
Adhesion to self ASTM-D-1000 2.75 N/mm
Cathodic disbondment Impact ASTM-G-8 <10 mm radius
resistance
(Single layer) ASTM-G-13 >20 drops
Tensile strength ASTM-D-638 14-20 N/mm2
Tensile modulus ASTM-D-638 10-37 N/mm2
Elongation ASTM-D-638 220-300 %
Dielectric strength >40 kV
Insulation resistance 1012 ohms/cm2
0
Operating temperature range 20 to+75 C
Interleaf over width 25 mm
Thickness Adhesive compound 0.90 mm
PVC carrier 0.75 mm
8.14.2 Comparison with PE tapes
Pipeline coatings based on polyvinyl chloride tapes had been widely used and
they are slowly being replaced by PE tapes due to the following reasons. PE
tapes are superior to PVC tapes in thermal stability. PVC, under the influence
of heat may be decomposed by dehydrochlorination. Since PVC tapes contain
plastisisers in the composition, there is possibility of loss of plasticizers due to
aging and the tape becoming brittle whereas PE tapes do not contain
plasticisers. PVC tapes are flexible and ductile only up to 180C below which
it becomes brittle whereas PE tapes are flexible and ductile up to 400C. PE
tapes achieve bond level of 2.8 to 3.4 kg. per cm. after 24 hours of application
whereas PVC tapes achieve only 0.89 kg per.cm. after 24 hours.
The cathodic protection current consumption in the case of PE range from 30-
80 uA/cm2 depending on environment. The maximum service temperature is
830C.
Polyethylene tapes, bearing either on one side or on both sides a coating of

butyl rubber, provide an outstanding protection against corrosion on both fully
wrapped pipelines as well as on welds and adjoining areas. They possess a
very low permeability for water - vapour, oxygen, carbon dioxide and water,
thus effectively preventing corrosion reactions at the steel surface to develop.
They also have a high resistance against impact, penetrating and shear. The

tapes with double layers of butyl rubber offer the highest degree of sealing the
steel surface from outside attacks.
8.15 FUSION BONDED EPOXY COATINGS
FBE consists of a bisphonel A based resin and a polyamide curing agent. In

order to coat pipes economically, it is necessary to have very fast production
rates hence fast curing. To obtain this fast cure, the resin, hardener and fillers
are made into one component. These are mixed above the melting point of
the resin in an extruder. After melt mixing, the product is cooled and then
milled into fine powder of size less than 100 microns. This powder is now
partially reacted and hence can cure fast when applied to hot pipe.
The electrostatically charged powder is sprayed over the heated pipe. On

contact it melts and then flows during its gel time and subsequently cures.
The powder should possess fast curing properties without losing flexibility. It
should have high impact strength without losing good cross liking. It should
provide adhesion to base metal which would not breakdown when
cathodically protected. It should have a long shelf life and a minimum wastage
due to overspray.
Fusion bonded epoxy powder coatings have high flexibility, outstanding

impact resistance, excellent adhesion and resistance to abrasion. They are
resistant to heat and they possess extremely low oxygen permeation and
hence provide extreme resistance to corrosion.
The high temperature performance, chemical resistance, resistance to soil

stress and excellent resistance to cathodic disbondment in comparison to
traditional coatings has resulted in the increased use of fusion bonded epoxy.
They have become more attractive due to several advances in both the
application process and in the raw material. FBE provide a more controllable
application process and a product whose quality can be assured prior to
laying of the pipeline.
8.15.1 Advantages of fusion bonded epoxy coatings
i) They are thermosetting materials giving tough, infusible films having a

wide range of temperature operation.
ii) They have excellent adhesion to a clean surface limiting the possibility
of stress corrosion cracking.
iii) They have excellent resistance to disbonding on cathodically protected

pipelines. They also require very low levels of supplementary cathodic
protection.

iv) They have good flexibility ensuring tolerance of field bending on-shore
and suitability for reel barge laying offshore, both at high and low
ambient temperatures.
v) They have high strength and toughness ensuring resistance to soil

stress, backfill and handling.
vi) They will not sag or cold flow when subjected to normal operating
temperature encountered on hot lines or downstream from compressor
stations, as evidenced by bell hole inspection after years of ground
service.
vii) Chemical inertness makes fusion bonded epoxy coatings highly

resistant to moisture penetration. Bacteria and fungus attack, soil
acids, alkalies and slags, hydrocarbons and other chemicals
associated with pipelines use.
viii) They have a compatible field weld coating system and easy repair of
damaged coating.
ix) They have a better overall corrosion resistance at low and high
ambient temperatures.
8.16 METHOD OF APPLICATION
The coating material is only part of the coating system. Application of the
coating to the pipe is as important as the material itself. Fusion bonded epoxy
coatings require a very simple application process which can be summarized
as follows:
Clean, heat, coat, cure and inspect.
Cleaning is by far the most important step in the application of any coating,
since the performance of the coating is directly related to the surface
preparation.
Blast cleaning is carried out to a near white surface finish, to Swedish

Standard SA 2 , with a nominal 40-70 micron anchor pattern. This is usually
accomplished using one or more blasting machines with steel grit as the
cleaning media. After cleaning, the interior of the pipe is blown free of residual
grit and other contaminants.
The next step in the process is to uniformly heat the pipe to a temperature in
the range of 232-2460C using a non-contaminating heat source. Three heating
methods are used-electrical induction, gas fired forced air and a combination
of high velocity direct flame impingement and infra-red.
After the pipe has been heated to the required temperature it passes through
a powder coating machine where the fusion bonded epoxy coating is
uniformly applied at a thickness between 350-400 microns using electrostatic

deposition. After application, the coating is allowed to cure using the residual
heat in the pipe. During the curing process, the coated pipe should be
carefully handled to avoid damage to the coating. After the coating has been
cured, the pipe can be force-cooled with air or water to facilitate inspection
and handling.
Coated pipe is electrically inspected using conventional search electrodes

operating at 5 volts per micron of coating thickness. Small imperfections in the
coating are repaired using hot melt patch sticks or two-part ambient
temperature curing liquid epoxy resins.
8.17 THREE LAYER POLYOLEFIN COATINGS (PE/PP)
Recently, new 3 layer pipe coating systems, based on an epoxy primer,

polymeric intermediate layer and polyethylene top coat have been introduced
which combine the chemical resistance and interfacial properties of epoxy
coatings with the thick film mechanical properties afforded by polyethylene.
8.17.1 Epoxy Primer
The epoxy primers used in 3 layer coatings are specially designed for the
purpose with the following major characteristics:
(a) To bond directly to the metal surface and to provide a continuous

protective film that is highly resistant to chemical attack, ensuring good
cathodic disbondment resistance.
(b) To provide interfacial bonding sites for the reactive functional groups in
the polymeric intermediate layer, ensuring high peel strength adhesion
in the coating system.
(c) To be compatible with the application temperatures normally used in

extrusion of polyolefin coatings and allow coating at the same
production rate.
Normally the epoxy primer used is a fusion bonded powder epoxy. The coat
thickness of the epoxy primer layer is considerably below that used in single
layer liquid or powder epoxy based coating where 350 to 450 microns is
normally specified. Generally about 60-100 microns is the thickness at which
the epoxy primer layer is normally used since the surface profile or angular
pattern of the metal surface itself after grit blasting is often around 40-50
microns.
8.17.2 Intermediate Polymer Layer
The intermediate layer used in 3 layer coatings consists of a specially

formulated hard type of co - or ter polymer compound usually based on the
core action of base polyolefin with various functional monomers such as ethyl
vinyl acetate, ethyl butyl acrylate, carboxyl acid, etc. Since the highly non

polar nature of the polyolefin top coat is incompatible with polar substrates
such as steel or the epoxy primer coat, the role of this intermediate layer is to
act as a bonding layer between the primer and top coats.
In order to allow interfacial bonds to form between these two layers, the
adhesive is applied before full polymerisation of the epoxy primer takes place.
Apart from the chemical composition of the polymer adhesive, the method of
fabrication also plays an important role, and a number of suitable formulations
are available commercially based on both grafting and co-polymerisation
production techniques. The thickness of the polymer adhesive layer is
generally around 250-400 microns depending on the particular method of
application, and is similar to that used in conventional hard adhesive based
2 layer systems.
8.17.3 Polyolefin Top Coat
The most widely used grade of polyolefin specified in 3 layer systems is low
density polyethylene although other polymers such as medium and high
density polyethylene and modified polypropylene are being increasingly used
for some applications where increased service temperatures are required.
The polyolefin top coat in 3 layer systems provides to a large extent the
mechanical properties of the system, due to its resistance to impact,
indentation and abrasion damage, and therefore the thickness depends on
the character of the polyolefin used as well as the pipe diameter.
The principal steps of the application are:
i) Removal of surface contaminants.

ii) Grit blasting to Sa 2 1/2 finish with average anchor pattern of 40 - 60
microns.
iii) Preheating of the pipes to the desired application temperature (150-
2100C).
iv) Application of the powder epoxy primer layer.
v) Application of the polymer intercoat layer.
vi) Application of the polyolefin top coat.
vii) Water cooling of the coated pipes.
8.18 INTERNAL COATING FOR PIPELINES CARRYING PETROLEUM

PRODUCTS AND SEAWATER
Introduction of cement lining for protection of steel pipe from corrosive water
is more than 100 years old in USA and it has become an accepted corrosion
control system for oil pipelines more than 50 years ago, in view of its
economy, durability and outstanding corrosion resistance.
In view of the improved latest techniques cement lining are available that can
give a life expectancy of 20 to 30 years for line pipes carrying corrosive water.

The unique mechanism of protection by cement linings is different and

superior to that of other lining systems used for interior of pipelines. The lining
is permeable and permits the corrosive water to migrate through the cross
section of the lining wetting the steel surface. During the process, water
absorbs the product of hydration process calcium hydroxide raising the pH
to an alkaline value of 11 or more thus passivating the steel surface and
inhibiting corrosion. In addition, the lining possesses an inherent ability of self
repairing the hair line cracks that may occur.
Method of lining
A good adhesion of the lining is obtained by spinning the cement mixture

slurry at high speed. Also a very smooth low friction surface can be obtained
in the process. The normal thickness of the lining is 25mm.
Materials for Cement Linings
There are a number of compositions of cement lining mortars and slurries

used by different applicators. But the most successful composition for oil field
applications is a cement / fly ash (artificial pozzolan) slurry consisting of 60%
API class C cement with high early strength and high sulfate resistance
containing zero tricalcium and 40% fly ash.

CHAPTER-9
9.0 NEW DEVELOPMENTS IN PAINTING/ COATING

The continuous research and development in the field of paints and coatings
have lead to development of new paint/ coating products in the market. Some
of the recent developments in the field of painting/ coating are as below:
9.1 TEMPERATURE INDICATING PAINTS
These coatings are intended for identification of hot spots and internal
refractory failures in critical equipments, exhibiting visible color change in
response to temperature rise. The coating also provides corrosion protection.
9.2 FIRE PROOFING (INTUMESCENT) COATING
The fire proofing coatings can be used in place of conventional fire proofing to
reduce the risk of structural collapse under extreme high temperatures of
hydrocarbon fires. These coatings have low density, low water absorption
characteristics and easy application process.
9.3 MOISTURE CURED URETHANES
The MC Urethanes are useful in applications requiring extreme resistance to

abrasion, for areas subjected to expansion and contractions. These coatings
are normally single pack low solid coatings.
9.4 HIGH TEMPERATURE COATINGS
These special coatings are formulated to be directly applied to hot steel

surface up to 6500C. These types of coatings are surface tolerant and can be
applied on manual cleaned surface and are particularly helpful in on-line
maintenance painting of hot equipment and piping. These special coating
systems are formulated with a highly engineered silicone resin, a thermally
stable acrylic resin and special inorganic pigments.
9.5 COMPOSITE REPAIR TECHNOLOGY
The composite repair system for piping is designed, installed, tested and
inspected as per technical specification ISO/TS 24817 which can be designed
for long lifetimes (up to 20years). Once applied, the composite wrap alone can
take care of the line pressure even if the parent metallic pipe gets completely
corroded.
The composite repair systems are typically composed of thermosetting

polymer and high strength reinforcement fibers. Composite repairs for pipeline
defects work by sharing the hoop load in the pipe wall. The yielding rate will
be controlled by the externally applied composite sleeve so that the maximum
allowable operating pressure can be safely maintained.

9.6 ANTIFOULING / FOULING RELEASE COATINGS
These are polymer based chemically inert coatings with resistance to fouling
due to water. The special coatings are designed to prolong the time for slime
and fouling to settle on the paint surface.
9.7 THERMAL SPRAY APPLICATION
Thermal spraying is a group of processes wherein a feedstock material is

heated and propelled as individual particles or droplets onto a surface. The
thermal spray gun generates the necessary heat by using combustible gases
or an electric arc. As the materials are heated, they are changed to a plastic
or molten state and are confined and accelerated by a compressed gas
stream to the substrate. The particles strike the substrate, flatten, and form
thin platelets (splats) that adhere to the irregularities of the prepared substrate
and to each other and cool down to build up into a laminar structure forming
the thermal spray coating. The common choice of coating material includes
aluminum, zinc, zinc-aluminum alloys and corrosion resistant alloys.

CHAPTER-10
10.0 COMMON PAINT COLOUR CODE OF IOCL

(For all Divisions of IOCL including Refineries & Petrochemicals,
Pipelines & Marketing)
10.1 SCOPE
This specification covers the requirement of colour scheme for the

identification of the contents of the pipelines carrying fluids, storage tanks and
equipment in IOCL refineries, petrochemicals, pipelines & marketing
installations. The following colour coding system has been made based on
international standards like ASME/ ANSI /BS & Indian Standard & IOCL
existing standard colour coding.
10.2 IDENTIFICATION
The system of colour coding consists of a ground colour or 1 M band painting

and secondary colour strips superimposed over the ground colour/ band
colour. The ground colour identifies the basic nature of the service and
secondary colour strips over the ground colour/ band colour distinguishes the
particular service. The ground colour shall be applied over the entire length of
the un-insulated pipes. For insulated lines ground colour shall be provided as
per specified length of 1 M at specified intervals to identify the basic nature of
service and secondary colour strips to be painted on these specified bands to
identify the particular service. Above colour code is applicable for both unit
and offsite pipelines, marketing & pipeline installations.
For ATF, AV Gas, MO Gas services the original strip colour should be as per
DGCA & DGQA guidelines and QC Manual of Marketing as given in
attachment Annexure-A. The original ground colour of ATF will be red oxide
and for AV gas & MO gas the ground colour will be orange. The details of the
strips colour and dimensions are indicated in the Annexure-A.
For cost optimization purposes the piping which do not need repainting, there
only the band of 1 M and strip painting to be done at identified intervals to be
done and whenever repainting of the complete line is scheduled the ground
colour of the line to be repainted.
The following ground colour designation for identification of basic

classification of various important services shall be followed:
Post Office Red - Fire protection materials

Off White/ Aluminium - Steam (all pressures)
Canary Yellow - Chemicals and dangerous materials
Dark Admiralty Grey - Crude oil, lube oil
Orange - Volatile petroleum products (motor
spirit and lighter)

Oxide red - Non-volatile petroleum products

(kerosene and heavier, including waxy
distillates and diesel, gas oil)
Black - Residual oils, still bottoms, slop oils
and asphalts, fuel oil
Sky blue - Water (all purities and temperatures)
Sea green - Air and its components and Freon
This clearly indicates that there are basic 4 colours i.e. orange, red oxide,
black & admiralty gray for covering all hydrocarbon services for easy
identification and ensuring safety precautions.
In the Common Paint Colour Code, there are three types of paint colours
namely:
a) Base colour for complete piping as per ANSI colour code namely
orange, red oxide, black and admiralty gray for hydrocarbon lines.
b) Band colour (wherever other colour codes are followed, insulated pipes,
where complete repainting is not overdue, ATF lines) to be used at
specified locations with approximate 1 meter or as specified in Sl. No.
10.3.1 width for easy identification of the range of hydrocarbon service.
c) Strip colour to be used as specified in the paint colour code for specific
identification of the service as per details given in Sl. No. 10.3.1.
The narrow strips presenting the identifies the specific service, may be
applied by painting or preferably by use of adhesive plastic tapes of the
specific colour on the ground colour or 1 M band painting.
10.3 COLOUR BANDS AND IDENTIFICATION LETTERING
The following specifications of colour bands shall be followed for identifying

the piping contents, size and location of bands & letters. The bandwidth and
size of letters in legends will depend to some extent upon the pipe diameter.
Either white or black letters are selected to provide maximum contrast to the
band colour. Bands usually are 50 mm wide and regardless of band width, are
spaced 25 mm apart when two bands are employed
Table 1.0: Colour bands and size of lettering for piping:
Outside diameter of pipe or Width of colour bands Size of legend

covering in mm in mm letters in mm
19 to 32 200 13
38 to 51 200 19
64 to 150 300 32
200 to 250 600 64
Over 250 800 89
In addition, ground colour as per specified length should be provided on

insulated piping for easy identification of nature of fluid, on which the colour

bands should be painted for identification of each service. The length of the
ground colour should be 3 times the width of normal band or 2 meters,
whichever is suitable depending on the length of the pipe.
Size of letters stenciled/ written for equipment shall be as given below:
Column and vessel : 150 mm (Height)

Pump, compressor and other machinery : 50 mm (Height)
In addition, the contents of the pipe and/or direction of flow may be further
indicated by arrows and legend. If a hazard is involved it must be identified
clearly by legend.
Colour bands: The location and size of bands, as recommended, when used,
shall be applied to the pipe.
- On both sides of the valves, tees and other fittings of importance.

- Where the pipe enters and emerges from walls and where it emerges from
road & walkway overpasses, unit battery limits.
- At uniform intervals along long sections of the pipe.
- Adjacent to tanks, vessels, and pumps.
For piping, writing of name of service and direction of flow for all the lines shall
be done at following locations:
Offsite Lines: Both sides of culverts, any one side of walkways, near tank
dykes, at tank inlet/outlet points and suction/ discharge of pumps/
compressors.
Unit Lines: At the battery limit, suction/ discharge of pumps/ compressors,

near vessels, columns, Tanks, Exchangers etc.
The letters will be in black on pipes painted with light shade colours and white
on pipes painted with dark shade colours to give good contrast.
Only writing of service name shall be done on stainless steel lines.

Precautions should be taken while painting by using low chloride content
painting to avoid any damage to the stainless steel pipes. It is preferable to
use adhesive plastic tapes to protect stainless steel pipes.
Colour band specification:
a) Unit Area: Bands at intervals of 6.0 meters.

Offsite Area: Bands at intervals of 10.0 meters.
b) Each pipe segment will have minimum one band indication, irrespective of
length.
c) The bands shall also be displayed near walkways, both sides of culverts,
tanks dykes, tanks, vessels, suction and discharge of pumps/
compressors, unit battery limit, near valves of line, etc.

For alloy steel/ stainless steel pipes and fittings in stores/ fabrication yard,
color band (Minimum wide) should be applied along the complete length of
pipe, bends/ tees, side-curved surface (on thickness) of flanges as well as
valves as per the metallurgy.
In case of camouflaging requirements of civil defence or any other locational

requirements, the same shall be followed accordingly.
10.3.1 The specification for application of the complete Piping identification colour
code, including base colour/ bands colours and strip colours, are presented in
the enclosed table.

IOCL RECOMMENDED PAINT COLOUR CODE
MATCHING AS PER RAL

Sl. NO. SERVICE RECOMMENDED COLOUR CODE COLOUR
NUMBERING
BASE STRIP
HYDROCARBON LINES (UNINSULATED) COLOUR COLOUR
1. CRUDE SOUR Dark Ad. Grey with 1 orange strip 7,012 2,011
2. CRUDE SWEET Dark Ad. Grey with 1 red strip 7,012 3,001
3. LUBE OILS Dark admiralty grey with 1 green strip 7,012 6,010
4. FLARE LINE Heat resistant Aluminium 9,006
5. L.P.G. Orange with 1 oxide red 2,011 3,009
6. PROPYLENE Orange with 2 oxford blue strip 2,011 5,013
7. NAPHTHA Orange with 1 green strip 2,011 6010
Orange with 2 green strip (Modified on

8. HEAVY NAPHTHA 2,011 6010
July10)
9. M.S. Orange with 1 dark ad. grey 2,011 7,012
Orange with 1 strip each of green, white & red 6010, 9010,
10. AV. GASOLINE (96 RON) 2,011
strips 3001
11. GASOLINE (regular, leaded) Orange with 1 black strip 2,011 9,005
12. GASOLINE (Premium, leaded) Orange with 1 blue strip 2,011 5,013
13. GASOLINE (White) Orange with 1 white strip 2,011 9,010

MATCHING AS PER RAL

NUMBERING
14. GASOLINE (Aviation 100/130) Orange with 1 red strip 2,011 3,001
15. GASOLINE (Aviation 115/145) Orange with 1 purple strip 2,011 4,006
16. N-PENTANE Orange with 2 blue strips 2,011 5,013
17. DIESEL OIL (White) Oxide red with 1 white strip 3,009 9,010
18. DIESEL OIL (Black) / LDO Oxide red with 1 yellow strip 3,009 1,023
19. KEROSENE Oxide red with 1 green strip 3,009 6,010
20. HY.KERO Oxide red with 2 green strips 3,009 6,010
21. DISULFIDE OIL (EX-MEROX) Oxide red with 1 black strip 3,009 9,005
22. M.T.O. Oxide red with 3 green strips 3,009 6,010
23. DHPPA Oxide red with 2 white strips 3,009 9,010
24. FLUSHING OIL Oxide red with 2 black strips 3,009 9,005
25. LAB FS Oxide red with 2 dark Ad. Grey 3,009 7,012
26. LAB RS Oxide red with 3 dark Ad. Grey 3,009 7,012
27. LAB (Off. Spec.) Oxide red with 1 light grey 3,009 7,035
28. N-PARAFFIN Oxide red with 1 blue strip 3,009 5,013

MATCHING AS PER RAL

NUMBERING
29. HEAVY ALKYLATE Oxide red with 1 red strip 3,009 3,001
30. BLOW DOWN, VAPOUR LINE Off White / Aluminium with 1-Brown strip 9,006 8,004
31. BLOW DOWN Off White / Aluminium with 2 brown strips 9,006 8,004
A.T.F.(Strip colour dimension 9,010 White

32. Red Oxide with 1 white & 3 black strips 8,003
as per Annexure-A) 9,005 Black
5,013 Blue
33. AV Gas Orange with blue & red strips 2,011
3,001 Red
1,023
34. MO Gas Orange with yellow & red strips 2,011 Yellow
3,001 Red
35. TOULENE Orange with 1 yellow strip 2,011 1,023
36. BENZENE Orange with 1 green strip 2,011 6,010
37. LAB PRODUCT Orange with 1 blue strip 2,011 5,013
38. FUEL OIL Black with 1 yellow strip 9,005 1,023
39. FUEL OIL (aromatic rich) Black with 2 yellow strips 9,005 1,023
40. ASPHALT Black with 1 white strip 9,005 9,010
41. SLOP & WASTE OILS Black with 1 orange strip 9,005 2,011
42. SLOP AROMATIC Black with 2 orange strips 9,005 2,011
PETRO-CHEMICALS

MATCHING AS PER RAL

NUMBERING
43. PROPANE Orange with 3 Blue strip 2,011 5,013
44. METHANE Orange with 1 Brown strip 2,011 8,004
45. CYCLOHEXANE Orange with 1 Pearl night blue strip 2,011 5,013
46. N-HEXANE Orange with 1 Pearl green bend 2,011 6,010
47. ETHANE Orange with 4 Blue strips 2,011 5,013
48. BLENDED FUEL OIL Black with 3 Yellow strips 9,005 1,023
49. ETHYLENE OXIDE Orange with 3 Green strips 2,011 6,010
POLYMER PELLETS &

50. Black with 1 white strips 9,005 9,010
SLURRY
51. HDPE PELLETS Black with 2 white strips 9,005 9,010
52. WAX Oxide Red with 1 Pastel Green Strip 3,009 6,010
53. GLYCOL Canary Yellow with 1 Pastel Green strip 1,023 6,010
54. BUTADIENE < 15% Orange with 1 Pastel Green strip 2,011 6,010
55. BUTADIENE 5 - 95% Orange with 2 Pastel Green strips 2,011 6,010
56. BUTADIENE > 95% Orange with 3 Pastel Green strips 2,011 6,019
57. ALDEHYDE SOLUTION Orange with 1 Blue, 1 Black strips 2,011 5013, 9005

MATCHING AS PER RAL

NUMBERING
5013, 9005
58. OCTENE-1 Orange with 1 Blue, 1 Black and 1 Blue strip 2,011
59. ETHYLENE Orange with 2 Blue strips + 1 Black strip 2,011 5013, 9005
60. PROPYLENE Orange with 2 Oxford blue strips 2,011 5,013
61. BUTENE -1 Orange with 2 Red strip 2,011 3,001
62. HEXANE Orange with 2 White strips 2,011 9,010
63. MEG Orange with 1 Blue lilac strip 2,011 4,005
64. DEG Orange with 2 Blue lilac strip 2,011 4,005
65. TEG Orange with 3 Blue lilac strip 2,011 4,005
66. POLYGLYCOL Orange with 3 Green strip 2,011 6,010
GLYCOL / WATER
67. Orange with 1 Sky blue strip 2,011 5,015
SOLUTION
68. DTA Orange with 2 Green strip 2,011 6,010
INTERMEDIATES- PETROCHEMICALS
69. MOTHER LIQUOR SOLUTION Orange with 3 pebble grey strips 2,011 7,032
70. ADDITIVES SOLUTION Sea green with 2 white strip 6,035 9,010
71. DEACTIVATORS Sea green with 2 orange strip 6,035 2,011

MATCHING AS PER RAL

NUMBERING
72. OFF GAS Sea green with 2 yellow strip 6,035 1,023
73. OFF GAS PLUS POLYMER Sea green with 2 Aluminum strips 6,035 9,006
74. RA SOLUTION Sea green with 2 oxide red strips 6,035 3,009
75. CYCLE GAS SYSTEM Oxide red with 2 Purple strip 3,009 4,006
76. DONOR Sea green with 2 black strips 6,035 9,005
CHEMICALS FOR REFINERY & PETROCHEMICALS
77. ISOPRENYL ALUMINUM Canary yellow with 1 copper brown strips 1,012 8,004
78. MAGNESIUM ETHYLATE Canary yellow with 2 copper brown strips 1,012 8,004
79. TITANIUM TETRA CHLORIDE Canary yellow with 1 chocolate brown strip 1,012 8,017
80. SULPHURIC ACID Golden Yellow with 3 red strips 1,004 3,001
81. CALCIUM HYDROXIDE Canary yellow with 3 black strips 1,012 9,005
82. SODIUM CHLORIDE Canary yellow with 1 white strip 1,012 9,010
83. FERRIC CHLORIDE Canary Yellow with 3 red oxide strips 1,012 3,009
84. SODIUM BI SULFIDE Canary yellow with 3 white strips 1,012 9,010
85. CHLORINE DIOXIDE Canary yellow with 1 orange strip 1,012 2,011

MATCHING AS PER RAL

NUMBERING
86. HYDRAZINE Canary yellow with 3 blue strips 1,012 5,013
87. CARBON DIOXIDE Orange with 4 Aluminum strips 2,011 9,006
88. CARBON MONOXIDE Orange with 3 Aluminum strips 2,011 9,006
89. TEAL Dark admiralty grey with 2 white strips 7,012 9,010
90. LIQUID PEROXIDE Canary yellow with 1 red and 1 blue strip 1,023 3001, 5013
91. CATALYST LINE Canary yellow with 2 Red strip 1,023 3,001
92. CO-CATALYST LINE Canary yellow with 3 Red strip 1,023 3,001
93. SODA ASH Na2C03 Canary yellow with 2 black strips 1012 9005
94. DOLOMITE CaMg (CO3)2 Canary yellow with 2 aluminium strips 1012 9006
Canary yellow with 2 black strips and then 1

95. ALUM Al2(SO4)3, 18H20 1012 9005, 6021
green strip in the direction of flow
DWPE (De Oily Poly

96. Canary yellow with 1 leaf brown strip 1012 8003
Electrolyte)
DOPE (De Oily Poly Electrolyte

97. Canary yellow with 2 leaf brown strips 1012 8003
caustic)

MATCHING AS PER RAL

NUMBERING
DOPE FOR ALL DIESEL
DOSING (CETANE
IMPROVER, LUBRITICTY
98. Canary yellow with 2 leaf brown strips 1012 8003
ADDITIVE, POUR POINT
DEPRESSANT, HSD
STABILIZER)
Canary yellow with 3 black strips and then 1

99. NUTRIENT (Urea + DAP) 1012 9005, 6021
green strip in the direction of flow
100. NaOCL Canary yellow with 2 white strips 1012 9016
1 black ground colour with 3 yellow strip in

101. PFO(Fuel) 9005 1023
centre
102. FLUX OIL Oxide red with 3 black strips 3,009 9,005
103. DECOKING AIR Sea green with 2 black strip 6,018 9,005
104. HEAVY GLYCOL Canary yellow with 2 Pearl gentian blue 1,012 5,025
Heat resistant Aluminium with 1 signal red

105. WET FLARE 9,006 3,001
strip
106. C6-C8 cut (Gasolene) Orange with 2 black strip 2,011 9,005
107. C9+ product(Diesel category) Oxide red with 1 white strip & 1 green strip 3009 9010,6010

MATCHING AS PER RAL

NUMBERING
108. C7+ Product (M.S.Category) Orange with 2 dark ad. grey 2,011 7,012
C6 RAFFINATE (Intermediate
109. Orange with 4 green strip 2,011 6010
Product)
110. METHANE BALLAST GAS Orange with 2 Brown strip 2011 8004
111. C4H Orange with 2 oxide red 2011 3009
CHEMICAL LINES (UNINSULATED)
112. TRI-SODIUM PHOSPHATE Canary yellow with 1 violet strip 1012 5000
113. CAUSTIC SODA Canary yellow with 1 black strip

1012 5000
114. PASSIVATION CHEMICAL Canary yellow with 2 black strip
115. SODIUM CHLORIDE Canary yellow with 1 white strip 1012 9010
116. AMMONIA Canary yellow with 1 blue strip 1012 5013
117. CORROSION INHIBITOR Canary yellow with 1 Aluminium strip 1012 9006
118. HEXAMETA PHOSPHATE Canary yellow with 2 black strip 1012 9005
119. ACID LINES Golden yellow with 1 red strip 1004 3001
120. MOLTEN SULFUR Golden yellow with 2 green strip 1004 6010

MATCHING AS PER RAL

NUMBERING
121. RICH AMINE Canary yellow with 2 blue strips 1012 5013
122. LEAN AMINE Canary yellow with 3 blue strips 1012 5013
123. SOLVENT Canary yellow with 1 green strip 1012 6010
124. LCS Canary yellow with 1 smoke grey 1012 7013
WATER LINES (UNINSULATED)
125. CYCLE WATER- LEAN Sky blue with 2 blue lilac strips 5,015 4,005
126. CYCLE WATER- RICH Sky blue with 1 blue lilac strips 5,015 4,005
127. JACKET WATER Sky blue with 3 black strips 5,015 9,005
128. JACKET WATER-BIOCIDE Sky blue with 2 aluminum strips 5,015 9,006
JACKET WATER-
129. Sky blue with 3 aluminum strips 5,015 9,006
CORROSION INHIBITOR
130. CHLORINATED WATER Sky blue with 1 green strip 5,015 6,010
131. BACK FLUSH WATER Sky blue with 3 signal red strips 5,015 3,001
132. CUTTING WATER Sky blue with 1 orange strip 5,015 2,011
133. REFRIGERATED WATER Sky blue with 2 violet blue strips 5,015 5,000

MATCHING AS PER RAL

NUMBERING
134. WASTE WATER Sky blue with 2 Signal red strips 5,015 3,001
135. EO / WATER SOLUTION Sky blue with 3 Green strips 5,015 6,010
136. BCWS / BCSWR Sky blue with 1 Brown Beige strip 5,015 1,011
137. RAW WATER Sky blue with 1 black strip 5,015 9,005
138. INDUSTRIAL WATER Sky blue with 2 signal red strips 5,015 3,001
139. TREATED WATER Sky blue with 1 oxide red strip 5,015 3,009
140. DRINKING WATER Sky blue with 1 green strip 5,015 6,010
141. COOLING WATER Sky blue with 1 light brown strip 5015 1,011
142. SERVICE WATER Sky blue with 1 signal red strip 5015 3,001
143. TEMPERED WATER Sky blue with 2 green strips 5015 6,010
144. DM WATER Sky blue with 1 Aluminium strip 5015 9,006
0
145. DM WATER ABOVE 150 F Sky blue with 2 black strips 5015 9,005
146. SOUR WATER Sky blue with 2 yellow strips 5015 1,013
147. STRIPPED WATER Sky blue with 2 blue strips 5015 5,013
148. ETP TREATED WATER Sky blue with 2 oxide red strips 5015 3,009

MATCHING AS PER RAL

NUMBERING
FIRE PROTECTION SYSTEM (ABOVE GROUND)
FIRE WATER, FOAM &

149. Post office red 3002
EXTINGUISHERS
AIR & OTHER GAS LINES (UNINSULATED)
150. SERVICE AIR Sea green with 1 signal red strip 6,018 3,001
151. INSTRUMENT AIR Sea green with 1 black strip 6,018 9,005
Milky White
152. NITROGEN* 9016
(Modified in Feb.10).
153. FREON Sea green with 1 yellow strip 6,018 1,023
154. CHLORINE Canary yellow with 1 oxide red strip 1,012 3,009
155. SO2 Canary yellow with 2 white strips 1,012 9,010
156. H2S Orange with 2 red oxide strips 2,011 3,009
157. Gas (Fuel)/ CNG Orange with 1 Aluminium strip 2,011 9,006
158. GAS (Sour)/ ACID (Gas) Orange with 2 Aluminium strip 2,011 9,006
159. GAS (Sweet) Orange with 2 signal red strips 2,011 3,001
160. HYDROGEN Orange with 1 light green strip 2,011 6,021
161. OXYGEN Sea green with 1 Blue strip 6,018 5,013

MATCHING AS PER RAL

NUMBERING
162. NATURAL GAS Orange with 3 Oxide red strips 2,011 3,009
STEAM & CONDENSATE LINES (UNINSULATED)
163. HP STEAM Off white / Aluminium with 1 yellow strip 9,006 1,023
164. MP STEAM Off white / Aluminium with 1 red strip 9,006 3,001
165. MLP STEAM Off white / Aluminium with 1 orange strip 9,006 2,011
166. LP STEAM Off white / Aluminium with 1 green strip 9,006 6,021
167. CONDENSATE Sky blue with 1 white strip 5,015 9,010
0
168. CONDENSATE ABOVE 150 F Sky blue with 3 oxide red strips 5,015 3,009
169. BFW Sky blue with 2 gulf red strips 5,015 3,001
170. VHP Off-white / Aluminum with 2 yellow strip 9,006 1,023
MHP STEAM (20 KG /

171. Off white / Aluminum with 3 yellow strips 9,006 1,023
CM2 G)
Other process lines e.g.
172. Process steam, process Light grey with 1Trafffic yellow strip 7,035 1,023
condensate, Process vents
Note: For all insulated steam lines, the colour coding shall be followed as given for uninsulated lines with the specified length of colour bands.
INSULATED HYDROCARBON PIPING

1 black ground colour with 1 yellow strip in
173. IFO SUPPLY 9005 1023
centre

MATCHING AS PER RAL

NUMBERING
1 black ground colour with 1 green strip in
174. IFO RETURN 9005 6010
centre
175. HPS 1 black ground colour with 1 red strip in centre 9005 3001
176. BITUMEN 1 black ground colour with 2 red strip in centre 9005 3001
1 black ground colour with 1 brown strip in

177. CLO 9005 8004
centre
1 black ground colour with 2 brown strip in
178. VB TAR 9005 8004
centre
VR AM (BITUMEN / VBU 1 black ground colour with 1 blue strip in
179. 9005 5013
FEED) centre
1 black ground colour with 2 blue strip in
180. VR BH 9005 5013
centre
1 black ground colour with 1 white strip in
181. VAC. SLOP 9005 9010
centre
1 black ground colour with 1 orange strip in
182. SLOP 9005 2011
centre
1 dark admiralty grey ground colour with 1 red
183. CRUDE SWEET 7012 3002
strip in centre
1 dark admiralty grey ground colour with 1
184. CRUDE SOUR 7012 2011
orange strip in centre
1 oxide red ground colour with 1 steel grey
185. VGO / HCU FEED 3009 7011
strip in centre
OHCU BOTTOM / FCCU 1 oxide red ground colour with 2 steel grey
186. 3009 7011
FEED strip in centre
187. RCO HIGH-SULFUR 1 black ground colour with 2 steel grey strip 9005 7011
188. RCO LOW-SULFUR 1 black ground colour with 1 steel grey strip 9005 7011

MATCHING AS PER RAL

NUMBERING
UNINSULATED EQUIPMENT, TANKS & STRUCTURES
189. HEATER STRUCTURE Steel grey 7,011
190. HEATER CASING Heat resisting Aluminium 9,006
191. VESSELS & COLUMNS Aluminium 9,006
192. HYDROGEN BULLETS Pink 3,014
193. LPG VESSELS Red Oxide 3,009
194. SO2 VESSEL Canary Yellow 1,012
195. HEAT EXCHANGERS Heat resisting Aluminium 9,006
196. FO TANK & HOT TANKS Black 9,005
197. ALL OTHER TANKS Aluminium / off white 9,006
CAUSTIC / AMINE / ACID

198. Golden Yellow 1,004
TANKS
199. SOUR WATER Sky Blue 5,015
OUTER SURFACE IN BOILER

200. Heat resisting Aluminium 9006
HOUSE
COMPRESSORS &
201. Dark Admiralty Grey 7012
BLOWERS
202. PUMPS Navy Blue 5014

MATCHING AS PER RAL

NUMBERING
203. MOTORS & SWITCH GEAR Bluish Green 5024
204. HAND RAILING Signal Red 3001
STAIRCASE, LADDER &

205. Black 9005
WALKWAYS
LOAD LIFTING EQUIPMENT &
206. Leaf Brown 8003
MONO RAILS ETC.
207. GENERAL STRUCTURE Black 9005
ELECTRICAL EQUIPMENT -
208. Pebble grey 7,032
INDOOR
ELECTRICAL EQUIPMENT -
209. Blue grey 7,031
OUTDOOR
210. LOCAL PANEL FACE Opaline green 6,026

PANEL REAR SURFACE,
211. FRAME WORK & Pale cream 9,001
MOUNTING PLATES
212. MONORAIL STOPPER Signal red 3,001
PIPES & FITTINGS OF ALLOY STEEL & SS MATERIAL IN STORES (REFER ARTICLE 5.0)
213. IBR Signal red 3001
214. 9Cr - 1Mo Verdigris green 6021
215. 5Cr - Mo Satin blue 5012
216. 2 Cr - 1Mo Aircraft yellow 1026

MATCHING AS PER RAL

NUMBERING
217. 1Cr - Mo Traffic yellow 1023
218. SS-304 Dark blue grey 5008
219. SS-316 Dark violet 4005
220. SS- 321 Navy blue 5014
SAFETY COLOUR SCHEMES
Black & alert orange strips

221. DANGEROUS OBSTRUCTION 9005,3002
DANGEROUS OR EXPOSED
222. Alert orange 3002
PARTS OF MACHINERY
MISCELLANEOUS COLOUR SCHEMES
223. OFF SPEC BUTENE-1 Orange with 3 red strips 2011 3001
COLOUR CODING FOR PIPING KEPT IN STORES
224. LTCS Leaf Brown 8003
225. P91 Pink 3,014
LOW CARBON GRADES SS

226. Aluminum / off white 9,006
(LIKE SS 304L, SS316L )
HIGH CARBON GRADES SS
227. Black 9005
(LIKE SS 304H)
Painting for Civil Defence requirements:

(i) The following items shall be painted for camouflaging, as per specific site requirement of Defence.
a) All columns
b) All tanks in offsites
c) Large vessels
d) Spheres
(ii) Two coats of selected finish paint as per defence requirement shall be applied in a particular pattern as per (iii) and as per the instructions of the
Engineer-in-Charge.
(iii) Method of camouflaging:
a) Disruptive painting for camouflaging shall be done in three colours in the ratio of 5:3:2 (all matt finish)
Dark Green Light Green Dark Medium Brown

5: 3: 2
b) The patches should be asymmetrical and irregular.

0 0
c) The patches should be inclined at 30 C to 60 C to the horizontal.
d) The patches should be continuous where two surfaces meet at an angle and the patches should be coincide with corners.
e) Slits and holes shall be painted in dark shades.
f) Width of patches should be 1 to 2 meters.

CHAPTER-11
11.0 PAINTING SCHEDULE AND FREQUENCY

The frequency of painting of refinery equipment, piping and structures depend
on several factors like:
d) Last painting carried out.

e) Present surface condition.
f) Surrounding atmosphere.
g) Inspection shutdown frequency
h) Experience of different painting/ coating systems
i) Economic considerations
The frequency of painting will vary from one location to other, depending on
various factors.
However, based on industry experience, the following painting frequencies for

external surfaces are suggested:
Sl. Frequency
Area Remarks
No. of Painting
1 External painting of equipment, 3/ 4 years May be combined
piping, structural and stacks in along with
Process Units shutdown of Units
2 External painting of equipment, 4 years
piping and structural in TPS, GT,
DM Plant area
3 External painting of equipment, 1 year
piping and structural in acidic,
caustic and toxic areas
piping and structural in LPG and
gantry area
piping and structural in ETP/ TTP
piping and structural in vicinity of
cooling towers and at jetty areas.
7 External painting of offsite piping 3 years
including fire water piping
8 External painting of offsite tanks 5 years
9 External painting of floating roof 2 years Floating roof only
of tanks
10 External painting of rotary 4 years
equipment

The painting schedule as indicated above should be integrated with the

existing maintenance & painting schedules in the refineries. The ground
colour in this painting manual has been maintained same. To optimize on the
expenditure, it is suggested that the painting should be taken up for the
painting systems of average life of 3-4 years are as follows:
1. If the existing paint system is more than 3 years old, it is proposed to

take up the re-painting jobs along with the re-painting frequency
indicated above.
2. In case the existing paint system is only 1-2 years old and there is
change in the ground colour/ strip colour only band colours along with
strip can be done at road crossing, battery limit etc. and the total painting
to be taken up only after the re-painting is called for.

CHAPTER-12
12.0 CODES, STANDARDS AND REFERENCES

The list of standards applicable for industrial painting and coating are listed in
the Chapter.
12.1 ISO STANDARDS
Standard Description
ISO 1461 Metallic coatings - Hot-dip galvanized coating on fabricated
ferrous products
ISO 1512 Paints and varnishes Sampling of products in liquid or
paste forms
ISO 1513 Paints and varnishes Examination and preparation of
samples for testing
ISO 1514 Paints and varnishes Standard panels for testing
ISO 1516 Paints and varnishes Closed cup equilibrium method
ISO 1517 Paints and varnishes Surface-drying test Ballotini
method
ISO 1519 Paints and varnishes Bend test (cylindrical mandrel)
ISO 1524 Paints and varnishes Determination of fineness of grind
ISO 2063 Thermal Spraying - Metallic and Other Inorganic Coatings -
Zinc, Aluminum and their Alloys
ISO 2080 Metallic and other inorganic coatings Surface treatment,
metallic and other inorganic coatings Vocabulary
ISO 2409 Paints and varnishes Cross-cut test
ISO 2431 Paints and varnishes Determination of flow time by use of
flow cups
ISO 2808 Paints and varnishes - Determination of film thickness
ISO 2811 Paints and varnishes Determination of density
ISO 2812 Paints and varnishes - Determination of resistance to
liquids
ISO 2813 Paints and varnishes Determination of specular gloss of
non-metallic paint films at 20 degrees, 60 and 85 degrees.
ISO 2814 Paints and varnishes - Comparison of contrast ratio (hiding
power) of paint of the same type and color
ISO 2815 Paint and Varnishes Buchholz Indentation Test Method
ISO 2632 Roughness Comparison Specimens, Cast Surfaces
ISO 2808 Paints and varnishes Determination of film thickness
ISO 2814 Paints and varnishes - Comparison of contrast ratio (hiding
power) of paint of the same type and color
ISO 3001 Plastics Epoxy compounds Determination of epoxy
equivalent
ISO 3231 Paints and varnishes Determination of resistance to
humid atmospheres containing sulphur dioxide
ISO 3233 Coating and varnishes determination of volume of dry
coating obtained from a given volume of liquid coating

ISO 3251 Paints and varnishes Determination of non-volatile matter
of paints, varnishes and binders for paints and varnishes
ISO 3549 Zinc dust pigments for paints Specifications and test
methods
ISO 3678 Paints and varnishes - Print-free test
ISO 4541 Metallic and other non-organic coatings - Corrodkote
corrosion test
ISO 4543 Metallic and other non-organic coatings - General rules for
corrosion tests applicable for storage conditions
filiform corrosion
ISO 4624 Paints and varnishes - Pull-off test for adhesion
ISO 4628 Paints and varnishes - Evaluation of degradation of paint
coatings, designation of intensity, quantity and size of
common types of defect
ISO 4998 Continuous hot-dip zinc-coated carbon steel sheet of
structural quality
humidity
ISO 6860 Paints and varnishes Bend test (conical mandrel)
ISO 6964 Polyolefine pipes and fittings: Determination of carbon
black content by calcinations and pyrolysis: Test method
and basic principles
ISO 7253 Paints and Varnishes Determination of Resistance to
Neutral Salt Spray.
ISO 7724 Paints and varnishes. Determination of colour and colour
difference
ISO 8130-6 Coating powders Part 6- Determination of gel time of
thermosetting coating powders at a given temperature
ISO 8401 Metallic coatings - Review of methods of measurement of
ductility
ISO 8403 Metallic coatings - Coatings anodic to the substrate -
Rating of test specimens subjected to corrosion tests
ISO 8501 Preparation of steel substrates before application of paints
and related products - Visual assessment of surface
cleanliness
and related products Test for the assessment of surface
cleanliness
and related products - Surface roughness characteristics of
blast cleaned substrates.
and related products - Surface preparation methods
ISO 9220 Metallic coatings - Measurement of coating thickness -
Scanning electron microscope method
ISO 9227 Corrosion tests in artificial atmospheres Salt spray tests

ISO 10308 Metallic coatings review of porosity test
and related products Specifications for metallic blast-
cleaning abrasives
ISO 11125 Paints and varnishes Preparation of steel substrates
before application of paints and related products. Test
methods for metallic blast-cleaning brasives
and related products Specifications for non-metallic blast-
cleaning abrasives
ISO 11127 Paints and varnishes Preparation of steel substrates
before application of paints and related products. Test
methods for non-metallic blast cleaning abrasives
ISO 12944 Paints and Varnishes Corrosion protection of steel
structures by protective paint systems
ISO 14713 Protection Against Corrosion of Iron and Steel in Structures
Zinc and Aluminum Coatings - Guidelines
ISO 14918 Thermal Spraying - Approval Testing of Thermal Sprayers
ISO 15741 Paints and varnishes - Friction-reduction coatings for the
interior of on and offshore steel pipelines for non-corrosive
gases
ISO 16348 Metallic and other inorganic coatings - Definitions and
conventions concerning appearance
ISO 19840 Paints and varnishes Corrosion protection of steel
structures by protective paint systems Measurement of,
and acceptance criteria for, the thickness of dry film on
rough surfaces
ISO 20340 Paints and varnishes Performance requirements for
protective paint systems for offshore and related structures
ISO 21809 Petroleum and natural gas industries External coatings
for buried or submerged pipelines used in pipeline
transportation systems
ISO 28199 Paints and varnishes - Evaluation of properties of coating
systems related to the application process
12.2 NACE STANDARDS
NACE 6A100 Coatings Used in Conjunction with Cathodic Protection
NACE 6A192 Dehumudification and Temperature Control During Surface
Preparation, Application, and Curing for Coatings/Linings of
Steel Tanks, Vessels, and Other Enclosed Areas
NACE 6H188 Coatings over Nonabrasive-Cleaned Steel Surfaces
NACE 10D199 Coatings for the Repair and Rehabilitation of the External
Coatings of Buried Steel Pipelines
NACE 2103 Liquid-Applied Coatings for High-Temperature Atmospheric
Service

NACE 37507 Corrosion Prevention by Protective Coatings
NACE 80200 Preparation of Protective Coating Specifications for
Atmospheric Service
NACE NO. 4 Brush-Off Blast Cleaning
NACE NO. 5 Surface Preparation and Cleaning of Metals by Water
jetting Prior to Recoating
NACE NO. 8 Industrial Blast Cleaning
NACE NO. 11 Thin-Film Organic Linings Applied in New Carbon Steel
Process Vessels
NACE RP0105 Standard Recommended Practice Liquid-Epoxy Coatings
for External Repair, Rehabilitation, and Weld Joints on
Buried Steel Pipelines
NACE RP0169 Standard Recommended Practice for Control of External
Corrosion on Underground or Submerged Metallic Piping
Systems
NACE RP-0176 Corrosion Control of Steel, Fixed Offshore Platforms
Associated with Petroleum Production
NACE RP0178 Fabrication Details, Surface Finish Requirements, and
Proper Design Considerations for Tanks and Vessels to be
Lined for Immersion Surface.
NACE RP0188 Discontinuity (holiday) testing of protective coatings
NACE RP0191 Application of Internal Plastic Coatings for Oilfield Tubular
Goods and Accessories
NACE RP0193 External Cathodic Protection of On-Grade Carbon Steel
Storage Tank Bottoms
NACE RP0198 Control of Corrosion Under Thermal Insulation and
Fireproofing Materials - A Systems Approach
NACE RP 0274 High voltage electrical inspection of pipeline coatings prior
to installation
NACE RP0287 Field Measurements of Surface Profile of Abrasive Blast
Cleaned Steel Surface Using Replica Tape.
NACE RP0304 Design, Installation, and Operation of Thermoplastic Liners
for Oilfield Pipelines
NACE RP0375 Field-Applied Underground Wax Coating Systems for
Underground Pipelines: Application, Performance, and
Quality Control
NACE RP0394 Standard Recommended Practice for Application,
Performance and Quality Control of Plant Applied, Fusion-
Bonded Epoxy External Pipe Coating.
NACE RP0490 Standard Recommended Practice for Holiday Detection of
Fusion- Bonded Epoxy External Coating of 250 to 760
Microns (10 to 30 mils)
NACE RP0399 Plant Applied, External Coal Tar Enamel Pipe Coating
Systems: Application, Performance, and Quality Control
NACE RP0402 Field-Applied Fusion-Bonded Epoxy (FBE) Pipe Coating
Systems for Girth Weld Joints: Application, Performance,
and Quality Control

NACE RP0602 Field-Applied Coal Tar Enamel Pipe Coating Systems:
Application, Performance, and Quality Control
NACE RP0892 Coatings and Linings over Concrete for Chemical
Immersion and Containment Service
NACE SP0108 Corrosion Control of Offshore Structures by Protective
Coatings
NACE SP0169 Control of External Corrosion on Underground or
Submerged Metallic Piping Systems
NACE SP0181 Liquid-Applied Internal Protective Coatings for Oilfield
Production Equipment
NACE SP0185 Extruded Polyolefin Resin Coating Systems with Soft
Adhesives for Underground or Submerged Pipe
NACE SP0188 Discontinuity (Holiday) Testing of New Protective Coatings
on Conductive Substrates
NACE SP0490 Holiday Detection of Fusion-Bonded Epoxy External
Pipeline Coatings of 250 to 760 um (10 to 30 Mils)
NACE TM0102 Measurement of Protective Coating Electrical Conductance
on Underground Pipelines
NACE TM0104 Offshore Platform Ballast Water Tank Coating System
Evaluation
NACE TM0105 Test Procedures for Organic-Based Conductive Coating
Anodes for Use on Concrete Structures
NACE TM0109 Aboveground Survey Techniques for the Evaluation of
Underground Pipeline Coating Condition
NACE TM0174 Laboratory Methods for the Evaluation of Protective
Coatings and Lining Materials on Metallic Substrates in
Immersion Service
NACE TM0183 Evaluation of Internal Plastic Coatings for Corrosion
Control of Tubular Goods in an Aqueous Flowing
Environment
NACE TM0185 Evaluation of Internal Plastic Coatings for Corrosion
Control of Tubular Goods by Autoclave Testing
NACE TM0186 Holiday Detection of Internal Tubular Coatings of 250 to
760m (10 to 30 Mils) Dry Film Thickness
NACE TM0204 Exterior Protective Coatings for Seawater Immersion
Service
NACE TM0299 Corrosion Control and Monitoring in Seawater Injection
Systems
NACE TM0304 Offshore Platform Atmospheric and Splash Zone
Maintenance Coating System Evaluation
NACE TM0384 Holiday Detection of Internal Tubular Coatings of Less
Than 250 Micrometers (10 mils) Dry-Film Thickness
NACE TM0404 Offshore Platform Atmospheric and Splash Zone New
Construction Coating System Evaluation

12.3 API STANDARDS
API Bull 91 Planning and Conducting Surface Preparation and Coating
Operations for Oil and Natural Gas Drilling and Production
Facilities in a Marine Environment
API RP 5L2 RP for Internal Coating of Line Pipe for Non-Corrosive Gas
Transmission Service
API RP 5L7 RP for Un-primed Internal Fusion Bonded Epoxy Coating of
Line Pipe
API RP 5L9 External Fusion Bounded Epoxy Coating of Line Pipe
API RP 652 Linings of Aboveground Petroleum Storage Tank Bottoms
API 1160 Managing system integrity for hazardous liquid pipelines
12.4 ASTM STANDARDS
ASTM 06.02 Paint-Products and Applications; Protective Coatings;
Pipeline Coatings
ASTM A 123/ Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel
A123M Products
ASTM A 143 Safeguarding Against Embrittlement of Hot-Dip,
Galvanized Structural Steel Products
ASTM A 153/ Zinc Coating (Hot-Dip) on Iron and Steel Hardware
A153M
ASTM A 385 Standard Specification for Zinc Dust Pigment
ASTM A 780 Specification for repair of damaged hot-dip galvanized
coatings.
ASTM A 972/ Standard Specification for Fusion Bonded Epoxy Coated
A972M Pipe Piles
ASTM B 117 Standard Practice for Operating Salt Spray (fog) Apparatus
ASTM C633 Standard Test Method for Adhesion or Cohesion Strength
of Thermal Spray Coatings
ASTM D16 Standard Terminology for Paint, Related Coatings,
Materials, and Applications
ASTM D 521 Test methods for chemical analysis of zinc dust (metallic
zinc powder)
ASTM D 552 Standard Test Methods for Mandrel Bend Test of Attached
Organic Coatings
ASTM D 570 Standard test method for water absorption of plastics
ASTM D 610 Standard Test Method for Evaluating Degree of Rusting on
Painted Steel Surfaces.
ASTM D 638 Standard Test Method for Tensile Properties of Plastics
ASTM D 822 Standard Practice for Filtered Open-Flame Carbon-Arc
Exposures of Paint and Related Coatings
ASTM D 823 Method of producing films of uniform thickness of paint,
varnish, lacquer and related products on test panels
ASTM D 968 Standard Test Methods for Abrasion Resistance of Organic

Coatings by Falling Abrasive
ASTM D 1000 Method of testing pressure sensitive adhesive coated tapes
used for electrical insulation
ASTM D 1141 Specification for substitute ocean water
ASTM D 1186 Standard Test Methods for Non-Destructive Measurement
of Dry Film Thickness of Non-Magnetic Coatings Applied to
a Ferrous Base.
ASTM D 1200 Test method for viscosity of paints, varnishes and lacquers
by Ford viscosity cup
ASTM D 1212 Standard Test Methods for Measurement of Wet Film
Thickness of Organic Coatings
ASTM D 1640 Standard Test Methods for Drying, Curing, or Film
Formation of Organic Coatings at Room Temperature
ASTM D 2092 Practices for preparation of zinc-coated galvanized steel
structures for paint
ASTM D 2240 Standard Test Method for Rubber PropertyDurometer
Hardness
ASTM D 2369 Test method for volatile content of coatings
ASTM D 2371 Test method for pigment content of solvent-reducible paints
ASTM D 2697 Standard Test Method for Volume Nonvolatile Matter in
Clear or Pigmented Coatings
ASTM D 2794 Standard Test Method for Resistance of Organic Coatings
to the Effects of Rapid Deformation (Impact)
ASTM D 3276 Standard Guide for Painting Inspectors (Metal Substrates)
ASTM D 3359 Method for measuring adhesion by tape test
ASTM D 3363 Standard Test Method for Film Hardness by Pencil Test
ASTM D 3418 Standard Test Method for Transition Temperatures and
Enthalpies of Fusion and Crystallization of Polymers by
Differential Scanning Calorimetry
ASTM D3451 Standard Guide for Testing Coating Powders and Powder
Coatings
ASTM D 4060 Standard test method for abrasion resistance of organic
coatings by the Taber abraser
ASTM D4228 Standard Practice for Qualification of Coating Applicators
for Application of Coatings to Steel Surfaces.
ASTM D 4285 Test method for indicating oil or water in compressor air
ASTM D 4414 Standard Practice for Measurement of Wet Film Thickness
by Notch Gages
ASTM D 4417 Method C Test method for Field Measurement of Surface
Profile
ASTM D 4541 Test method for pull-off strength of coatings using portable
adhesion testers
ASTM D 4752 Standard Test Method for Measuring MEK Resistance of
Ethyl Silicate (Inorganic) Zinc-Rich Primers by Solvent Rub
ASTM D 4940 Standard Test Method for Conductimetric Analysis of
Water Soluble Ionic Contamination of Blasting Abrasives
ASTM D 5144 Standard Guide for Use of Protective Coating Standards in

Nuclear Power Plants
ASTM D 5162 Standard Practice for Discontinuity (Holiday) Testing of
Nonconductive Protective Coating on Metallic Substrates
ASTM D7490 Standard Test Method for Measurement of the Surface
Tension of Solid Coatings, Substrates and Pigments using
Contact Angle Measurements
ASTM E 337 Standard Test Method for Measuring Humidity with a
Psychrometer (Wet and Dry Bulb Temperatures)
ASTM F 21 Standard Test Method for Hydrophobic Surface Films by
Atomiser Test
ASTM G 8 Test method for cathodic disbanding of pipeline coatings
ASTM G14 Standard Test Method for Impact Resistance of Pipeline
Coatings (Falling Weight Test)
ASTM G17 Standard Test Method for Penetration Resistance of
Pipeline Coatings (Blunt Rod)
ASTM G 53 Recommended practice for operating light and water
exposure apparatus (fluorescent UV-condensation type) for
exposure of nonmetallic materials
ASTM G65 Standard Test Method for Measuring Abrasion Using the
Dry Sand/ Rubber Wheel Apparatus
ASTM G99 Standard Test Method for Wear Testing with a Pin-on-Disk
Apparatus
12.5 BS STANDARDS
BS 3900 Methods for Testing Coatings
BS 4164 Specification for coal tar based, hot applied coating
materials for protecting iron and steel including suitable
primers
BS 5493 Code of Practice for Protective Coating of Iron and Steel
against Corrosion
BS 6374 Lining of Equipment with Polymeric Materials for the
Process Industries
12.6 SSPC STANDARDS
SSPC Volume 1 Good Painting Practice
SSPC Volume 2 Systems and Specifications
SSPC-SP COM Surface Preparation Commentary for Steel and Concrete
Substrates
SSPC-SP 1 Solvent Cleaning
SSPC-SP 2 Hand Tool Cleaning
SSPC-SP 3 Power Tool Cleaning
SSPC-SP 5 White Metal Blast Cleaning
SSPC-SP 6 Commercial Blast Cleaning

SSPC-SP 7 Brush-Off Blast Cleaning
SSPC-SP 8 Pickling
SSPC-SP 10 Near-White Blast Cleaning
SSPC-SP 11 Power Tool Cleaning to Bare Metal
SSPC-SP 12 Surface Preparation and Cleaning of Metals by Water
jetting Prior to Recoating
SSPC-SP 13 Surface Preparation of Concrete
SSPC-SP 14 Industrial Blast Cleaning
SSPC-SP 15 Commercial Grade Power Tool Cleaning
SSPC-TR 1 Thermal Pre-Cleaning
SSPC-TR 2 Wet Abrasive Blast Cleaning
SSPC-TR 3 Dehumidification and Temperature Control During Surface
Preparation, Application, and Curing for Coatings/ Linings
of Steel Tanks, Vessels, and other enclosed spaces
SSPC-TR 4 Preparation of Protective Coating Specifications for
Atmospheric Service
SSPC-TR 5 Design, Installation, and Maintenance of Protective
Polymer Flooring Systems for Concrete
SSPC-AB 1 Mineral and Slag Abrasives
SSPC-AB 2 Cleanliness of Recycled Ferrous Metallic Abrasives
SSPC-AB 3 Ferrous Metallic Abrasive
SSPC-PS 1.00 Guide for Selecting Oil Base Painting Systems
SSPC-PS 1.09 Three-Coat Oil Base Zinc Oxide Painting System (Without
Lead or Chromate Pigment)
SSPC-PS 1.10 Four-Coat Oil Base Zinc Oxide Painting System (Without
Lead or Chromate Pigment)
SSPC-PS 1.13 One-Coat Oil Base Slow Drying Maintenance Painting
System (Without Lead or Chromate Pigments)
SSPC-PS 2.00 Guide for Selecting Alkyd Painting Systems
SSPC-PS 4.00 Guide for Selecting Vinyl Painting Systems
SSPC-PS 4.02 Four-Coat Vinyl Painting System
SSPC-PS 4.04 Four-Coat White or Colored Vinyl Painting System (For
Fresh Water, Chemical, and Corrosive Atmospheres)
SSPC-PS 7.00 Guide for Selecting One-Coat Shop Painting Systems
SSPC-PS 8.00 Guide to Top coating Zinc-Rich Primers
SSPC-PS 9.01 Cold-Applied Asphalt Mastic Painting System with Extra
Thick Film
SSPC-PS 10.01 Hot-Applied Coal Tar Enamel Painting System
SSPC-PS 10.02 Cold-Applied Coal Tar Mastic Painting System
SSPC-PS 11.01 Black (or Dark Red) Coal Tar Epoxy-Polyamide Painting
System
SSPC-PS 12.00 Guide to Zinc-Rich Coating Systems
SSPC-PS 12.01 One Coat Zinc-Rich Painting System
SSPC-PS 13.01 Epoxy Polyamide Painting System
SSPC-PS 14.01 Steel Joist Shop Painting System
SSPC-PS 15.00 Guide for Selecting Chlorinated Rubber Painting Systems
SSPC-PS 15.01 Chlorinated Rubber Painting System for Salt Water

Immersion
SSPC-PS 15.02 Chlorinated Rubber Painting System for Fresh Water
Immersion
SSPC-PS 15.03 Chlorinated Rubber Painting System for Marine and
Industrial Atmospheres
SSPC-PS 15.04 Chlorinated Rubber Painting System for Field Application
Over a Shop- Base Inorganic Zinc-Rich Primer
SSPC-PS 16.01 Silicone Alkyd Painting System for New Steel
SSPC-PS 17.00 Guide for Selecting Urethane Painting Systems
SSPC-PS 18.01 Three-Coat Latex Painting System
SSPC-PS 19.00 Guide for Selecting Painting Systems for Ship Bottoms
SSPC-PS 20.00 Guide for Selecting Painting Systems for Boot toppings
SSPC-PS 21.00 Guide for Selecting Painting Systems for Topside
SSPC-PS 22.00 Guide for Selecting One-Coat Preconstruction or
Prefabrication Painting Systems
SSPC-PS 23.00 Specification for the Application of Thermal Spray Coatings
(Metallizing) of Aluminum, Zinc, and Their Alloys and
Composites for the Corrosion Protection of Steel
SSPC-PS 24.00 Latex Painting System for Industrial and Marine
Atmospheres, Performance-Based
SSPC-PS 26.00 Aluminum Pigmented Epoxy Coating System Materials
Specification
SSPC-PS 27.00 Alkyd Coating System Materials Specification,
Performance-Based
SSPC-Paint Commentary on Paint Specifications
COM
SSPC-PA COM Commentary on Paint Application Monitoring and
Controlling Ambient Conditions During Coating Operations
SSPC-QP COM Commentary on Qualification Procedures
SSPC-Guide 6 Guide for Containing Debris Generated During Paint
Removal Operations
SSPC-Guide 7 Guide for the Disposal of Lead-Contaminated Surface
Preparation Debris
SSPC-Guide 9 Guide for Atmospheric Testing of Coatings in the Field
SSPC-Guide 10 Guide to Specifying Coatings Conforming to Volatile
Organic Compound (VOC) Content Requirements
SSPC-Guide 12 Guide for Illumination of Industrial Painting Projects
SSPC-Guide 13 Guide for the Identification and Use of Industrial Coating
Materials in Computerized Product Databases
SSPC-Guide 14 Guide for the Repair of Imperfections in Galvanized,
Organic, or Inorganic Zinc-Coated Steel Using Organic
Zinc-Rich Coatings
SSPC-Guide 15 Field Methods for Retrieval and Analysis of Soluble Salts
on Steel and Other Nonporous Substrates
SSPC-Guide 16 Guide to Specifying and Selecting Dust Collectors
SSPC-Guide 17 Guide to Developing a Corporate Safety Program for
Industrial Painting and Coating Contractors

SSPC-TU 1 Surface-Tolerant Coatings for Steel
SSPC-TU 2 Design, Installation, and Maintenance of Coating Systems
for Concrete Used in Secondary Containment
SSPC-TU 3 Over coating
SSPC-TU 5 Accelerated Testing of Industrial Protective Coatings
SSPC-TU 6 Chemical Stripping of Organic Coatings from Steel
Structures
SSPC-TU 7 Conducting Ambient Air, Soil, and Water Sampling During
Surface Preparation and Paint Disturbance Activities
SSPC-TU 8 The Use of Isocyanate-Containing Paints as Industrial
Maintenance Coatings
SSPC-TU 9 Estimating Costs for Protective Coatings Projects
SSPC-TU 10 Procedures for Applying Thick Film Coatings and Surfacing
Over Concrete Floors
SSPC-TU 11 Inspection of Fluorescent Coating Systems

Annexure-I
INSPECTION FORMATS
Standard Checklist for Paint Application
Sl.
Particulars Observations Signature
No.
1 Finalization of paint specification as per site
condition
2 Finalization of application procedure
(Surface preparation, over coating interval,
application method etc)
3 Paint material (paint, thinner) check at site
(Batch no. , certificate, exp. date etc)
4 Check surface preparation
5 Check whether environment conditions
(temperature, humidity) are suitable for
paint application
6 Check mixing of paint components
including thinner
7 Check applied primer coat (visual, DFT)
8 Check over coating interval
9 Repeat steps 5, 6, 7 & 8 for subsequent
coats
10 Testing of applied paint
11 Check final DFT
12 Final inspection for any defects and
appropriate repairs, if required
Note: In case of any abnormality observed in any step, suitable rectification shall be
carried out.

Annexure-II
PICTORIAL STANDARD FOR SURFACE PREPARATION

Annexure-III
QUALITY ASSURANCE PLAN
Sr. To be Inspection
No. Activities Ref. Std. Item to Check Hold Points Equipment/ Tool Acceptance Criteria
done by by
1 Surface Pre ISO 8501-3 Weld, Edges, Post hot work & Grinder, Hammer, IOCL IOC / Paint As per P3 0f ISO
treatment Corners, Holes, Pre surface metal file, other appointed Manufacture 8501-3, edges round
Notches, crevices. preparation tools vendor r's Inspector off - 2mm, surface
should be free of weld
slag, weld
spatter,porosity,
undercut other weld
defect
2 Raw Material As per IOC Data Sheet Pre-Coating 1.Visual Painting IOC / Paint As per specification
Inspection specification MSDS Application Inspection Vendor Manufacture Material to be used as
Manufacturer's 2.Surface r's Inspector per shelf life. Safety
Test Preparation Tools: and storage is as per
Certificate Solvent, Bresle MSDS
Test Kit,wire
brush tools,coarse
emmery paper-
40/80(Silicon
Carbide) other
tools & tackles
3 Safety As per MSDS Pre-Coating Safety helmet, Painting IOC Availability of all safety
MSDS Application eye goggles, ear Vendor consumables during
plug, body paint application.
coverall, hand Requirement as per
gloves, safety respective locations
shoes, full body procedures/ guidelines
safety belt, face to be strictly followed.
mask, face Test certificate of air
protector vessel and safety
(washing) valve.

done by by
4 Ambient Condition ASTM E 337 Dry & wet bulb Pre-Coating Surface Painting IOC / Paint RH<85%, Substrate
temperature, % Application temperature Vendor Manufacture temperature then Dew
Relative Humidity, gauge, r's Inspector Point Temp by at least
0
Dew point hygrometer, Dew 3 C. To be monitored
Temperature, point calculator an recorded on hourly
Surface basis. Application
0
Temperature below 50 C and
0
greater than 10 C only.
5.1 Surface SIS 0559 00 Surface to be blast Pre-Coating Visual & random Paint IOC / Paint The surface profile
Preparation: / ISO 8503 cleaned to match Application blast/ anchor Vendor Manufacture measurements shall
1. Abrasive Blast the Grade of SA 2 profile shall be r's Inspector not be less minimum
clean to SA 2 as per SIS 0559 00 made on one per value specified by the
/ ISO8503 / SSPC ten(10) square paint Manufacturer.
SP10/ NACE meters (Silica sand,
STANDARD potentially silica
containing material
and copper slag not
permitted.)
5.2 Surface SSPC SP1/ 1. No oil Grease Pre-Coating Visual Painting IOC / Paint SSPC SP-1(remove
preparation: SP2 /ST3 contamination Application Vendor Manufacture excess grease and
1.To remove all oil 2. All loose material r's Inspector spray clean with
& grease by solvent should be removed solvent).
cleaning. 3. Check adhesion SSPC SP3/ST3
2. All loose paint, as per ASTM 3359 (Heavy scale removal
rust scale, blisters (Before painting on by Impact tool followed
are removed by old Paint) by power tool)
hand tool.3. Heavy
scaling prior to be
removed by impact
tools like hammer
followed emery
paper & wire brush
4.Surface cleaning
to SSPC ST3

done by by
6 1. Water washing NACE No.5/ 1. Low pressure Pre-Coating Extraction of Painting IOC / Paint 5gm/cm. Test
after surface SSPC SP12 water cleaning of Application soluble salt and Vendor Manufacture frequency to be
preparation (Refer ISO 8502-9 the substrate 2. conductometric r's Inspector decided by IOCL/ paint
5.2) & also before Free from salt test - The Bresle Manufacturer's
coat application if contamination. Salt method using Inspector based on
over coating level below Bresle Salt Kit. site condition. Fresh
interval more than 5gm/cm water TDS to be less
seven days or salt then 150 ppm.
level more than
acceptable limits.
Detergent to be
used prior to water
wash for complete
removal of Algae/
microorganisms. 2.
Salt contamination
test.
7 Recording of DFT SSPC - PA2 100 % area to be Pre-Coating DFT meter Painting IOC / Paint SSPC PA2
of the coating prior recorded as per Application Vendor Manufacture
to application SSPC PA2 r's Inspector
frequency
8 X cut Adhesion test ASTM Random checking Pre- Coating - Painting IOC / Paint 5A or 4A (post 7 days
D3359/ to be done application in Vendor Manufacture curing) if tested as per
ISO4624 case of shop r's Inspector ASTM D3359. 5 Mpa if
coated & after tested as per ISO 4624
drying of each
coat.
9 Mixing & Thinning As Per Data Material mix with Pre- coating Mechanical stirrer/ Painting IOC / Paint Compliance of paint
Sheet power stirrer before application mixer Vendor Manufacture Data Sheet
application r's Inspector
10 First stripe coat As per All weld joints, During coating Epoxy grade Painting IOC / Paint Stripe coat should be
application standard Edges & pitted area application. brush with long Vendor Manufacture visible and checked for
Industry should be striped and flat handle r's Inspector all applicable areas.
Practice coated before
painting by brush

done by by
application.
11 Primer coat As per 100% area Post primer DFT meter, Painting IOC / Paint SSPC PA2 (if painting
application industry coating airless spray, 60:1 Vendor Manufacture applied on existing /
standard. application. / 70:1 airless Tip - r's Inspector shop painted surface,
19 or 21 Thou. the required DFT
Nozzle pressure should be added to the
2100 - 3500 PSI existing DFT).
12 Second full coat As per 100% area Post second DFT meter, Painting IOC / Paint SSPC PA2 + existing
application (Build / industry coat airless spray, 60:1 Vendor Manufacture DFT
Tie coat) standard. application. / 70:1 airless Tip - r's Inspector
19 or 21 Thou.
Nozzle pressure
2100 - 3500 PSI
13 Top coat As per 100% area Post third coat DFT meter, Painting IOC / Paint SSPC PA2 + existing
application industry application airless spray, 60:1 Vendor Manufacture DFT
standard. / 70:1 airless Tip - r's Inspector
19 or 21 Thou.
Nozzle pressure
2100 - 3500 PSI
14 X cut Adhesion test ASTM Randomly to be Pre- Coating Elco meter, Painting IOC / Paint 5A or 4A (post 7 days
D3359/ checked post curing application in adhesion kit with Vendor Manufacture curing) if tested as per
ISO4624 case of shop tape r's Inspector ASTM D3359. 5 Mpa if
coated & after tested as per ISO 4624
drying of each
coat. Post
system curing -
7 days.
15 Measurement of ASTM Random checking During Notch gauges Painting IOC / Paint ASTM D4414 - 95
WFT D4144 - 95 of WFT as per paint application of Vendor Manufacture
datasheet. each coat r's Inspector

Annexure-A
DETAILS OF BAND COLOURS FOR SPECIFIC PRODUCTS OF MARKETING

PIPELINES

Annexure-B
CHECKLIST FOR PAINTING
Location: ____________________ Equipment No.:______________
Area of Application: ______________________
Sr Checked & Found Signature &

Item Remarks
No. Satisfactory (Y/N) date
1. Batch test certificates of the
paints available at site
2. Painting is of correct spec.
3. Compressor is of right CFM
4. Air receiver and safety valve test
certificate
5. Humidity is checked & found
satisfactory as per the
requirement of paint spec.
6. Abrasive used is of proper size
7. Blasting pressure at the nozzle
2
tip is 7 kg/cm .
8. Correct size nozzle is used
9. Blasted surface is compared to
the pictorial standards and profile
measured.
10. Abrasive is removed from the
blasted surface with soft cloth or
air before application of primer
11. Mixing of the primer is done as
per the spec.
12. Correct type spraying gun is
used for primer application.
13. Primer is applied within specified
time as per the spec.
14. Availability of a digital elcometer
15. DFT checked at random
nd
16. Application of 2 coat of primer
17. DFT checked
st
18. Application of 1 finish coat
19. DFT checked
nd
20. Application of 2 finish coat
21. DFT checked
22. Overall DFT as per spec.

IOCL Painting Manual & Colour Code - June - 2015

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IOCL Painting Manual & Colour Code - June - 2015

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IOCL Painting Manual, Rev.

-1, June 2015

Corrosion is natural phenomena of metals and alloys. It has highest

The mechanism of corrosion is explained on the basis of the operation of

Certain corrosive agents in petroleum products cause corrosion depending on

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other pollutants like chloride, sulphur-dioxide etc, in the atmosphere. The

Corrosion can be mitigated through a number of ways like proper designing,

1.2 ATMOSPHERIC CORROSIVITY MAP OF INDIA

Figure 1.1: Atmospheric Corrosivity Map of India

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1.3 SELECTION OF PAINT SYSTEM

i) Paints for protection against external environment

The paints/ coating systems for protection against external environment

The coatings systems for protection against soil side corrosion of

1.4 CLASSIFICATION OF ZONES

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2.0 BASICS OF PAINTS AND COATINGS

2.2 MECHANISM OF PROTECTION

The mechanism of protection through paints / coatings can be different for

2.2.1 Barrier Mechanism

This is the most general and popular mechanism of protection by paints,

Figure 2.1 : Mechanism of Barrier Protection

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2.2.2 Inhibitive / Passivation mechanism

The inhibitive / passivation mechanism uses anti-corrosive / inhibitive

Figure 2.2 : Mechanism of Protection by Inhibitive Primers

2.2.3 Sacrificial mechanism

The sacrificial mechanism works by use of metallic pigments for sacrificial

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Figure 2.3 : Mechanism of Sacrificial Protection

2.2.4 Working of a Multi-coat Protective Coating System

A multi-coat protective coating system predominantly consists of:

i) An anticorrosive primer containing either an inhibitive or a sacrificial

A paint scheme consisting of a primer, undercoat/s and topcoat, utilizes the

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2.3 PAINT CONSTITUENTS

Paint is a complex liquid coating material composed of pigments, binders and

i) to provide color and reinforcement

Main pigments determine the function of the coating (primer, undercoat,

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2.3.4 Alkyd Resins

2.3.6 Chlorinated rubber

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crosslink with it.

2.3.8 Epoxy Resins

Cycloaliphatic epoxides have been developed that offer improvements in light

2.3.9 Co-polymer curing agents

Although epoxies are generally considered as catalyzed, the crosslinking

Figure-5 Reaction of Epoxy group with Amine groups

Although a variety of cross linking agents can be used (including mercaptans,

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The polymines (for example diethylene - triamine, hydroxyethyl diethylene

However, for immersion service, it is a good practice to wipe it from the

Recognizing this problem, many coating manufacturers supply the amine as a

Polymide curing agents are the condensation products of a dimerized fatty

2.3.10 Coal - tar - Epoxies

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2.3.11 Epoxy - Phenolic Coatings

Phenolic cross - linked epoxy coatings are extremely resistant to acids,