METHOD STATEMENT FOR SURFACE PREPARATION

AND PAINTING OF PIPES AT POWER BLOCKS

PROJECT: SHAGAYA 50 MW CONCENTRATED SOLAR

THERMAL POWER PLANT

CLIENT: TSK FLAGSOL

DanemDocument No. : DG/TSK/ PPW/ MOS/01

Rev. No. : 00
Date : 27/5/2018
Page : 3 OF 28
 METHOD STATEMENT FOR SURFACE PREPARATION AND
PAINTING FOR PIPING

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CONTENTS

SL NO TITLE PAGE NO
1 PURPOSE 5
2 SCOPE 5
3 DEFINITION AND ABBREVIAION 5
4 REFERENCE DOCUMENTS 5
5 EQUIPMENT DETAILS 5
6 CALIBRATION DETAILS 5
7 INSTRUCTIONS 6
8 BLAST CLEANING OPERATIONS 6
9 PAINT APPLICATION 7
10 DRYING AND CURING 7
11 HANDLING OF PAINTED STEEL WORK 8
12 PAINTING SYSTEM 9
12.1 COLOR CODE 9
13 PAINT MANUFACTURER 10
14 DOCUMENTATION 10
15 REPAIR 10
15.1 SURFACE PREPARATION 10
15.2 COATING 10
15.3 INSPECTION & TEST 10
16 HSE REQUIREMENTS 11
17 PAINTING REPORT FORMAT 13
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18 PRODUCT DATA SHEET 14-28

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1.0 Purpose

1.1 The purpose of this procedure is to define a method to ensure that Surface
preparation and Painting is carried out under controlled conditions to meet the Paint
Specification

2.0 Scope

2.1 The scope of this procedure is to establish the Blasting and Painting minimum
requirements according to relevant International Standard.

3.0 Definition and Abbreviation

QA/QC Quality Assurance/Quality Control

DE Danem Engineering Works FZE
QS Quality System
DFT Dry Film thickness
PPE Personal Protective Equipment

4.0 Reference Documents

4.1 General Standard for Blasting and Painting

4.2 Reference doc no: ENG0-000201-00-TUB-ET-0005, ISO 12944
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5.0 Equipment details

5.1 Hygrometer ,Dew point calculator for weather conditions.

5.2 DFT Gauge (ELCOMETER) for checking Paint thickness
5.3 Needle Gauge for checking the pressure on blasting

6.0 Calibration details

All the equipment’s / Instruments including DFT gauge are to be calibrated. The
calibration status will be attached with Equipment / Instrument. The recent calibration
certificate will be available at site.

7.0 Instructions
7.1. Blast cleaning of steelwork shall not commence until the following preparation work
has been carried out in the fabrication yard.
7.1.1. All welding slag, spatter, arc strikes and temporary attachments to be removed and
ground flush.
7.1.2. Edges of all sections and plates shall be dressed and rounded in 2 mm radius to
remove sharp edges or burrs.
7.1.3. All oil, grease and other harmful substances shall be removed by solvent or by
washing according to SSPC-SP1
7.2. Paint shall be accepted only in unbroken containers with date of manufacture and
clear description of the product with Product reference, batch number and shelf life.
7.3. Test certificates shall be procured from the manufacturer with each batch purchased.
7.4. Paint Storage.
7.4.1. The product must be stored in accordance with manufacturer instruction.
7.4.2. Paint, which is not being used within the shelf life, shall be discarded.
7.4.3. The product must be kept in a cool and ventilated place, protected from heat and
direct sunlight. Containers must be kept tightly closed.
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8.0 Blast cleaning operations

Blast cleaning of the steel surfaces shall be carried out and conform with:

a) Manufactures Coating Manual : Surface finishes of blast cleaned steel for painting.

1. The abrasives for blasting shall be free from contamination and silicates.
Abrasives shall be released at a pressure not less than 100 psi. Refer equipment
detail 5.0 for checking the parameters.

2. All re-used abrasives must be properly screened and air washed to remove dust
etc.

3. The average blast profile produced by the measurement of bottom of the lowest
valleys to the top of the highest peaks of roughness of the surface shall be 35 to 75
microns.
Using ISO 8503 testex tape.

4. Blasting Abrasive: Garnet or Grit . Batch Certificate will be submitted at the time
of Blasting

5. All accessible areas of above 60Deg temperature lines shall be SSPC-SP10 (Sa
2.5) confirms to Level of blast cleaning.

6. After blasting all dust, shall be removed by moisture free compressed air or
brush .

7. All areas for painting must be kept clean and dry and the painting must take
place within the time specified, i.e. before visible re-rusting occurs or within 6 hours
after blasting.

8. All pipe lines of below 60Deg service, Mild exposure areas of above 60Deg
service such as pipe support areas and all other inaccessible areas shall be
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confirm with SSPC-SP2(ST-2) & SSPC-SP3 ( ST-3). ie hand tool & power tool
cleaning to be used.

9.0 Paint Application

1. The paint should be mixed and applied as per the manufacturer’s

recommendation and detailing ratio. Thinning shall be acceptable only up to 5% by
volume.

2. When paint is to be used from a company with no previous experience with us,
a specialist from the supplier must be called in to check that our methods are
correct, and that, in a trial application. Guaranty certificate from manufacturer is
mandatory in such case.

3. The Steel temperature shall be at least 5 º C above the dew point.

Refer equipment detail 5.0 for checking the parameters.

4. The ambient temperature shall be not less than 10 º C with a humidity level of
below 85%. Refer equipment detail 5.0 for checking the parameters.

5. Each coat of painting on the substrate shall be applied by the method of

rollers and brush.

10.0 Drying and curing

1. No coat of paint shall be applied until the preceding coat

is dry & cured. To be cleaned
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before over coating .For the coating Intervals & more datas refer the paint data
sheets.

2. The paint shall be considered dry for re-coating when another coat can
be applied without development of any film irregularities such as lifting or loss
of adhesion of undercoats and the drying time of the applied coat does not
exceed the maximum specified for it as a first coat.
3. The drying, re-coating and curing periods must be as specified by the
manufacturer. But the actual drying time can be determined on site, depending
on the existing system, generic types, number of coats, thinning, temperature,
ventilation etc.

4. The paint shall be protected from dust, dirt, rain and condensation, until
dry to the fullest extent possible. The painting area shall be covered with
tarpaulin sheets, garden net etc…

5. The dry finished coatings shall be of uniform texture, colour and

thickness and free from sags, runs, inclusions or any other defects.

6. The dry film thickness shall be tested as soon as the paint has dried and
no material will be delivered until the Inspector has checked and passed it as
conforming to the required specification. The dry film thickness shall be tested
by a measuring equipment called Elcometer . Each coat shall be checked with
Elcometer according the painting system thickness requirement.

11.0 Handling of painted steelwork

1. No steelwork shall be handled until the time for drying specified is completed.

2. All lifting slings shall be covered to prevent damage to painted surfaces.

3. Painted steelwork may only be loaded or offloaded by hoisting equipment.

4. Softwood bearers shall be used between items to separate them horizontally

and vertically and prevent chaffing and scoring during transport to site.
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12.0 Painting System:

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12.1 Color code

FLUID COLOR RAL NO

DWater/E. Glycol Green RAL 6018

DWater/P. Glycol Green RAL 6018
Brown with RAL
Fuel Oil additional 8001,30
red color 00
Yellow with RAL
Nitrogen additional 1021,
black color 8022
Brown with RAL
Oil water additional 8001,30
red color 00
Raw water Green RAL 6018
Service water Green RAL 6018
Sewage Black RAL 9005
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Waste water Black RAL 9005

13.0 Paint Manufacturer :- Manufacturer shall be confirmed as per the availability of

Raw Materials required to execute the Works.

14.0 Documentation

Inspection report shall be prepared for blasting & coating as per Danem Surface
Preparation Painting Check List. The report shall be attached with Testex tape (Press-
O-Film) and painting reports showing all the relevant information.
Painting report format attached – page 11 of 11

15.0 Repair (TOUCHUP OF PAINT DUE TO HANDLING & MECHANICAL DAMAGE)

15.1 Surface preparation

Small areas that are locally damaged, Clean the rough paint surface area and
additional 1” around the rectified area by mechanical means, like using the needle gun,
wire brush or emery paper etc.
15.2 Coating

As per the painting specification apply one coat at clean surface by roller. Allow curing
as per paint Manufacturer specification. The surface shall then be repaired by the local
application of the requisite number of coat of paints to obtain the original coating
system and thickness as per the Paint Specification

15.3 Inspection & Test

The following tests and inspections are foreseen

- Rust grades
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- Check of blast cleaning profile using a suitable profile meter

- Check of paints documentation

- Check of expiry dates of the priming and finishing coats

- Check environmental conditions

- Visual examination of appearance and uniformity of the painted surface

- Check of top coating and drying time, in accordance with the directions of
the paint Manufacturer

- Check visually the painted surface and measure the DFT

- Adhesion test - A Cross hatch test should be carried out on the test panels (applicable
only for SA 2.5 + painting). One test panel for Each Paint System .

16.0 HSE requirements

1. Compressor and associated pressure vessels shall be provided against over-

pressuring, by
fitting relief valves.

2. Blasting cleaning and spray painting equipment shall be continuously bonded from
nozzle
to compressor which shall be earthed and conductive hoses used to prevent build-up
of
static electricity

3. The blasting operator’s hood or headgear shall be ventilated by clean cool air served
through a regulator/filter to prevent blasting residues from being inhaled by the
operator. The air supply from the compressor, be passed through suitable filters and
be free from oil and water.

4. All personnel activity involved in basting and painting activity shall wear the following
Protective Equipment’s.
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i) While Blasting : Protective hood, gloves, breathing apparatus mask, safety

footwear, and
Safety blasting helmet.
ii) While Spraying: Half mask, Chemical Cartridge, Visors, Goggles, Painting
Coveralls,
Safety Shoes.

iii) While Scaffolding: Scaffolding Gloves, Body Harnesses, Safety Shoes, safety
Helmets, Safety
Goggles, Normal Coveralls

iv) General PPEs: Coverall, Safety Helmet, Safety Goggles, Cotton Gloves, Dust
masks, ear
Plugs/Ear Muffs, safety Shoes.

v) Minimum one fire extinguisher shall be placed next to each compressor.

vi) A full and sufficiently stocked first aid safety box shall be available at the work
place, and
this shall be in the custody of the foreman or the work place person in charge.