Painting Specification Storage Tank PDF

Client Name : BASF India Limited Specification G3IR-1000-55-SP-9001
Project Name : Project GIR Date 12 Apr 2012

Project Number: G3IR Page 1 of 16
Painting ( Protective Coating )
Document No: G3IR-1000-55-SP-9001
Unit: General
Discipline: Mechanical
Document Type: Specification
Document Title: Painting ( Protective Coating )
0 12-Apr-2012 Issued for RFQ AV AA VP

Fluor BASF
Revision Date Purpose Prepared By Checked By
Approved By
This document was prepared for BASF INDIA LIMITED by FLUOR DANIEL INDIA PVT LTD (“CONTRACTOR”) and based in part on
information not within the control of either owner or contractor. Neither owner not contractor have made an analysis, verified or rendered an
independent judgement of the validity of the information provided by others. While it is believed that the information contained herein will be
reliable under the conditions and subject to the limitations set forth herein, neither owner nor contractor guarantee the accuracy thereof. Use of
this report or any information contained herein shall be at user’s sole risk.
G3IR-1000-55-SP-9001_Rev 0 Page 1 of 16

Record of Revisions
This specification has been revised as indicated below and described in the revision record on the
following page. Please destroy all previous revisions.
Revision Date Description

No.
0 12-Apr-2012 Issued for RFQ ( No change except document Name; FEED document G2IR
is replaced by G3IR)
G3IR-1000-55-SP-9001_Rev 0 Page 2 of 16

TABLE OF CONTENTS
1. GENERAL ...................................................................................................................................................... 5
1.1. Scope ........................................................................................................................................................... 5
1.2. Exceptions .................................................................................................................................................. 5
1.3. Terminology ................................................................................................................................................ 5
2. REFERENCES ............................................................................................................................................... 7
2.1. ASTM (American Society for Testing and Materials).............................................................................. 7
2.2. SSPC (Steel Structures Painting Council) ............................................................................................... 7
2.3. ANSI/ASME/NEMA ...................................................................................................................................... 7
2.4. BIS................................................................................................................................................................ 8
2.5. Manufacturer’s Application Data Sheets ................................................................................................. 8
2.6. Regulations of Governmental Agencies Related To Personnel Health and Safety As Applicable To
Painting ....................................................................................................................................................... 8
3. EXECUTION ................................................................................................................................................... 8
4. GENERAL PAINTING REQUIREMENTS ...................................................................................................... 9

4.1. Items Which Do Not Require Painting ..................................................................................................... 9
4.2. Items Which Require Protection From Painting ..................................................................................... 9
4.3. Scheduling Of Work ................................................................................................................................... 9
5. SURFACE PREPARATION ......................................................................................................................... 10

5.1. Carbon Steels (Bare Metal) ..................................................................................................................... 10
5.2. Carbon Steels (Pre-painted, Primed Surfaces Requiring Further Coating) ....................................... 10
6. MATERIAL REQUIREMENTS ..................................................................................................................... 11

6.1. Environmental Compliance ..................................................................................................................... 11
6.2. Compressed Air........................................................................................................................................ 11
6.3. Abrasives .................................................................................................................................................. 11
6.4. Cleaners And Paint Materials.................................................................................................................. 11
6.5. Paint Application Equipment .................................................................................................................. 12
7. FINISH COLORS AND IDENTIFICATION ................................................................................................... 12
8. APPLICATION OF PRIMERS AND FINISHES ........................................................................................... 12
9. COATING REPAIRS .................................................................................................................................... 13
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9.1. Repairs to primed, finish painted surfaces shall be as follows: ......................................................... 13
10. QA/QC (QUALITY ASSURANCE AND QUALITY CONTROL) ................................................................. 13

10.1. Documentation .................................................................................................................................... 13
10.2. Instruments.......................................................................................................................................... 14
10.3. Minimum Inspection Required Prior To and During Surface Preparation .................................... 14
10.4. Minimum Inspection Required Prior To Painting ............................................................................ 14
10.5. Minimum Inspection Required During Painting............................................................................... 15
10.6. Minimum Inspection Required After Painting .................................................................................. 15
11. SUPPLIERS & PRODUCTS .................................................................................................................. 16
12. ATTACHMENTS .................................................................................................................................... 16
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1. GENERAL
1.1. Scope
This specification covers external painting of aboveground plant facilities exposed to weather and operating at
temperatures less than 538 °C (1000°F).
1.2. Exceptions
This Specification is not applicable to architectural components and buildings. This specification does not cover
Galvanizing.
1.3. Abbreviation and Terminology
APPLICATION DATA shall mean application instructions, recommendations and guidelines described in the
published literature of the coating materials' Manufacturer, referenced industry standards and any specific
requirements noted in this specification and any drawings issued to the CONTRACTOR. In case of conflicting
requirements between the documents, CONTRACTOR shall submit all conflicting information to the
ENGINEER for resolution. If the published literature of the Manufacturer does not contain required
information, CONTRACTOR shall obtain additional information from the parent corporate office if the local
Manufacturer is a licensee or a subsidiary of a multinational organization. Any deviations from or changes to
Manufacturer's published literature shall be subject to ENGINEER's review, acceptance or rejection without
comment, explanation and/or justification.
Note: Where recommendations, instructions and guidelines are given in permissive language such as
“May,” “Should,” and “Recommended,” compliance with those recommendations, instructions and
guidelines shall be considered mandatory unless otherwise instructed by the ENGINEER.)
Approved Equal shall mean a product approved by the ENGINEER as equal to the product specified in this
specification.
Carbon steels shall mean carbon steels including alloy steels with chromium content of 9¼ % or less.
Coat shall mean one full layer of the specified material applied to the specified thickness. Multiple passes
including initial mist pass are necessary to form a coat. A mist pass is not considered a full coat. The cost of a
coat shall include the cost of mist pass (es).
Note: Mist coats are the same as mist passes.
CONTRACTOR shall mean the painting contractor.
CUI is Corrosion under Insulation.
ENGINEER shall mean the FLUOR corrosion engineer responsible for the development or maintenance of
this Specification.
Dew point The temperature of a given air/water-vapor mixture at which, under atmospheric pressure,
condensation starts.
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DFT (Dry Film Thickness) shall mean the thickness of the dry film of the coating. In the absence of a
specified range, the value stated shall mean a minimum value and the maximum value shall not be more than
1.5 times the stated value.
DFT Measurement shall mean the average value of three readings recorded by dry film thickness gage. The
readings shall be within a 6 inch radius and evenly spread out from a given spot.
Catalog Equipment shall mean catalog items or assemblies of catalog items such as control instruments,
electrical equipment, compressors, motors, pumps and similar items which are not specifically designed and
custom fabricated for the project.
Custom Equipment shall mean equipment specifically designed and fabricated for the project, such as process
equipment, skid units, boilers, heat exchangers, heaters, heat recovery steam generators (HRSGs), vessels,
drums, shop fabricated tanks, stacks, made-to-order equipment and related items including structural
components.
Insulated surfaces shall mean steel surfaces which will be insulated.
Manufacturer shall mean the manufacturer of the specified paint.
Operating temperature shall mean the maximum temperature of the substrate surface exposed to weather
(indoor and outdoor) during operating conditions. For example, operating temperature of refractory lined
equipment for painting purposes shall be the temperature of the metal surface exposed to the weather during
operation. The steam out temperature of piping and equipment shall not be considered as a basis for paint
system selection unless specifically instructed in writing by the Owner and acknowledged in writing by
FLUOR.
Owner shall mean the Owner of the Project or its authorized representative.
Piping shall mean piping, pipe fittings, valves, pipe supports and accessories unless a particular item and/or
size limitation is stated.
Stainless Steel shall mean austenitic stainless steel such as Type 304, 316, 321 and 347.
Structural steel shall mean structural steel other than the structural steel which is an integral part of fabricated
equipment by the SUPPLIER. (Example: Structural steel of a boiler structure shall be painted in the same
manner as the boiler's other surfaces.)
SUPPLIER shall mean fabricator and/or supplier of pipe, equipment, structural steel, and other items to be
painted.
Tanks shall mean field fabricated above ground storage tanks (AST).
Uninsulated surfaces shall mean carbon steel surfaces which will not be insulated.
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Work shall mean all labor, supervision, installed and consumable materials, services, equipment, instruments,
tools, and each and every item of expense necessary for preparing the surfaces for paint application, application
of paint materials, repairs, quality control, and cleanup thereafter.
RAL & DB color code are widely used color shade matching systems.
SIS is Swedish Standard Institution.
SSPC is Steel Structures Painting Council.
2. REFERENCES
The latest revision, including addenda, of the following references in effect on the latest date of this Specification
form a part of this Specification. Except as modified by the requirements specified in this Specification or on the
drawings, all Work performed shall comply with the following references. Any conflicts between the following
references and this Specification shall be resolved by the ENGINEER.
2.1. ASTM (American Society for Testing and Materials)
 B117 Standard Test Method of Salt Spray (Fog) Testing

 D3276 Standard Guide for Painting Inspectors (Metal Substrates)
 D4541 Standard Test Method for Pull-off Strength of Coatings Using Portable Adhesion Testers
 D3359 Standard Test Method for measuring by tape test
 D4285 Test Method for indicating oil or water in Compressor Air
 D4752 Standard Test Method for measuring MEK resistance of ethyl silicate (inorganic) Zinc-Rich
Primer by Solvent Rub.
 NACE RP0287 Field Measurement of Surface Profile of Abrasive Blast Cleaned Steel Surfaces Using
Replica Tapes
2.2. SSPC (Steel Structures Painting Council)
 SSPC-SP1 Solvent Cleaning

 SSPC-SP2 Hand Tool Cleaning ( Equivalent SIS St 2)
 SSPC-SP3 Power Tool Cleaning ( Equivalent SIS St 3)
 SSPC-SP5 White Metal Blast Cleaning ( Equivalent SIS Sa 3)
 SSPC-SP6 Commercial Blast Cleaning ( Equivalent SIS Sa 2)
 SSPC-SP10 Near White Blast Cleaning ( Equivalent SIS Sa 2. ½)
 SSPC-SP11 Power Tool Cleaning To Bare Metal
 SSPC-Vis1 Visual Standard For Abrasive Blast Cleaned Steel (Standard Reference
Photographs)
 SSPC-VIS 3 Visual Standard for Power and Hand-Tool Cleaned Steel
 SSPC-TR3/ NACE 6A192 Dehumidification and Temperature Control during Surface Preparation,
Application and Curing for Coatings/ Lining of Steel Tanks, Vessels
and other Enclosed Spaces.
 SSPC-PA2 Measurement Of Dry Paint Thickness With Magnetic Gages
2.3. ANSI/ASME/NEMA
 A13.1 Scheme for the Identification of Piping Systems
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 Z535.1 Safety color code
 ISO 11127 Parts 1-7 Paints and Varnishes – Preparation of Steel Substrates before application of
paints and related Products. Test methods for non-metallic blast-cleaning abrasives.
2.4. INDIAN STANDARDS (BIS)
 IS 2379 : 1990 Pipelines-Identification-colour code
2.5. Manufacturer’s Application Data Sheets
2.6. Regulations of Governmental Agencies Related To Personnel Health and Safety as

Applicable To Painting
3. EXECUTION
The SUPPLIER shall perform all Work related to surface preparation, priming and finish painting of the CATALOG
EQUIPMENT including all attachments thereto in accordance with the SUPPLIER's standard paint system subject to
the Owner's choice of finish colors, semi-gloss finish and minimum corrosion protection level of 2000 hours (salt fog
resistance) when tested in accordance with ASTM B117.
The SUPPLIER shall perform all Work related to surface preparation and priming of the following items including all
attachments (excluding pre-painted shelf items) thereto in accordance with the Painting Schedule of this specification:
 Custom Equipment
 Piping
 Structural steel (non-galvanized) and miscellaneous items except tank plates for field erection
The CONTRACTOR shall perform all Work related to the following tasks, by way of example but not by limitation,
necessary to complete the application of all painting systems in accordance with this specification.
 Cleaning of surfaces to remove all dirt, foreign matter, grease, oil, etc. with fresh water and/or degreaser.
 Repair of damaged surfaces of shop coating.
 Surface preparation and priming of bare metallic surfaces.
 Finish painting of primed surfaces.
 Repainting of custom equipment with damaged finish paint.
 Application of safety color coding and pipe identification.
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4. GENERAL PAINTING REQUIREMENTS
4.1. Items Which Do Not Require Painting
The following items do not require any surface preparation or painting unless otherwise specified.
 Non-metallic items such as concrete, glass, plastic, wood and etc.
 Non-ferrous metals such as aluminum, copper, brass and etc.
 Galvanized surfaces except for safety color coding or coating repair.
 Insulation weatherproofing.
 Uninsulated stainless steel surfaces ( For insulated surfaces refer to Attachment 1)
4.2. Items Which Require Protection from Painting
Surfaces which could be damaged by abrasives, dust, or paint overspray shall be protected by wrapping, taping,
or other means to prevent damage. Such surfaces shall include, by way of example, but not by limitation, the
following:
 Alloys (Monel, Incoloy, or Hastelloy)

 Bearings
 Conduit
 Control panels
 Control valves
 Couplings
 Equipment nameplates
 Expansion joint bellows
 Fire sprinkler heads
 Flange and nozzle facings
 Glass, rubber, gasket materials etc.
 Identification tags
 Instrument glasses and gauge dials
 Machined surfaces (threads, valve stems, pump and cylinder rods, shafts, etc.)
 Screws
 Spring hanger graduations
 Stainless steel surfaces (except as specified)
 Valve stems and position indicators
Note: Stainless steel surfaces shall be protected from zinc and aluminum rich coatings. Any accidental
overspray of zinc and aluminum, including trace amounts, over stainless steel surfaces must be
completely removed.
4.3. Scheduling Of Work
Unless otherwise stated in the APPLICATION DATA and approved by the ENGINEER, painting shall be done
when:
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 Pressure testing is complete
 Ambient temperature is above 10°C
 Metal surface temperature is at least 5°C above the dew point
 Relative humidity is less than 85%
 There is no likelihood of rain within 24 hours after painting
 Protection of surfaces, not required to be painted e.g., stainless steel, is in place
5. SURFACE PREPARATION
5.1. Carbon Steels (Bare Metal)
Surfaces shall be thoroughly washed with potable water to remove all water soluble salts, dirt and dust. The
water washing shall be considered critical especially if the surfaces are exposed to salty environment. If any
grease and oils are present on the surface, the surfaces shall be further washed with biodegradable non-ionic
detergent solution until the surfaces are completely free of all surface contamination. There shall be no smudge
on the surface when rubbed with a clean cloth. Surfaces cleaned with detergent shall be thoroughly rinsed with
potable water to remove traces of detergent. Solvent Cleaning methods shall be as outlined in SSPC SP-1.
Under no circumstances, shall the substrate remain without a primer coat for more than 4 hours.
Welded areas shall be blast cleaned or ground to remove burrs, mill scale, weld spatter, flux, or protrusions.
Weld reinforcement shall not be removed and base metal shall not be ground below the surface. Surface profile
measurements for abrasive blast cleaned surfaces shall be made with a Keane Tator profile comparator, clemtec
anchor profile chips, Testex Press-O-Film or other Contractor accepted method suitable for abrasive being
used.
Surface preparation and anchor pattern (surface profile) shall be as specified for each individual paint system.
Profile of the abrasive blasted surfaces shall comply with the requirements provided by the paint system and
measured in accordance with standard NACE RP0287.
Only grit blasting shall be used for surface preparation. All rough welds shall be rounded and contoured. Sharp
edges shall be rounded, chamfered and broken. The surface profile depth shall be achieved by using a medium
that has good angularity of form, sharp cutting edges and is substantially free from “half rounds”.
Before applying any coating, blast cleaned surfaces shall be vacuumed and wiped with a clean cloth to remove
all traces of dust.
Cleaned surfaces shall be coated within eight hours and before occurrence of any trace of rust. If rust is
noticed, the surface shall be blast cleaned again. Where the item to be painted is large, it shall be cleaned and
primed in sections.
The maximum allowable level of water soluble salt contamination shall be 20mg/m2. Surfaces that do not meet
this criterion shall be reprocessed.
5.2. Carbon Steels (Pre-painted, Primed)
All surfaces shall be thoroughly degreased and washed in the manner stated for bare carbon steels above.
The washed surfaces shall be completely dry prior to further application of paint materials. Any additional
surface preparation, such as sanding, required by the coating manufacturer shall be followed prior to top-
coating.
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6. MATERIAL REQUIREMENTS
6.1. Environmental Compliance
All cleaners, primers, finishes and solvent materials shall be environmentally safe products and shall not
contain hazardous materials such as CFCs, lead, chromates and etc. which cause air, soil and water pollution.
Products which do not comply with the pollution regulations of the local governmental agencies are not
allowed for use on this Project. The SUPPLIER and the CONTRACTOR are responsible for verifying the
product compliance with local environmental regulations. Disposal of residual materials ( spent abrasives,
coating materials, solvents etc.) shall be performed fully in accordance with rules, regulations and laws in force
in the country where the coating work is performed.
6.2. Compressed Air
The compressed air shall be passed through a cooler.
All air compressors shall be of a sufficient size to deliver atleast 100 PSI at the nozzle. In no circumstance, shall
the compressed air temperature more than 100 C. Each compressor shall have two coalescing oil/moisture
removal filters, one located at the discharge of the after-cooler and one close to the blast/spray gun. Filters
must remove 99.999% of oil from the compressed air. Compressed air used for blasting and lining application
must be clean, oil free and dry.A compressed-air cleanliness test (blotter test) as described in ASTM D4285
shall be used for checking air cleanliness.
6.3. Abrasives
Abrasives shall be composed of clean, dry, hard particles free of foreign substances such as dirt, oil, grease,
toxic substances, organic matter, mill scale and water soluble salts. The pH of the abrasive materials shall be
6.0 to 8.5. Abrasives shall be sharp garnet or grit of Rockwell hardness (40 to 50 HRC) and properly graded.
Abrasive particle size shall be suitable for producing an angular sharp anchor profile. Shot is not acceptable.
Conductivity measured according to ISO 11127-6 shall not exceed 300 microSiemens/cm measured at 20°C
and chloride content shall be less than 25 ppm. In no circumstance shall silica abrasive be used.
6.4. Cleaners and Paint Materials
The degreaser shall be non-toxic and non-ionic biodegradable water based cleaner.
Petroleum, kerosene, diesel oil or other fatty solvents shall not be used.
Primer and finish paint materials shall be those listed in Attachment.
Primers and finishes shall be factory tinted, sealed, and labeled products and approved by the ENGINEER.
Each label shall show the product name, number, type of paint, lot or batch number, color and instructions for
mixing and/or thinning. Solvents shall be products of the same manufacturer and be used in accordance with
the APPLICATION DATA.
All finish paints shall be semi-gloss finishes.
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6.5. Paint Application Equipment
Spray equipment shall be as recommended in the APPLICATION DATA. Sufficient number of spare parts
shall be made available at the work site.
7. FINISH COLORS AND IDENTIFICATION
Finish colors shall match RAL code colors shown in Attachment 3 (Plant colors and identification). Each
SUPPLIER shall furnish samples of available colors to FLUOR for items finish painted in the shop.
8. APPLICATION OF PRIMERS AND FINISHES
Proper functioning of the in-line moisture and oil traps shall be evaluated daily by allowing the air supply
(downstream of the traps) to blow against a clean, white cloth in accordance with ASTM D4285. No moisture or oil
should be deposited on the cloth. If contaminants are detected, the equipment deficiencies shall be corrected and the
air stream shall be retested. Cleaned surfaces determined to have been blasted since the last successful test shall be
degreased and re-blasted with clean air and abrasive. Primers and finishes determined to have been applied using
contaminated air shall be removed and recoated using clean air.
All painting shall be in accordance with this specification and the APPLICATION DATA; Attachment 1, Primers and
Finishes and Painting Schedule, unless otherwise approved in writing by the ENGINEER.
Storing; thinning; mixing order; mixing procedure, including the mixer speed and mixing time; handling; and
application of paint materials shall be in accordance with the APPLICATION DATA.
Pigmented and catalyzed materials shall be thoroughly mixed and strained before applying. Materials which have not
been applied within the pot-life times shall be discarded and properly disposed off.
Coatings and primers shall be delivered to the jobsite in the original containers bearing manufacturer’s name, product
designation, batch number, shelf life and date of manufacture.
Paints with metallic pigments such as zinc and aluminum shall be continuously agitated to prevent settling of the
pigment while being applied.
Ends of pipe, and edges of structural steel items that will require welding shall be masked off after blast cleaning and
left unpainted 1½" from the edge to facilitate welding. The masking material shall be removed as soon as possible
after painting.
Paint shall be airless spray applied if the adjacent property can be protected from overspray. Otherwise, the paint shall
be applied by roller or brush.
Weld lanes, bolt heads, corners, and edges require an initial brush coat before the application of the paint system to
assure wetness of the surface.
Paint materials shall be uniformly applied in even, parallel passes overlapping each pass 50% immediately followed
by cross-spray passes to obtain a continuous film without bare spots, pinholes or holidays. The coated surface shall
have no runs, sags, solvent blisters, dry spray or other blemishes. All irregularities shall be removed or repaired and
recoated.
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Intercoat contamination shall be minimized by maintaining proper cleanliness and by applying all coatings within the
time period stated in the APPLICATION DATA. If contaminants are present, they shall be removed before applying
subsequent coats.
9. COATING REPAIRS
9.1. Repairs to primed, finish painted surfaces shall be as follows:
 Damaged coatings shall be removed unless they are tightly bonded to the substrate metal. The surface
shall be wiped with a clean rag to remove all dust and loose materials. If there is any oil, grease or other
foreign matter, it shall be washed with water based non-ionic, biodegradable detergent followed by further
rinsing with potable water to remove all traces of the detergent. The surface shall then be dried.
 Products used for repair of defects and damages shall be supplied by the same paint manufacturer of the
original paint system.
 Areas with spot rust, burnt residue, weld spatter and other solid adherent foreign matter shall be cleaned
per SSPC-SP11, Power Tool Cleaning to Bare Metal, using 3M ScotchBrite surface conditioning discs.
 Existing coating shall be feathered and roughened at the edges with sandpaper or rotary discing.
 All dust shall be removed from the surface by vacuuming, brushing and wiping with a clean cloth.
 Repair materials shall be as follows:
1. Modified epoxy for operating temperatures ambient through 120°C.
2. Silicone acrylic for operating temperatures 121°C through 260°C.
3. Silicone aluminum for operating temperatures 260°C through 480°C.
4. Any repair shall be performed according to the instructions listed in the PDS (product data sheet)
published by the paint manufacturer.
 Primer repair material shall not overlap the existing adjacent finish. However, the finish repair material
shall overlap the adjacent existing finish a minimum of two inches.
10. QA/QC (QUALITY ASSURANCE AND QUALITY CONTROL)
10.1. Documentation
The SUPPLIER and CONTRACTOR are solely responsible for all QA/QC activities regardless of any QA/QC
activities performed by FLUOR. The SUPPLIER and CONTRACTOR shall maintain documentation to
comply with the guidelines of ASTM D3276 with the exception that the Inspection Checklist in the Appendix
shall be considered mandatory. Inspection shall also comply with the following additional requirements. Any
approvals for products and procedures submitted by the SUPPLIER and CONTRACTOR shall be considered
additional to the requirements stated in the specification and shall not be considered as a substitution to the
requirements of this specification.
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All QA/QC documentation for work performed shall be made available to FLUOR on demand and without
notice. If the SUPPLIER and CONTRACTOR are unable to produce the QA/QC documentation to the
satisfaction of FLUOR, such absence of documentation shall be sufficient cause for FLUOR to reject the work
performed.
When work is completed, SUPPLIER shall prepare a final report including the following data: surface
preparation characteristics, Trade name and characteristics of each paint system applied, Sequence of the coats
applied for each paint system, Atmospheric and thermo-hygrometric conditions, inspections and tests
performed and the relevant results, including final acceptance reports; Repairs, if any and corrective actions
undertaken.
FLUOR's review (or lack thereof) of quality control documents shall not be construed as acceptance of
omissions or defective work. Nor shall it in any way lessen the SUPPLIER's responsibilities to provide a
completely operative system or component in full compliance with this specification.
10.2. Instruments
The SUPPLIER and CONTRACTOR shall supply, calibrate and maintain the following instruments for
inspection. Alternate instruments may be approved by the ENGINEER.
Temperature and Humidity Gardner Certified Hygrometer and Temperature Indicator

Surface cleanliness SSPC-Vis 1 or NACE blast cleaned panels
Surface profile Elcometer surface profile gauge (Model 123), Keane-Tator Surface
Profile Comparator or Testex Press-O-Film
Wet Film Thickness Elcometer Model 154 or Nordson Wet Film Thickness Gauge
Dry Film Thickness Elcometer Inspector Model 111 or Mikrotest Dry Film Thickness
Gauge, Elcometer Paint Inspection Gauge Model 121 (required for
inspection of multiple coats)
Bond or adhesion strength Elcometer Adhesion Tester Model 106
10.3. Minimum Inspection Required Prior To and During Surface Preparation
Verify that nearby inlets of air intake and vacuum systems equipment are properly protected before initiation of
blast cleaning operations.
Verify that items requiring protection from abrasives and dust are properly protected.
Verify that the surface temperature is 5°C above the dew point and rain is not forecasted within the scheduled
painting time plus 24 hours.
Check abrasive quality, air quality and surface profile.
Verify that cleaned surfaces are free of contamination.
10.4. Minimum Inspection Required Prior To Painting
Verify that the storage, shelf life, mixing, thinning and application of primers and finishes are in accordance
with the APPLICATION DATA.
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All surfaces shall be visually inspected to assure that the proper surface conditions necessary for painting exist.
Document the temperature, humidity and substrate surface temperature.
Verify that surfaces not to be coated are masked off or otherwise protected prior to painting of adjacent
surfaces. Stainless steel must be protected from zinc and aluminum rich coatings.
10.5. Minimum Inspection Required During Painting
Verify that the recoating time is in accordance with the APPLICATION DATA.
Verify that the paint materials are applied within the shelf life and pot life.
Verify that the materials are properly strained and mixed in the recommended order and that the reaction time
as necessary was allowed.
Verify that the moisture and oil filters, of the air lines, are functioning properly.
Check for initial mist pass of the coating to avoid bubbling.
Check for criss-cross spray pattern to assure proper film buildup.
Check for proper atomization and avoid dry spray.
Verify the wet film thickness of primer and finish coats. The wet film shall be uniform without runs or sags.
10.6. Minimum Inspection Required After Painting
Verify that the paint film is free of defects. The painted surface shall be free of blisters, bubbles, craters, sags,
runs, dry spray, lap marks and unnecessary brush marks.
Verify the bond strength of primer and finish coats. The adhesive bond between the substrate and the prime
coat (except silicone aluminum) shall be at least equal to or better than Grades 4A and 4B when tested per
ASTM D3359 Standard Test Method for Measuring Adhesion by Tape Test. The number of tests shall be at
least TEN (10) for each batch of bulk items and FIVE (5) for each piece of equipment at random locations
selected by the ENGINEER. In case of failure, the number of tests shall be increased to the level approved by
the ENGINEER.
Verify that all masking tape has been removed.
Verify that the coating is cured as specified in the APPLICATION DATA. Cure of catalyzed materials may be
determined by exposure to a suitable solvent as recommended by the coating manufacturer. Inorganic zinc
primers may be tested for cure by burnishing the surface with a dull metal object such as a coin or paper clip
and/or testing by exposure to a suitable solvent as noted above.
Nondestructive dry film thickness gauges shall be calibrated in accordance with the gauge manufacturer's
instructions at the beginning of each day. Type I (magnetic pull-off) gauges shall be calibrated using Certified
Coating Thickness Calibration Standard of National Institute of Standards and Technology (NIST). Type II
(magnetic flux) gauges shall be calibrated by using plastic shim standards supplied by the gauge manufacturer.
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The DFT measurement of each layer of coating at any given spot shall be within the minimum and maximum
values specified for the individual coating layer of the coating system. The number of nondestructive DFT
measurements shall be at least five per item or at the following rate whichever is higher.
 Pipe and Structural steel: 1 for each 20 lineal feet

 Equipment (except tanks): 1 for each 100 ft2
 Tanks: 5 for each 1000 ft2
The ENGINEER may require thickness measurement of individual coats of a multi-coat system. Such
destructive measurements of coating thickness shall be performed by the SUPPLIER and CONTRACTOR
when directed by the ENGINEER.
10.7. Certification of Personnel
All personnel involved in the inspection process defined above shall be NACE Level 3 or FROSIO Certified,
and shall have adequate experience.
11. SUPPLIERS & PRODUCTS
Refer Attachment 02 “Paint Materials for Client Approval”.
12. ATTACHMENTS
Attachment 01 Primers and Finishes & Painting Schedule
Attachment 02 Paint Materials for Client Approval
Attachment 03 Plant Colors and Identification
G3IR-1000-55-SP-9001_Rev 0 Page 16 of 16
Project Number: G3IR Attachment 01 Page 1 of 3
Primer and Finishes & Painting Schedule
Piping, equipment and tanks specified to be insulated shall not be primed or finish painted. However, all protrusions
through the insulation and portions not covered by insulation (such as flanges, nozzles, supports, clips, manways,
and saddles) shall be painted in accordance with the paint system specified for uninsulated surfaces. The painting
requirements specified in the Painting Schedule below pertains to all uninsulated surfaces including uninsulated
surfaces of partially insulated piping and equipment.
Painting
Surface Application Operating
System Primer (1st coat) Finish (2nd coat) Finish (3rd coat)
Preparation Method Temperature Range
From To Thickness Thickness Thickness
Vessels, Exchangers, Tubular equipment and Piping - Uninsulated
Inorganic Zinc
Modified Epoxy Acrylic urethane
Silicate
5 – 8 mils 3 – 4 mils
2.5 – 3.0 mils
( 125 – 200 DFT) ( 75 – 100 DFT)
( 63 – 75 DFT)
System - A1
For CS & LAS Spray 120°C Alternative
SSPC-SP10 Ambient
(Uninsulated)
Epoxy Based
Inorganic Zinc
Micaceous iron Acrylic urethane
Silicate
oxide (MIO) 2 – 3 mils
2.5 – 3.0 mils
4 – 8 mils ( 50 – 75 DFT)
( 63 – 75 DFT)
( 100 – 200 DFT)
Inorganic Zinc Silicone Acrylic
Silicone Acrylic
Silicate ( Note 4 )
1.5 – 2 mils
2.5 – 3 mils 1.5 – 2 mils
System - A2 ( 37 – 50 DFT)
( 63 – 75 DFT) ( 37 – 50 DFT)
CS & LAS Spray
SSPC-SP10 121°C 260°C Alternative
(Uninsulated)
Inorganic Zinc Heat resisting Heat resisting
Silicate Aluminum Aluminum
2.5 – 3 mils 1.5 to 2 mils 1.5 to 2 mils
( 63 – 75 DFT) ( 37 – 50 DFT) ( 37 – 50 DFT)
System – A3 Inorganic Zinc
Silicone Aluminum Silicone Aluminum
CS & LAS Spray Silicate
SSPC-SP10 260°C 480°C 1 – 2 mils 1 – 2 mils
(Uninsulated) 2.5 – 4 mils
( 25 – 50 DFT) ( 25 – 50 DFT)
( 63 – 100 DFT)
System-A4
Stainless Steel
Not Not All temperature
( Uninsulated) None None None
Applicable Applicable ranges
( Note 9)
G3IR-1000-55-SP-9001_ Attachment 1_ Rev 0 Page 1 of 3

Operating
Painting Primer (1st coat) Finish (2nd coat) Finish (3rd coat)
Surface Application Temperature Range
System From To Thickness Thickness Thickness
Preparation Method
Vessels, Exchangers, Tubular equipment and Piping - Insulated
System - B1
Phenolic Epoxy Phenolic Epoxy
For CS & LAS Any
SSPC-SP 10 Ambient 149°C 5 to 7 mils 5 to 7 mils None
(Insulated)
( 125 – 175 DFT) ( 125 – 175 DFT)
System – B2
For CS & LAS Not Not
150°C Above None None None
(Insulated) Applicable Applicable
System - B3
SS Epoxy phenolic Epoxy phenolic
Not Any
(Insulated) Ambient 149°C 4 to 6 mils 4 to 6 mils None
Applicable
( Note 8 , 9) ( 100 – 150 DFT) ( 100 – 150 DFT)
System - B4
SS Not
Not
(Insulated) Applicable 150°C Above None None None
Applicable
( Note 8 , 9)
Custom or catalogue equipment, valves and instruments
System - C1
(Uninsulated) Supplier Standard Paint System
System - C2
(Insulated) Supplier Standard Paint System
Storage Tanks ( Field Erected )
Modified Epoxy
System - D1 Inorganic Zinc Silicate Acrylic urethane
Not 5 – 8 mils
For CS SSPC-SP 10 Ambient 120°C 2.5 – 3.0 mils 3 – 4 mils
Applicable ( 125 – 200
Uninsulated ( 63 – 75 DFT) ( 75 – 100 DFT)
DFT)
Epoxy phenolic
System - D2 Epoxy phenolic
Not 4 to 6 mils
For CS SSPC-SP 10 Ambient 120°C 4 to 6 mils None
Applicable ( 100 – 150
Insulated ( 100 – 150 DFT)
DFT)

Operating
Painting Temperature Range Finish (2nd
Surface Application Primer (1st coat) Finish (3rd coat)
System coat)
Preparation Method From Thickness Thickness Thickness
Thickness
System - D3
For SS Not Not
( Uninsulated) Ambient 120°C None None None
Applicable Applicable
( Note 9)
System –D4 Epoxy phenolic

Epoxy phenolic
For SS Not 4 to 6 mils
Any Ambient 120°C 4 to 6 mils None
( Insulated) Applicable ( 100 – 150
( 100 – 150 DFT)
( Note 8, 9) DFT)
Structural Steel
( Paint system for structural steel in place of Galvanizing )
Epoxy Based
Micaceous iron
System – E3 Inorganic Zinc Silicate Acrylic urethane
oxide (MIO)
( Only Carbon SSPC- SP3 Any Ambient 120 C 2.5 – 3.0 mils 1.5 – 2 mils
4 – 8 mils
Steel ) ( 63 – 75 DFT) ( 37 – 50 DFT)
( 100 –200
DFT)
1) Blast cleaning requirement applies to first (prime) coat only. Refer to section 5 for surface preparation
requirement before applying as a finish coat.
2) Paint materials containing zinc and aluminum shall not come in contact with stainless steel surfaces to
avoid embrittlement.
3) Deleted.
4) Non heat curing silicon acrylic paint or silicon acrylic paint having heat curing temperature 120 C
shall be used.
5) The average surface profile shall be 1.5 to 2.0 mils for inorganic zinc rich, urethane and epoxy paints,
and 0.50 to 0.75 mils for silicone paints.
6) Exterior painting, except inorganic zinc spray application, within plant is restricted to brush or roll
application unless a written exception signed by the owner.
7) DFT listed is nominal range. Consult individual supplier data sheets for recommended thickness.
8) Painting under insulation is required to prevent corrosion under Insulation due to presence of chloride.
9) All Stainless Steel surfaces shall be pickled and passivated as per Manufacturer Standard.

Paint Materials for Client Approval
Materials specified or referenced by a manufacturer's name and/brand are intended to describe the type and quality
level of the material desired and are not intended to be restrictive or to exclude similar items by other
manufacturers. Alternate materials require approval from the ENGINEER before being used. Any approval given
by the ENGINEER for alternate materials and/or application methods is subject to change if the performance of the
alternate materials or application method is later found to be inferior to the specified materials and methods. In
such cases, the SUPPLIER and CONTRACTOR shall remove and replace the applied coatings and revert the
materials and application to comply with this Specification at no cost to FLUOR.
Approval is limited to application over surfaces operating at and application conditions less severe than the
conditions stated in the published literature of the paint material manufacturer.
Equipment fabricator shall refer paint supplier product datasheet before applying painting. They shall also confirm
the painting product as required per painting schedule in Attachment 1.
 Indian Manufacturer:
Type & Paint Inorganic Epoxy Acrylic Phenolic Silicone Silicone Modified Epoxy
Supplier Zinc Mastic urethane Epoxy Acrylic Aluminum Epoxy MIO
Silicate
Shalimar Tuffkote Supplier Shalithane Supplier Supplier Lustotherm Supplier Epigard

Paints Silicate – to Finish to provide to MC 550 to provide HB MIO
CGC / provide detail to provide detail to
Epigard detail to contractor detail to contractor
Zinc Rich contract / owner contracto / owner
Primer or / r / owner
owner
Asian Paints Apcosil Rust-o- Apcothane Apcoguar Acrysil Heat Apcodur Apcodur
605 cap CF 678 d CF 707 HR resisting EHB epoxy MIO
aluminiu finish silicone paint
m 90 % aluminum
paint
Nerolac Nerosil Supplier Nerothane Neropoxy Supplier Nerotherm Supplier Neropoxy

118 to Enamel Phenolic to 538 to provide 266 MIO
provide PU provide detail to
detail to detail to contractor
contract contracto / owner
or / r / owner
owner

Sigma Supplier to Supplier Supplier Supplier Supplier Supplier to Supplier Supplier to

Coatings provide to to provide to provide to provide to provide provide
detail to provide detail to detail to provide detail to detail to detail to
contractor detail to contractor contractor detail to contractor / contractor contractor /
/ owner contract / owner / owner contracto owner / owner owner
or / r / owner
owner
Bombay Zinc-O-Sil Pentadur Pentathan Pentadur Supplier Kangaroo Supplier Supplier to

Paints 75 Mastic e FP 4510 HB to HHR to provide provide
5515 phenolic provide Aluminum detail to detail to
5540 detail to 4950- contractor contractor /
contracto 400C, / owner owner
r / owner Pentolite
HHR
Aluminum
500C
Berger Supplier to Supplier Supplier Supplier Supplier Supplier to Supplier Supplier to

Paints provide to to provide to provide to provide to provide provide
detail to provide detail to detail to provide detail to detail to detail to
contractor detail to contractor contractor detail to contractor / contractor contractor /
/ owner contract / owner / owner contracto owner / owner owner
or / r / owner
owner
 International Manufacturer:
Type & Paint Inorganic Epoxy Epoxy Acrylic Phenolic Silicone Silicone Epoxy
Supplier Zinc Zinc Mastic urethane Epoxy Acrylic Aluminum MIO
Silicate Rich
Carboline CarboZinc Carbo Carboguard Carbothane Phenoline Thermaline Thermaline Supplier

11 Zinc 859 890 134 HG 1205 4900 4700 to provide
detail to
contractor
/ owner
Akzonobel / Inter zinc Inter zinc Interseal Interthane Intertherm Intertherm Intertherm Supplier
International 22 52 670 HS 990 228; 875 50 to provide
Paint detail to
Interline contractor

850 / owner
PPG Dimetcote Amercoat Amerlock Amercoat Amercoat Amercoat Amercoat Supplier

Amercoat 9 Series 68 HS 400/2 450H 90 HS 874HS 878 to provide
Series detail to
contractor
/ owner

PLANT COLORS AND IDENTIFICATION
Painting colors on equipments & structural steel shall be as per Table 1.

Structures shall be color coded to warn personnel of potential physical hazards for safety. Safety identification
color coding shall be in accordance with the Table 2.
The identification of piping color systems (Ground color for piping, Color bands, Color codes for general service,
Color codes for industrial gases, Color codes for hydrocarbons, Labels, Labels dimensions, Lettering, Visibility
marks), except colors listed in Table 3, shall be done in accordance with IS 2379 : 1990, PIPELINES-
IDENTIFICATION COLOR CODE.
Except for safety color coding and unless otherwise stated in following tables, the finish colors shall be light ivory
for equipment, piping and structural steel.
 TABLE 1: COLORS FOR EQUIPMENTS & STRUCTURAL STEEL:
This table describes the color & color shade of the top coat of equipments and structural steel.
GENERAL
ITEM TO BE PAINTED COLOR RAL CODE / DB COLOR SHADE
Structural steel ( Open Area ) Dark Grey DB 703 / 701
Basalt Grey ( Alternative if Dark grey RAL 7012

is not available )
Squirrel Grey RAL 7000

Structural Steel ( Covered Area)
Pure White ( Alternative if Squirrel RAL 9010
grey is not available )
Columns, drums, vessels, pumps, Light Grey RAL 7035

heat exchangers T<120C
Columns, drums, vessels, pumps, Aluminum RAL 9006

heat exchangers T>120C
Steps and handrails except top and Jet Black RAL 9005
bottom (Top and bottom color as per
table 2)
Spheres and storage tanks White RAL 9010
Outdoor Machines Silver Green DB 601

Roofed Machines Blue Grey RAL 7031
Reseda Green RAL 6011
Instrument, panels consoles, panel MS Manufacturer’s standard

boards and cabinets
 TABLE 2: COLORS FOR SAFETY IDENTIFICATION:
This table describes the colors required for safety of Operators.
SAFETY IDENTIFICATION COLORS
ITEM TO BE PAINTED COLOR RAL CODE
Dangerous obstructions Black/Yellow Lines sloped RAL 9005/1021

at 45 minimum 50% of
surface yellow
Dangerous or exposed parts of Alert Orange RAL 2003

machinery
Fire-Fighting equipment Fire Red RAL 3000
First aid equipment Dark Green RAL 6028
Rigging/Lifting items: Davits, Static parts Yellow/Black Lines sloped RAL 1021/9005
Lifting beams, overhead traveling at 45 minimum 50% of surface yellow
cranes and portal cranes
Moving parts Alert Orange RAL 2003
Top & Bottom of handrails for Yellow/Black stripes RAL 1021/9005

ladders and stairways, where
indicated
Road Marking White RAL 9010
Identification for “Stop” and Red RAL 3002

“Danger”,e.g. flammable liquid
containers, emergency stop
switches, fire protection equipment
and apparatus
Identification for marking hazardous Alert Orange RAL 2003

parts of machines which may cut,

crush, or other wise injure
Identification for “Safety” and Dark Green, White lettering RAL 6028,
location of “First Aid”, and “Safety
Equipment RAL 9010
 TABLE 3: COLORS FOR PIPING:
This table describes the color & color shades of pipelines as per the type of fluid.
PIPING COLOR TABLE
ITEM TO BE PAINTED GROUND COLOR COLOR COLOR

(RAL CODE) OF FIRST BAND OF SECOND BAND
(RAL CODE) (RAL CODE)
General Services ( Water)
Boiler Feed Water Sea Green Gulf Red
Condensate Sea Green Light Brown
Drinking / Low Pressure process Sea Green French Blue Signal Red
water
Fire Water Fire Red Crimson Red
Domestic, Hot ( 40 °C to 50 °C) Sea Green Light Grey
Warm Water / Temper Water Sea Green Light Grey Canary Yellow
Cold Water down Services from

Canary Yellow
Storage Tank Sea Green French Blue
Chilled Water Sea Green Black Canary Yellow
Cooling Water Sea Green French Blue
Sea, River, Untreated (Raw)Water Sea Green White
Treated Water Sea Green Light Orange
Process Water & Low Pressure Sea Green Oxide red

Process Water

Quench Water Sea Green Dark Grey
Waste Water Sea Green Canary Yellow Signal Red
Dematerialized Water Sea Green Gulf Red
General Services ( Air & Steam)
Plant Air Sky Blue Silver Grey
Instrument Air Sky Blue French Blue
Compressed Air ( ≤ 15 kg/cm2) Sky Blue
Compressed Air ( ≥ 15 kg/cm2) Sky Blue Signal Red
Dry Vacuum White
Wet Vacuum White Dark Violet
High Pressure Steam ( 40 bar) Aluminum to IS French Blue

2339
Low Pressure Steam Aluminum to IS Canary Yellow
2339
General Services ( Oils)
High Speed Diesel Light Brown
Transformer Oil Light Brown Light Orange
Acids
Sulfuric Acid Dark Violet Brilliant Green Light Orange
Hydrochloric Acid Dark Violet Signal Red Light Orange
Phosphoric Acid Dark Violet Silver Grey
Chemicals and Allied Products
Caustic Solution / NaOH (47%) Smoke Grey Light Orange
Sodium Carbonate Solution Dark Violet Jasmine Yellow
Hydrocarbons

Methanol Dark Admiralty Grey Deep buff
Benzene Dark Admiralty Grey Canary Yellow
Ethylene Oxide Canary Yellow Dark Violet Brilliant Green
Butadiene Dark Admiralty Grey Black
Ethylene Glycol Dark Admiralty Grey Brilliant Green Gulf Red
Other Chemical Product not listed OWNER TO OWNER TO DECIDE

in IS 2379 code ( DECIDE
SLES,SLS,MDI,PMDI, (Painting Contractor
ME,CMDI, Fatty Alcohol, (Painting Contractor shall use the color as per
Hydrogen Peroxide, Ester, Citric shall use the color as Owner Suggestion.)
Acid, Methanol, Dehyton, Sodium per Owner
Methylate, LABSA, Texapon N70 suggestion.)
)
Industrial Gases
Ammonia Canary Yellow Dark Violet
Sulphur Dioxide Canary Yellow Dark Violet Golden Brown
Flare Gases/ Off Gases Canary Yellow
Chloro-fluoro derivative of Canary Yellow Light Grey Dark Violet

methane & ethane
Hydrogen Canary Yellow Signal Red French Blue
Nitrogen Canary Yellow Black
Oxygen Canary Yellow White
PNG / Fuel Gas Canary Yellow Grey Dark Violet
Sewage Black
Emergency Vent ( Mouth of pipe) Canary Yellow
NOTE1: For insulated pipeline, the color bands shall be applied on parts of the cover sheet.

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Client Name : BASF India Limited Specification G3IR-1000-55-SP-9001

Project Name : Project GIR Date 12 Apr 2012

Painting ( Protective Coating )

Document No: G3IR-1000-55-SP-9001

Document Type: Specification

Document Title: Painting ( Protective Coating )

0 12-Apr-2012 Issued for RFQ AV AA VP

Painting ( Protective Coating )

Revision Date Description

Painting ( Protective Coating )

4. GENERAL PAINTING REQUIREMENTS ...................................................................................................... 9

5. SURFACE PREPARATION ......................................................................................................................... 10

6. MATERIAL REQUIREMENTS ..................................................................................................................... 11

7. FINISH COLORS AND IDENTIFICATION ................................................................................................... 12

8. APPLICATION OF PRIMERS AND FINISHES ........................................................................................... 12

9. COATING REPAIRS .................................................................................................................................... 13

Painting ( Protective Coating )

10. QA/QC (QUALITY ASSURANCE AND QUALITY CONTROL) ................................................................. 13

11. SUPPLIERS & PRODUCTS .................................................................................................................. 16

12. ATTACHMENTS .................................................................................................................................... 16

Painting ( Protective Coating )

1.3. Abbreviation and Terminology

Note: Mist coats are the same as mist passes.

CONTRACTOR shall mean the painting contractor.

CUI is Corrosion under Insulation.

Painting ( Protective Coating )

Insulated surfaces shall mean steel surfaces which will be insulated.

Manufacturer shall mean the manufacturer of the specified paint.

Painting ( Protective Coating )

SIS is Swedish Standard Institution.

SSPC is Steel Structures Painting Council.

2.1. ASTM (American Society for Testing and Materials)

 B117 Standard Test Method of Salt Spray (Fog) Testing

2.2. SSPC (Steel Structures Painting Council)

 SSPC-SP1 Solvent Cleaning

 A13.1 Scheme for the Identification of Piping Systems

Painting ( Protective Coating )

2.4. INDIAN STANDARDS (BIS)

 IS 2379 : 1990 Pipelines-Identification-colour code

2.5. Manufacturer’s Application Data Sheets

2.6. Regulations of Governmental Agencies Related To Personnel Health and Safety as

 Repair of damaged surfaces of shop coating.

 Surface preparation and priming of bare metallic surfaces.

 Finish painting of primed surfaces.

 Repainting of custom equipment with damaged finish paint.

 Application of safety color coding and pipe identification.

Painting ( Protective Coating )

4.1. Items Which Do Not Require Painting

 Non-metallic items such as concrete, glass, plastic, wood and etc.

 Non-ferrous metals such as aluminum, copper, brass and etc.

 Galvanized surfaces except for safety color coding or coating repair.

 Uninsulated stainless steel surfaces ( For insulated surfaces refer to Attachment 1)

4.2. Items Which Require Protection from Painting

 Alloys (Monel, Incoloy, or Hastelloy)

4.3. Scheduling Of Work

Painting ( Protective Coating )

5.1. Carbon Steels (Bare Metal)

5.2. Carbon Steels (Pre-painted, Primed)

Painting ( Protective Coating )

6.1. Environmental Compliance

6.2. Compressed Air

The compressed air shall be passed through a cooler.

6.4. Cleaners and Paint Materials