3814 vw sg 000001 is03 coating specifications

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GENERAL SPECIFICATION

COATING SPECIFICATION AND SYSTEMS

Document Identification Code

3814-VW-SG-000001

Sheet 2/28 Issue 03 Client: CDEEE - Corporación Dominicana de Empresas Eléctricas Estatales

Plant: 2x360 MW Coal-Fired Power Plant Location: Punta Catalina, Baní República Dominicana

This document is CDEEE’s property, and cannot be used by others for any purpose, without prior written consent

CONTENTS

1 PURPOSE .............................................................................................................................................. 4

1.1 WHERE THIS DOCUMENT IS APPLICABLE .............................................................................................. 4 1.2 EXCLUSION ....................................................................................................................................... 4 1.3 MATERIALS NOT TO BE COATED .......................................................................................................... 4

2 DEFINITIONS ........................................................................................................................................ 5

2.1 CONTRACTUAL TERMS ....................................................................................................................... 5 2.2 TECHNICAL TERMS ............................................................................................................................ 5

3 CODES, REGULATIONS AND STANDARDS ....................................................................................... 6

4 SAFETY ................................................................................................................................................. 6

5 GENERAL PRESCRIPTIONS ................................................................................................................ 7

5.1 GENERAL RULES ............................................................................................................................... 7 5.2 WARRANTY ....................................................................................................................................... 8

6 ELECTRICALS ...................................................................................................................................... 8

6.1 PROCESS CONTROL PANELS AND HARDWARE ...................................................................................... 8 6.2 OTHER ELECTRICAL ITEMS ................................................................................................................. 9

7 MACHINERY ....................................................................................................................................... 12

8 STEEL STRUCTURES, PIPING, EQUIPMENTS ................................................................................. 13

9 SURFACE PREPARATION ................................................................................................................. 13

9.1 STEEL PREPARATION ....................................................................................................................... 13 9.2 REMOVAL OF EXOGENOUS COMPOUNDS AND DEGREASING ................................................................ 13 9.3 SURFACE PREPARATION .................................................................................................................. 13 9.4 FERROUS SURFACES ....................................................................................................................... 13 9.5 GALVANIZED SURFACES .................................................................................................................. 14 9.6 ALUMINUM AND ALUMINUM-ALLOY, LEAD, COPPER, AND OTHER NONFERROUS METAL SURFACES .......... 14

10 GENERALS PRESCRIPTIONS FOR COATS AND APPLICATIONS .............................................. 14

10.1 CAN DELIVERY AND STORAGE PLACE ................................................................................................ 14 10.2 APPLICATION PROCEDURE AND PARAMETERS ................................................................................... 15 10.3 ADDITIONAL REQUIREMENTS ............................................................................................................ 17 10.4 STATUS OF DELIVERY AND PACKING ................................................................................................. 17 10.5 WORKERS QUALIFICATION ............................................................................................................... 17 10.6 PRODUCTS ..................................................................................................................................... 18

11 REPAIRING ...................................................................................................................................... 18

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12 WORKSHOP AND ON SITE INSPECTION TEST PLAN ................................................................. 19

12.1 PURPOSE ....................................................................................................................................... 19 12.2 PRE JOB MEETING .......................................................................................................................... 19 12.3 INSPECTION TESTS .......................................................................................................................... 20

13 DOCUMENTATION .......................................................................................................................... 22

13.1 BEFORE THE BEGINNING OF PAINTING ACTIVITIES: ............................................................................. 22 13.2 AT THE END OF PAINTING ACTIVITIES: ............................................................................................... 23

14 COATING SYSTEMS ....................................................................................................................... 23

15 FINAL COLOR CODE ...................................................................................................................... 27

16 PIPING IDENTIFICATION ................................................................................................................ 28

APPENDICES:

ATTACHMENTS:

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1 PURPOSE

1.1 Where this document is applicable

The purpose of this document is to define the coating requirements for exterior metal surfaces of above ground items, such as steel structures, equipments, electricals, etc. relevant to Punta Catalina Project.

This specification has been developed considering the contractual “SECTION 09 90 00 PAINT AND COATING” specification, in case of conflict, this specification prevails.

This specification is not applicable to buildings (even if made of ferrous materials), wood and plywood surfaces, concrete and cementitious surfaces, for which “SECTION 09 90 00 PAINT AND COATING” specification applies.

1.2 Exclusion

This specification does not cover the materials and requirements for:

Internal lining (of piping, pressure vessel, tanks, etc.)

Fibre reinforced plastic coating

Protection of concrete

Coating for underground piping

Fireproofing application

Contact with chemicals (acids, alkalis, organic solvents, gases, etc.)

Mechanical action (abrasion, etc.)

Micro-organisms (marine fouling, bacteria, fungi, etc.)

Coatings/painting for buildings, wood and plywood, concrete and cementitious surfaces

1.3 Materials not to be coated

Do not paint following unless indicated otherwise:

Surfaces concealed and made inaccessible by panel-boards, fixed ductwork, machinery and equipment fixed in place.

Surfaces in concealed spaces. Concealed spaces are defined as enclosed spaces above suspended ceilings, furred spaces, attic spaces, crawl spaces, elevator shafts and chases.

Steel to be embedded in concrete.

Copper, stainless steel, aluminium, brass, and lead except existing coated surfaces.

Hardware, fittings, and other factory finished items.

New zinc-coated, aluminium, and copper surfaces under insulation.

New aluminium jacket on piping.

New interior ferrous piping under insulation.

Plastic materials.

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Internal surfaces of piping and equipment, unless otherwise specified.

Wrought surfaces, identification plates, instrument panels, valve rods and threads, pump shafts and engine shafts, hot dip galvanized bolting, mechanical seals, hot dip galvanized cable trays, push buttons and concrete brickwork.

All materials and parts that obviously do not have to be coated.

2 DEFINITIONS

For terms and definitions of general use refer to the Project Coordination procedure.

Terms and definition specific of the current scope are:

2.1 Contractual terms

The COMPANY is CDEEE - Corporación Dominicana de Empresas Eléctricas Estatales

The CONTRACTOR is in charge of all or part of the following: engineering, procurement and construction

The Coating Contractor is the party carrying out the site coating

The Coat Manufacturer is the firm that produces paints/coats and relevant thinners

The VENDOR is the party manufacturing or supplying equipment, machinery, piping, fasteners, structural, miscellaneous and support steels, etc. to perform the duties specified by CONTRACTOR. The VENDOR is responsible for shop coating

PARTY is:

either VENDOR or Coating Contractor or

both VENDOR and Coating Contractor

The Party Coating Specialist is the person appointed by PARTY (internal or external consultant, appointed by PARTY at own care and cost), familiar with coating activities including the relevant international standards, who is in charge to review Project coating specifications, in order to:

Highlight any deviation from this working procedure due to not applicable requirements to the items belonging to the supply

Transfer job specification into shop/site work orders to surface preparation, coating application and coating inspection personnel.

2.2 Technical terms

The term "steel structure" includes the main steel structures (columns, beams, etc.), ladders, platforms, stairs, hand rails, floor plates, gratings, cable conduits and support for both instrumentation and electrical.

The term "equipment" includes boilers, pressure vessels, heat exchangers shell and tube type, reactors, socket filters, absorbers, etc. The equipment, in function of the dimensions, can be shop or

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field/site assembled.

The term "machinery" includes:

Rotary machines (such as pumps and compressors, turbines), packages (skid or site assembled), bridge cranes

motors, transformers, instruments valves and instruments

Plate heat exchangers

any item not included in other definitions

The term “electricals” includes process control panels and hardware and items listed in paragraph 6.

Roughness (Rz): means the surface profile of the substrate measured as "the average value of the absolute values of the heights of five highest profile peaks and the depths of five deepest profile valleys within the sampling length" (ISO 4287-1).

Operating temperature: means the maximum operating temperature made provision for the item. This temperature shall take into consideration any process condition such as steam out, reactor beds regeneration steps, etc. This temperature shall be used to select the applicable painting system.

Ethyl silicate inorganic zinc (ESI) and inorganic zinc as intended in this specification are the same primer.

Exterior refers to surfaces which are outside of the buildings, exposed to weather and environment

Interior refers to surfaces which are inside of the buildings, not exposed to weather and environment

PDS means technical product datasheet

3 CODES, REGULATIONS AND STANDARDS

Work shall be performed according to the following Codes and Standards, the coating manufacturers' recommendations and this specification. Unless specifically designated by date, the latest edition of each publication shall be used, together with any amendments/supplements/revisions:

EN ISO or ISO: 2808, 4287-1, 8502-3

SSPC: PA1, PA2, PA17, PA Guide3, PA Guide15, Paint 20, QP1, SP1, SP7, SP10, SP11, VIS1

ASTM: D3359, D4541, D4752, D6386

ASME A13.1

4 SAFETY

The basic concept of safety in surface preparation, coating application and inspection is being knowledgeable in safety procedure, proper use of safety equipment and being aware of the hazard involved. Before starting coating application, it is recommended that VENDOR read all available safety data of handled materials.

Coating Contractor must have a written Safety program. CONTRACTOR before starting any work shall approve the Safety program. Coating Contractor shall be responsible for the safety of his personnel.

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Coating Contractor must observe SSPC-PA Guide 3 "A guide to safety in paint application" and all the safety prescriptions relevant to plant area.

Environmental Protection: in addition to requirements specified elsewhere for environmental protection, provide coating materials that conform to restrictions of local Air Pollution Control District and regional jurisdiction. Notify CONTRACTOR of any paint specified herein which fails to conform.

Lead content: do not use coatings having lead content over 0.06% by weight of nonvolatile content.

Chromate content: do not use coatings containing zinc-chromate or strontium-chromate.

Asbestos content: materials shall not contain asbestos.

Mercury content: materials shall not contain mercury or mercury compounds.

Silica: abrasive blast media shall not contain free crystalline silica.

Human carcinogens: materials shall not contain ACGIH 0100 confirmed human carcinogens (A1) or suspected human carcinogens (A2).

5 GENERAL PRESCRIPTIONS

5.1 General rules

PARTY shall:

advise the CONTRACTOR every time that some prescriptions given in this specification can be improved or do not comply with experience;

provide all materials necessary for work execution;

verify that all surfaces to be coated are suitable for surface preparation and/or coating;

protect all equipment, machinery, piping, structures, miscellaneous steels and any other areas from the following type of damage: mechanical, environmental, abrasive (caused during blast cleaning), coat droppings or over-spray;

remove from the site all used tools and machinery at the end of work;

submit the technical data-sheets of all products (coats, thinners, solvents, etc.) in order to obtain approval from CONTRACTOR;

have the instrumentation and the personnel able to carry out the requested tests ;

reapply any coating that CONTRACTOR do not consider satisfactory according to this coating specification or that do not have passed the tests;

carry out any necessary coating touch-up;

keep the working area cleaned of all empty coat cans and waste materials daily.

COMPANY/CONTRACTOR reserves the right to choose up to two coatings that have been delivered to shop/site to be tested at no cost to COMPANY/CONTRACTOR.

Take samples of each chosen product as specified in the paragraph "Sampling Procedures”.

Test each chosen product as specified in paragraph "Testing Procedure".

Products which do not conform, shall be removed from job site and replaced with new products that conform

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to referenced specification.

Use Batch Quality Conformance Testing to prove conformance of manufacturer's paint to specified MPI standard. This testing is accomplished before materials are delivered to job site.

Provide testing for paint products. Test paint products as specified in paragraph "Testing Procedure".

Sampling Procedure:

Owner will select paint at random from products that have been delivered to job site for sample testing. Contractor shall provide one quart samples of selected paint materials. Samples shall be taken in presence of Owner, and labeled, identifying each sample. Provide labels in accordance with paragraph "Packaging, Labeling, and Storage" of this specification.

Testing Procedure:

Provide Batch Quality Conformance Testing for specified products, as defined by and performed by MPI. As alternative to Batch Quality Conformance Testing, Contractor may provide Qualification Testing for specified products above to appropriate MPI product specification, using third-party laboratory approved under paragraph "Qualification Testing" laboratory for coatings. Qualification testing lab report shall include backup data and summary of test results. Summary shall list all reference specification requirements and result of each test. Summary shall clearly indicate whether tested paint meets each test requirement. Qualification Testing may take 4 to 6 weeks to perform, due to extent of testing required.

5.2 Warranty

PARTY shall provide, for painting systems, a guarantee period as long as requested by contract. Once the guarantee period has expired, the deterioration degree shall comply with the acceptance criteria indicated in the contract.

6 ELECTRICALS

For electricals, instructions in paragraphs 6.1 to 6.2 are applicable and shall be followed.

Coating shall be carried out under VENDOR full responsibility and without issuing to CONTRACTOR any procedure for comments and/or approval.

6.1 Process control panels and hardware

Surfaces shall be commercial blast cleaned in accordance with SSPC SP6.

After preparation of surfaces, pits or indentations shall be filled with a 100% solid catalyzed epoxy putty compound.

After hardening of putty filler, filled areas shall be sanded smooth. Entire exterior surface shall be smooth and uniform to receive paint.

Manufacturer's standard interior and exterior paint shall be acceptable as primer coat.

Prepare interior and exterior surfaces for finish coat of paint in accordance with manufacturer's instructions.

Spray-apply paints to produce smooth, uniform coat, free of defects. SSPC PA-1 shall apply.

Each coat shall be properly cured according to manufacturer's instructions before application of succeeding

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coats.

6.2 Other electrical items

SECTION TITLES * EQUIPMENT PAINTING PROCEDURE/COATING REQUIREMENTS

Control Consoles and Furnishings

Control Consoles and Furnishings

Common Work Results for Electrical

Auxiliary Power Transformers

Sheet steel with corrosion-resistant finish

Isolated Ground (IG) Outlets

General

A. Manufacturer’s standard coating systems shall be factory-applied. Coating systems shall provide resistance to corrosion caused by weather and industrial environments. 1. Surfaces inaccessible after factory or field assembly shall be protected for life of equipment. 2. Painted surfaces shall be filled to provide smooth, uniform base for painting. 3. Surfaces requiring field welds shall not be coated within 3” (75 mm) of field weld. B. Coating material and application techniques shall conform to regulations of air quality management agency having jurisdiction. C. Exterior surfaces of control and electrical equipment, including panels, cabinets, switchgear, transformers, and motors shall be manufacturer’s standard colors unless specified otherwise. D. Apply high-temperature coating systems to uninsulated equipment operating at temperatures at or above 200°F (93°C).

Common Work Results for Electrical Package Equipment

Auxiliary Power Transformers

Sheet steel with corrosion-resistant finish

Isolated Ground (IG) Outlets

Above-Grade Race Way Pull Boxes and Junction Boxes

A. General use areas, protected or indoor: Galvanized sheet steel with a metal thickness meeting UL 50.. B. Process or wet locations, indoor or outdoor: Galvanized steel or aluminum with gasketed covers attached with stainless steel hardware using raintight hubs. C. Temperate marine environment, indoor or outdoor: Aluminum with gasketed covers attached with stainless steel hardware using raintight hubs. D. Hazardous areas: UL-approved for area classification.

Wire Way

A. Metal gage thickness shall conform to NEC. B. NEMA 1: Minimum 16-gage steel with baked enamel finish, hinged or removable covers with captive stainless steel screws. C. NEMA 3R: Minimum 16-gage galvanized steel with baked enamel finish, gasketed drip-shield cover, with stainless steel screws, weatherproof. D. NEMA 4X: Minimum 14-gage Type 304 stainless steel with neoprene gasket, hinged cover, stainless steel external screw clamps, and external mounting tabs. E. NEMA 12: Minimum 16-gage steel with baked enamel finish with gasketed, hinged cover with stainless steel screws, dust-tight.

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Cable Trays Cable Trays 1. Natural finish of aluminum material. 2. Hot-dip galvanized or zinc-coated after welding and fabrication for steel.

Hardware

A. Connecting hardware for aluminum and steel tray, fittings, and accessories shall be zinc-plated and shall maintain solid electrical connection for grounding path. B. Fiberglass tray shall use Type 316 stainless steel bolts, nuts, and washers.

Medium Voltage Varaible Frequency Drives

A. Manufacturer standard finishes for corrosion resistance. B. Provide two 1-pint spray cans of enamel for touch up.

Non Segregated Phase Bus Duct System

Non Segregated Phase Bus Duct

A. Enclosure shall be cleaned, rinsed, and phosphatized prior to painting. B. Coating process: Electrostatically applied polyester powder with final baked-on average thickness between 1.5 and 4.0 mils. C. Standard exterior finish color. D. Finish shall have minimum pencil hardness of 2H as tested in accordance with ASTM D3363. E. Finish shall pass ASTM B117 salt spray test for minimum of 1000 hours. F. Finish shall pass ASTM D2794 impact testing with minimum values of 160 in-lb for direct impact and 120 in-lb for reverse impact.

DC AND SAFE AC SYSTEMS

Surface preparation and paint shall be suitable for the installed environmental conditions.

Lighting Emergency Ligthing

Corrosion-resistant,

Substation Structures, Buses and Insulators

STEEL STRUCTURES

Steel work, including bolts, shall be hot-dip galvanized after fabrication, unless otherwise specified. Galvanizing, tests, and inspection: ASTM A123 and A385.

Insulators

Metering and Relaying Panels Metering and Relaying Panels

Metering and Relaying Panels

1. Primer coat: Rust-resisting primer. 2. Finish coat color: . ANSI Z55.1 No. 70 sky gray, weather resistant enamel. Suitable for the installed environmental conditions as outlined in Section 01 30 00. 3. Protect undersurface of metering and relaying panels and aisle from corrosion with suitable protective coating. 4. Provide 1 quart of matching touch-up paint in aerosol spray cans.

SUBSTATION EQUIPMENT

Stainless steel or galvanized. Apply to exposed parts after fabrication.

Medium Power Transformers Bushing

Tank Radiators

A. Type: Polyurethane or epoxy, durable. B. Tank paint: manufacturer’s standard ANSI gray. C. Radiators: manufacturer’s standard ANSI gray or bare galvanized steel.

Large Power Transformers Bushing

Tank Radiators

A. Type: Polyurethane or epoxy, suitable for the environmental conditions. B. Tank paint: manufacturer’s standard ANSI gray. C. Radiators: manufacturer’s standard ANSI gray or bare galvanized steel.

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POWER CIRCUIT BREAKERS 230 kV AND ABOVE

Primer coat: 1. Pigment shall include zinc-chromate with no rust exciting pigments. 2. Vehicle used shall be designed to give maximum adhesion to equipment being painted as well as to provide tight undercoat for succeeding coats. B. Intermediate and finish coats: 1. Finish: Extremely resistant to fumes, weather, temperature changes, oil and other environmental conditions to which it may be exposed. 2. Paint shall have longwearing, non-chalking, non-fading qualities and be applied to a thickness to be highly durable. C. Method of applying paint: 1. Surfaces of tanks, covers, and bases shall be grit blasted to SSPC SP10-63 near white metal before painting. 2. Surfaces shall be free from moisture, oil, dirt, rust, scale, and other foreign material prior to painting. 3. Surface and paint shall be same temperature at time of painting. 4. Primer coat shall be applied within 3 hours of grit blasting. 5. After primer coat has thoroughly air dried, 2 coats of paint shall be applied. 6. Each coat shall be allowed to thoroughly air dry before next coat is added. 7. Paint shall be applied in dust-free atmosphere. 8. Surfaces shall be sprayed, dipped, or painted by "flow method." 9. Each coat, including primer coat, shall be at least 1.5 to 2.0 mils thick. 10. Total thickness of all coats shall be minimum of 4.5 to 6.0 mils. 11. Hinges, joints, bends, crevices, and other parts exposed to external atmosphere shall be thoroughly protected with primer and paint.

GENERATOR CIRCUIT BREAKER

A. Design surfaces of circuit breaker, operating mechanism and other parts exposed to possible corrosion to prevent accumulation of moisture. B. Primer coat: 1. Pigment shall include zinc chromate with no rust exciting pigments. 2. Vehicle used shall be designed to give maximum adhesion to equipment being painted as well as to provide a tight undercoat for succeeding coats. C. Intermediate and finish coats: 1. Finish: Extremely resistant to fumes, weather, temperature changes, oil and other environmental conditions to which it may be exposed. 2. Paint shall have longwearing, non-chalking, non-fading qualities and be applied to a thickness to be highly durable.

Vibration Measurement Devices

Vibration Monitoring Panels

Process Control Panels And Hardware


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A. Surfaces shall be commercial blast cleaned in accordance with SSPC SP6. B. After preparation of surfaces, pits or indentations shall be filled with a 100% solid catalyzed epoxy putty compound. C. After hardening of putty filler, filled areas shall be sanded smooth. Entire exterior surface shall be smooth and uniform to receive paint. D. Manufacturer's standard interior and exterior paint shall be acceptable as primer coat. E. Prepare interior and exterior surfaces for finish coat of paint in accordance with manufacturer's instructions. F. Color: 1. Interior and subpanels: Slate gray. 2. Exterior: a. Outdoor panels: White. b. Indoor panels: Slate gray. G. Spray-apply paints to produce smooth, uniform coat, free of defects. SSPC PA-1 shall apply. H. Each coat shall be properly cured according to manufacturer's instructions before application of succeeding coats.

Fiber Optic Cable System Fiber Optic Patch Panel

ISOLATED-PHASE BUS DUCT SYSTEM

Prime paint exterior and provide final paint finish with manufacturer standard color.

Large Cylindrical-Rotor Synchronous Generators

Generator Control

1) Primer coat: Rust-resisting primer. 2) Finish coat: ANSI Z55.1 No. 70 sky gray, weather-resisting enamel. 3) Undersurface of switchgear and aisle shall be protected from corrosion with suitable protective coating. 4) Provide 1 quart (each color) of matching touch-up paint in aerosol spray cans

A. Manufacturer’s standard finishes shall apply. B. ANSI standard color: As listed on Data Sheets.

* from: CORPORACIÓN DOMINICANA DE EMPRESAS ELÉCTRICAS ESTATALES (CDEEE)

LICITACIÓN PÚBLICA INTERNACIONAL No. CDEEE-LPI-01-2013 PARA LA SELECCIÓN DEL CONTRATISTA QUE EJECUTARÁ LOS TRABAJOS DE INGENIERÍA, PROCURA Y CONSTRUCCIÓN (EPC) DE DOS (2) UNIDADES TERMOELÉCTRICAS EN BASE A CARBÓN MINERAL CON UNA CAPACIDAD DE 300 MW (±20%) CADA UNA

Especificaciones Técnicas (versión en inglés), 04 de julio de 2013

7 MACHINERY

Pumps, compressors, turbines, packages, motors, transformers, instruments valves and instruments, if not differently stated, shall be coated with the manufacturer standard coating system, suitable for service.

Coating shall be carried out, as minimum following, Coat Manufacturer written recommendations and as per PDS; in any case, under VENDOR full responsibility and without issuing to CONTRACTOR any procedure for comments and/or approval.

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8 STEEL STRUCTURES, PIPING, EQUIPMENTS

For steel structures, piping and equipments the instructions in the below paragraphs (from 9) are applicable and shall be followed.

9 SURFACE PREPARATION

9.1 Steel preparation

The metallic surface to be protected by paint shall comply with the following:

Free from weld spatter

Sharp edges rounding off or chamfered

Weld seams continuous with regular wave and smooth

As clarification, for structural steel no sharp edge shall be present (this requirement is applicable on any surface including but not limited to flanges, cut surfaces, drilled surfaces, punched surfaces, bolt holes etc.).

9.2 Removal of exogenous compounds and degreasing

Before starting any de-rusting operation or painting application (when the primer has been already applied), metal surface shall be free from grease, oil and salt. SSPC-SP1 is the standard for removing the exogenous compounds and the method selected shall not spoil the metal surface or remove or softening the primer already applied. It is forbidden to use chlorinated solvent on stainless steels.

The water shall be pure, free from bacteria, clean and lacking of suspended solid.

These operations shall perform manually, with the help, whenever necessary, of hard fiber brushes. It is allowed to use high-pressure water.

The original conditions of steel surfaces shall examine as per SSPC-VIS1.

9.3 Surface preparation

Surface preparation shall be carried out only when the steel temperature is at least 3 °C above the dew point temperature of the surrounding air.

Temperature and humidity shall be continuously monitored.

Surface preparation shall not be carried out under the rain or in a misty atmosphere or in presence of dew and on moist surfaces.

9.4 Ferrous surfaces

The abrasive selected shall:

obtain the required grade of SSPC standard and

produce a roughness (Rz) that guarantees a perfect primer adhesion as indicated in the PDS

Abrasives materials shall comply with SSPC-AB 1 - 4. Silica sand is not allowed.

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Abrasive material consisting only of steel shot shall not be used for surfaces to be coated with ESI; a mixture of steel shot and at least 25% (w/w) steel grit is acceptable.

Only mineral abrasive materials excluding slag shall be used for austenitic stainless steels and/or hot dip galvanized steel. Corundum and garnet are the preferred ones.

Compressed air for blast cleaning shall be dehumidified and free of oil or any similar impurities. Non-oil lubricated compressors are recommended.

Abrasive blasting outdoors is authorized only when the place is sufficiently equipped to avoid environment pollution in the surrounding area. The maximum value of breathable dust, lacking in asbestos and silica, is 10 mg/m3 TLV - TWA, unless otherwise indicated in local laws.

Surface preparation as per SSPC-SP11 has to be authorized by CONTRACTOR and it can be used only for repairing of limited areas or when abrasive blasting is not really feasible or permissible.

Surface preparation by means of blasting shall be performed when wet paint is not in progress in the surrounding area.

The primer that has been already applied on the surface shall:

be perfectly adherent and free from voids

have homogeneous thickness

Scratches and/or defects shall repair by full painting system starting from surface preparation.

9.5 Galvanized surfaces

Surface preparation shall be as per ASTM D6386.

Note: galvanized steel to be coated shall not be "passivated" or "stabilized”.

9.6 Aluminum and aluminum-alloy, lead, copper, and other nonferrous metal surfaces

Surface cleaning: solvent clean in accordance with SSPC-SP1 and wash with mild non-alkaline detergent to remove dirt and water soluble contaminants.

10 GENERALS PRESCRIPTIONS FOR COATS AND APPLICATIONS

10.1 Can delivery and storage place

All the products shall be delivered at shop or at field/site in original, unopened cans with labels intact. Minor damage to cans is acceptable provided that the cans have not been punctured or the lid seal broken.

The labels shall report, at least: name of manufacturer, type of coat and related thinner, instructions for processing, colour, batch number, analysis of contents, identification of all toxic substance, weight (gross and net), filling date and expiration date.

All cans shall remain unopened until required for use. Coatings must be used before shelf life has expired.

Storage place shall:

be ventilated to avoid solvent vapours accumulation and not exposed directly to sun light

have a temperature and relative humidity as per Coat Manufacturer instruction

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Coating products, which has deteriorated during storage, shall not be used.

10.2 Application procedure and parameters

Coatings shall be thinned and/or mixed according to Coat Manufacturer's data sheets. The mixing shall be very accurate and carried out by a mechanical mixer. Coatings shall be used only within the limits of its pot-life and shall be discharged before the pot-life time has expired. The pot-life of any coating is specified on data sheets.

Different brands or types of coatings shall not be inter-mixed unless approved by both Coat Manufacturers by written declaration on headed paper. The thinner shall be the same recommended by Coat Manufacturer.

Coating application shall be carried out only at the following conditions:

Air temperature: 5 ÷ 40 °C. Min value of 10 °C for two components catalyses coating

Air relative humidity: 85%. Min value of 50% for zinc primer application

Steel temperature: at least 3 °C above the dew point temperature of the surrounding air

Temperature and humidity shall be continuously monitored.

Coating application shall not be carried out under rain or in a misty atmosphere or in presence of dew and on moist surfaces.

The surface coated shall be protected by: rain, dust, salts and pollution during both application and curing.

The primer application shall be performed before any visible rusting occurs and within maximum 4 hours from surface preparation. Should the surface be contaminated prior to application, the surface shall be restored.

Welds shall be primed only after completion of all required pressure testing.

Coating application shall be carried out, preferably, by airless spray. CONTRACTOR shall authorize other application methods.

Stripe coating method, by brush or roller, shall be applied on all the areas difficult to reach such as: welds, bolts, nuts, corners, edges, etc. The stripe coating shall be applied before each coat layer.

Intermediate and/or finish coating application shall be performed only if the previous coat is in perfect condition. The over-coating time indicated in the data sheets shall be used to establish the time schedule. Prior to over-coating the inorganic zinc rich primer, rub test (see paragraph 12.3, MEK test) shall be carried out.

Surfaces that will be inaccessible after assembly, including the surfaces of lap joint flanges, nozzle necks, lap joint stub ends, lap rings, bolt holes and some welded joints, shall receive the complete coating system before assembling.

The application of the whole coating system shall occur without sag, runs, blistering, wrinkling and spots.

Each coat layer shall have a different colour from the previous one, to prevent uncoated areas and to facilitate inspection.

Not insulated parts belonging to insulated piping and/or equipment (e.g.: flanges, nozzles, etc.) shall be coated with the corresponding system used for not insulated surface. The coating shall be applied also to the insulated part for an extension of approximately 30 cm (see next figure), when possible.

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Not insulated parts that shall

be painted with the cycle for

not insulated surfaces Insulation material

Extension to be painted with the cycle

for not insulated surfaces

30 cm 30 cm

Intermediate coating on ESI shall be applied with the method of the "mist coat" to remove the air and the water entrapped.

Stainless steel shall never come in contact with coat containing low melting point metals and in particular zinc or zinc salts. The PARTY shall cover the stainless steel surfaces whenever application of coat containing low melting point metals is in progress near stainless steel surface.

The welded pipe support shall be painted with the same painting system of the associated piping. Surface preparation shall be in accordance with paragraph 8 of this specification. Coating system to be repaired as per Coat Manufacturer recommendations.

Coating system applied on steel structures shall not obstruct the earthing system. In principle, only a conductive primer, such as ESI or zinc rich epoxy, shall be applied on the contact surfaces fixed by fasteners. The drawing below shows the min surface to be coated only with primer. Party could propose alternative solutions if these are more practical and/or provide a better earthing system.

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10.3 Additional requirements

Thermosetting paints: topcoats over thermosetting paints (epoxies and urethanes) should be applied within overcoating window recommended by Manufacturer.

Floors: for nonslip surfacing on ramps, provide MPI 77 with non-skid additive, applied by roller in accordance with manufacturer's instructions.

Clean, pre-treat, prime, and paint new fire extinguishing sprinkler systems including valves, piping, conduit, hangers, supports, miscellaneous metalwork, and accessories. Apply coatings to clean, dry surfaces, using clean brushes. Clean surfaces to remove dust, dirt, rust, and loose mill scale. Immediately after cleaning, provide metal surfaces with one coat primer per schedules. Shield sprinkler heads with protective covering while painting is in progress. Upon completion of painting, remove protective covering from sprinkler heads. Remove sprinkler heads which have been painted and replace with new sprinkler heads. Provide primed surfaces with following:

Piping in Unfinished Areas: Provide primed surfaces with one coat of red alkyd gloss enamel applied to minimum dry film thickness of 1.0 mil in attic spaces, spaces above suspended ceilings, crawl spaces, pipe chases, mechanical equipment room, and spaces where walls or ceiling are not painted or not constructed of prefinished material. In lieu of red enamel finish coat, provide piping with 2” (50 mm) wide red enamel bands or self-adhering red plastic bands spaced at maximum of 20’ (6 m) intervals.

Piping in Finished Areas: Provide primed surfaces with two coats of paint to match adjacent surfaces, except provide valves and operating accessories with one coat of red alkyd gloss enamel applied to minimum dry film thickness of 1.0 mil. Provide piping with 2” (50 mm) wide red enamel bands or self-adhering red plastic bands spaced at maximum of 20’ (6 m) intervals throughout piping systems.

10.4 Status of delivery and Packing

Metal surface of steel structures, pressure equipment, machinery, electrical and instrumentations shall be delivered at site fully painted as per Table 2 and Table 3, unless different instructions have been given in the purchase order.

Items shall have to be packed in order to reduce as much as possible any type of damages during transportation. No handling shall be performed before the coating system is cured to an acceptable level. Packing, handling and storage facilities shall be made of non-metallic type (refer to Project dedicated documentations).

10.5 Workers qualification

PARTY that perform field surface preparation or coating application shall be certified by the Society for Protective Coatings (formerly Steel Structures Painting Council) (SSPC) to the requirements of SSPC QP 1 prior to contract award, and shall remain certified while accomplishing any surface preparation or coating application. Notify CONTRACTOR/COMPANY of any change in contractor certification status.

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10.6 Products

In principle, paint products shall be selected between those certified by Master Painters Institute (MPI); here follows some example:

MPI 1 – Aluminum Paint

MPI 101 - Epoxy Anti-Corrosive Metal Primer

MPI 107 - Rust Inhibitive Primer (Water-Based)

MPI 108 - High Build Epoxy Coating, Low Gloss

MPI 113 - Exterior Pigmented Elastomeric Coating (Water Based)

MPI 116 - Epoxy Block Filler

MPI 141 - Interior High Performance Latex MPI Gloss Level 5

MPI 145 - Institutional Low Odor / VOC Interior Latex, MPI Gloss Level 3

MPI 164 – Exterior W.B. Light Industrial Coating, Gloss, MPI Gloss Level 6

MPI 19 - Inorganic Zinc Rich Primer

MPI 2 - Aluminum Heat Resistant Enamel (up to 427 C and 800 F

MPI 21 - Heat Resistant Enamel, Gloss (up to 205 degrees C and 400 degrees F), MPI Gloss Level 6

MPI 22 - Aluminum Paint, High Heat (up to 590 degrees C and 1100 degrees F.

MPI 39 - Interior Latex-Based Wood Primer

MPI 4 - Interior/Exterior Latex Block Filler

MPI 42 - Latex Stucco and Masonry Textured Coating

MPI 45 - Interior Alkyd Primer Sealer

MPI 47 - Interior Alkyd, Semi-Gloss, MPI Gloss Level 5

MPI 48 - Interior Alkyd, Gloss, MPI Gloss Level 6

MPI 50 - Interior Latex Primer Sealer

MPI 57 - Interior Oil Modified Urethane Clear Satin

MPI 77 - Epoxy Gloss

MPI 79 - Alkyd Anti-Corrosive Metal Primer

MPI 9 - Exterior Alkyd, Gloss, MPI Gloss Level 6

MPI 90 – Interior Wood Stain, Semi-Transparent

MPI 95 - Quick Drying Primer for Aluminum

Alternative non certified products could be accepted, but they shall be approved by COMPANY.

11 REPAIRING

On principle, the repairing shall be carried out starting from surface preparation and from application requirements as indicated in this specification.

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Coat Manufacturer shall provide detail instruction for repairing on its own headed paper which shall be attached to PARTY working procedure (see paragraph 13).

Welding and flaming weaken the binder of the coat. Therefore, in addition to the visibly defected surface at least 50 mm wide area shall be removed.

In case of repairing, the affected areas shall be delimited by using adhesive tape to form squares or rectangles.

In repairing hot dip galvanized structures, damaged areas shall be treated as follows:

Surface preparation: SSPC-SP10 or SSPC-SP7 only for limited areas, Rz as per technical data sheet or Coat Manufacturer recommendation

Primer: organic zinc rich (92% min of zinc in DFT) applied at the same thickness of the original coating

In case of dissimilar joint seams between two different steels (for example carbon steel/stainless steel), also the more noble steel surfaces shall be coated by a width of 50 mm in addition to the welding seam unless otherwise specified. Coating based on zinc or zinc salts cannot be used for coating/repairing stainless steel and carbon steel joints.

12 WORKSHOP AND ON SITE INSPECTION TEST PLAN

12.1 Purpose

This procedure covers the tests to be included in the quality control plan of the VENDOR (V) for static equipment, packages, machinery and structural steel of the PAINTING CONTRACTOR (PC) for on-site erection of piping, storage tanks, final painting and touch-up. This procedure shall be applied before, during and after paint application.

Activities mentioned in paragraph 12.2 and inspection plan mentioned in paragraph 12.3 shall be applied only to orders whereas CONTRACTOR deems it necessary. The bases for defining which orders are involved are:

At least one item to be painted has a surface larger than 100 m2

Overall surface to be painted is larger than 200 m2

Machinery, special items and electrical components installed outdoor that have huge impact on plant performance

Main steel structures

12.2 Pre Job Meeting

PARTY shall notify CONTRACTOR, at least 3 months before the beginning of any painting activity, when ready for painting pre-meeting.

Painting pre-meeting (to be held at Painting Workshop) will be attended by: Party Coating Specialist, Coat Manufacturer and CONTRACTOR.

The purpose of the pre job meeting is to:

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Assure suitability of the workshop

Check instruments availability calibrated and certified

Highlight any criticality relevant to the supply

Assure readiness and skill of PARTY to perform the anti-corrosive painting according to this working procedure and mentioned standards. In particular, the following points shall be available:

Organizational chart showing all personnel involved in painting activities including surface preparation, coating application and coating inspection personnel

Written responsibility list, internal record of training, qualification, experience, (CV, resume) for all personnel involved in painting activities (surface preparation, coating application and coating inspection personnel). Personnel appointed shall have significant experience with projects in similar site conditions and with same kind of paints

Knowledge of international standards relevant to painting activities mentioned in this specification. In particular, Party Coating Specialist shall demonstrate familiarity with the international standards, capability to issue suitable working procedure in accordance with Project Requirements. Failure to meet such requirements imply that PARTY shall address at own care and cost qualified external consultant in order to supervise such activities

Suitable daily log for recording all test results

12.3 Inspection tests

The following table represents a general guideline for inspection to be considered during painting activities. This guideline is applicable also for machinery (in such case test frequency shall be based on lot of production for painting activities).

PARTY shall incorporate this guideline in the PAINTING PROCEDURE to be issued or propose an equivalent one. Only the tests technically applicable to the supply shall be mentioned.

PARTY shall inform CONTRACTOR providing technical justification if some tests of Table 1 are not applicable to own supply.

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Table 1 – Inspection Tests

Test type Method Frequency Acceptance criteria Consequence

Storage of paints

- Storage period As per Coat Manufacturer instructions

New products to be provided

Environmental conditions

Ambient (air) temperature

Three times per shift

10 ÷ 40 °C

No blasting or coating. Use of heater and/or dehumidifiers to match acceptance criteria

Steel temperature min. 3 °C above dew point

Relative humidity 50 ÷ 85 %

Additional requirements

Any more stringent requirement indicated in the PDS

Visual examination of metal surface

Visual check 100 % of all surfaces

As paragraph 9.1 Defects to be repaired

No grease, oil and contaminants shall be present

Cleaning as per SSPC-SP1

Cleanliness

Ferrous:

SSPC-SP10 100 % visual of all surfaces

as per SSPC-SP10

Re-blasting Galvanized:

ASTM D6386 as per ASTM D6386

ISO 8502-3 Spot checks Max quantity and size

rating 2

Re-cleaning and retesting until acceptable

Roughness SSPC-PA17 Each component or once per 50 m2

As per primer PDS Re-blasting

Salt test SSPC-Guide 15 Once after abrasive blasting per item.

Max conductivity corresponding to 50 mg/m2

Repeated washing with potable water and retesting until acceptable

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Test type Method Frequency Acceptance criteria Consequence

Wet film thickness check

ISO 2808 Spot checks According to PDS

Additional paint to be applied or repaired as per Coat Manufacturer instruction

MEK test

(for ESI only) ASTM D4752

Each component or once per 100 m2

Rating min 4 No overcoating. Wait until curing is completed. Retest

Visual examination of coating

Visual check 100 % of surface after each coat

No solvent retention, surface contamination, pinholes, popping, runs, sagging, etc

Removal and repairing of defects

Dry Film thickness

SSPC-PA2

Zero set on blasted reference surface

As per standard Level 4

Repair as per Coat Manufacturer instruction, additional coats or recoating as appropriate

Adhesion

ASTM D4541

One per painting system per day (or lot ) of production to be carried out, after curing, on reference panel blasted and coated at the same time and condition of the item

min 5 MPa,

unless otherwise declared by Coat Manufacturer

Coating to be rejected

ASTM D3359,

Method A

min 4A, unless otherwise declared by Coat Manufacturer

13 DOCUMENTATION

PARTY shall submit the following documentation to CONTRACTOR:

13.1 Before the beginning of painting activities:

Working procedure for approval (comments/review); it shall contain, as minimum, the following information:

1. Scope of Work, describing for each item to be coated:

Base material

Surface temperature: normal operating + upset conditions (i.e. catalyst regeneration, steam-out)

Presence of insulation/fireproofing

2. Applicable Documents:

Reference to project specifications and requested applicable standards

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3. Coating System:

Primer coat, type, DFT, product code (technical datasheet)

Intermediate coat, type, DFT, product code (technical datasheet)

Finish coat, type, DFT, product code (technical datasheet)

Total DFT of the entire coating system

4. Finish colour in accordance with project specification.

5. Application method:

Surface preparation such as steel dressing, degreasing and abrasive blasting

Surface profile (Rz)

Application method such as by stripe coat and airless

Ambient conditions, from surface preparation to final curing

6. Inspection:

Containing all applicable inspection tests required by present specification

7. Repairing Procedure:

issued by Coat Manufacturer, describing methods and suitable products

8. Technical data sheets of coating products:

Coat Manufacturer’s original technical datasheets shall be included as a part of the Working Procedure.

9. Daily log (coating inspection report) Template

suitable to contain result of inspection tests, as well as other information such as painting periods (date and start/end time for each step); products (base and hardener) lot/batch number; minimum, maximum and the average DFT for each layer, etc.

10. Any needed official declaration issued by Coat Manufacturer, on its own headed paper, relevant to fundamental information/confirmation in case that the same are not indicated on the product datasheet (e.g. confirmation of zinc content in dry film; maximum acceptable DFT for each coat etc.).

13.2 At the end of painting activities:

Daily log and Repairing list (if any) and what was done.

PARTY shall also preserve the documentation until the warranty period is expired.

14 COATING SYSTEMS

Table 2 and Table 3 show the coating systems to be applied.

All DFT (dry film thickness) are minimum values.

Coating systems/products shall be selected considering the substrate operating temperature. If maximum resistance temperature is not reported on PDS, a Coat Manufacturer declaration shall be provided.

Where DFT (for single layer and/or system) is not specified, instructions in PDS and/or Coat Manufacturer

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recommendations (to be issued to CONTRATOR for review/approval) shall be applied.

Requested gloss shall be respected.

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Table 2 - Coating chart:

EXTERIOR METAL, FERROUS AND NON-FERROUS

Substrate Coating System System

DFT System Number

Steel/Ferrous Surfaces, up to 212 °F (100 °C)

Epoxy; MPI EXT 5.1R-G6 (Gloss)

10 mils 1 primer: MPI 20 (3 mil)

intermediate: MPI 108 (5 mil)

topcoat: MPI 164 (2 mil)

Galvanized Surfaces Epoxy; MPI EXT 5.3K-G6 (Gloss)

8 mils 2 primer: MPI 20

intermediate: MPI 164

topcoat: MPI 164

Aluminium, Aluminium Alloy and Other Miscellaneous non-Ferrous Metal Items not otherwise specified except hot metal surfaces, roof surfaces, and new prefinished equipment. Match surrounding finish

Alkyd; MPI EXT 5.4F-G6 (Gloss)


intermediate: MPI 9

topcoat: MPI 9

Surfaces adjacent to painted surfaces; Mechanical, Electrical, Fire extinguishing sprinkler systems including valves, conduit, hangers, supports, exposed copper piping, and miscellaneous metal items not otherwise specified except floors, hot metal surfaces, and new prefinished equipment. Match surrounding finish

Alkyd; MPI EXT 5.1D-G6 (Gloss)


intermediate: MPI 9

topcoat: MPI 9

Hot metal surfaces including smokestacks subject to temperatures 213 ÷ 400 °F (101 ÷ 204 °C)

Heat-Resistant Enamel; MPI EXT 5.2A

5 primer: MPI 21

Surface preparation and number of coats per manufacturer's

instructions.

Ferrous metal subject to high temperature, 401 ÷ 750 °F (205 ÷ 399 °C)

Inorganic Zinc Rich Coating; MPI EXT 5.2C

6 primer: MPI 19


instructions.

Surfaces made bare cleaning to SSPC-SP10/NACE No. 2 subject to temperatures 751 ÷ 1100 °F (400 ÷ 593 °C)

Heat Resistant Coating; MPI EXT 5.2D

7 primer: MPI 22


instructions.

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Table 3 - Coating chart:

INTERIOR METAL, FERROUS AND NON-FERROUS


DFT System Number

Metal, Mechanical, Electrical, Fire extinguishing sprinkler systems including valves, conduit, hangers, supports, surfaces adjacent to painted surfaces (Match surrounding finish), exposed copper piping, and miscellaneous metal items not otherwise specified except floors, hot metal surfaces, and new refinished equipment up to 212 °F (100 °C)

Alkyd; MPI INT 5.1E-G6 (Gloss)

5.25 mils

8 primer: MPI 79


topcoat: MPI 48

Metal floors (non-shop-primed surfaces or non-slip deck surfaces) with non-skid additive (NSA), load at manufacturer's recommendations

Epoxy; MPI INT 5.1L-G6 (Gloss) 5.25 mils

9 primer:

MPI 101 intermediate:

MPI 77

topcoat: MPI 77

(plus NSA)

Metal in areas requiring a high degree of sanitation, and other high humidity areas not otherwise specified except floors, hot metal surfaces, and new prefinished equipment

Alkyd; MPI INT 5.1E-G6 (Gloss) 5.25 mils

10 primer: MPI 79


topcoat: MPI 48

Ferrous metal in concealed damp spaces or in exposed areas having unpainted adjacent surfaces

Aluminum Paint; MPI INT 5.1M 4.25 mils

11 primer: MPI 79

intermediate: MPI 1

topcoat: MPI 1

Miscellaneous nonferrous metal items not otherwise specified, except floors, hot metal surfaces, and new prefinished equipment. Match existing surrounding finish

Alkyd; MPI INT 5.4J-G6 (Gloss) 5 mils

12 primer: MPI 95


topcoat: MPI 48

Hot metal surfaces including smokestacks subject to temperatures 213 ÷ 400 °F (101 ÷ 204 °C)

Heat Resistant Enamel; MPI INT 5.2A

5 primer: MPI 21

Surface preparation and number of coats per

manufacturer's instructions.

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DFT System Number

Ferrous metal subject to high temperature, 401 ÷ 750 °F (205 ÷ 399 °C)

Inorganic Zinc Rich Coating; MPI INT 5.2C

6 primer: MPI 19



Surfaces made bare cleaning to SSPC-SP10/NACE No. 2 subject to temperatures 751 ÷ 1100 °F (400 ÷ 593 °C)

High Heat Resistant Coating; MPI INT 5.2D

7 primer: MPI 22



15 FINAL COLOR CODE

Equipment, piping, machinery, support steel, etc. shall have the final colour according to Table 4.

Table 4 – General main plant components color scheme

Item Color RAL

Equipment excluding storage tanks Light grey 7035

Storage tanks Pure white 9010

Boilers Light grey 7035

Piping (excluding firewater) and valves Light grey 7035

Steel structure, support, shelters and miscellaneous steel Medium grey 7038

Machinery

(excluding electric and instrument equipment and where it is required safety colors) Platinum grey 7036

Transformers, electrical equipment and motors Reref to dedicated specifications, datasheets and /or documents.

Electric and instrument panels

Electric cable conduits (when painted)

Control desks and panels (control rooms)

Instruments Manufacturer standard

Fire-fighting equipment, accessories and piping Red 3000

Handling equipment (e.g. bridge cranes and hoist) Yellow 1021

Handrails, ladder, cages Yellow 1021

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16 PIPING IDENTIFICATION

Piping identification, including surfaces in concealed spaces: Provide in accordance with ASME A13.1. Place stenciling in clearly visible locations.

On piping not covered by ASME A13.1, stencil approved names or code letters, in letters a minimum of 1/2” (13 mm) high for piping and a minimum of 2” (50 mm) high elsewhere.

Stencil arrow-shaped markings on piping to indicate direction of flow.

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