INSTALLATION and INSPECTION INSTRUCTION for POWDER COATING AIR FLUIDIZED BED SYSTEM GAS TURBINE BOLTED AIR INTAKE & EXHAUST

CHEVRON LOUVERS

Surface Preparation Method of Burn-Off & Cleanliness Level of SSPC-SP-10

1Gas Turbine Ships Bolted Chevron Louvers Installation and Inspection Instruction August 14, 2007

1. SCOPE: 1.1 Cleaning, Surface Preparation, and Powder Coating Requirements for Gas Turbine Ship Bolted Air Intake

and Exhaust Chevron Louvers 2. REFERENCES: 2.a. Systems and Specifications, Steel Structures Painting Council, Volume 2 2.b. SSPC-PA 2, Measurement of Dry Coating Thickness with Magnetic Gages 2.c. MSDS and NAVSEA approved manufacturers ASTM F 718 sheets, Shipbuilders and Marine Paints

and Coating Product / Procedure Data Sheet for QPL-24712, Type IV powder coating and paint system being applied:

1st Powder Coat: Morton Zinc Rich Epoxy---------------------------------------------------------1020 Mils DFT 2nd Powder Coat: TGIC Polyester--------------------------------------------------------------------515 Mils DFT Base Coat: Tidal Coat Patch Kit Base (AC-5000) or equivalent -----------------------------2535 Mils DFT

(Not to exceed 45 Mils DFT) Topcoat: Tidal Coat Patch Kit Top Coat (AC-5001) Color No. 26270 or equivalent-----24 Mils DFT 2.d. ASTM D 4417, Method C, Standard Test Methods for Field Measurement of Surface Profile of Blast

Cleaned Steel 2.e. NACE Standard RPO-188-90, Recommended Practice for Discontinuity (Holiday) Testing of Non-

Conductive Coatings Applied over a Conductive Substrate 2.f. ASTM-D-2794, Standard Test Method for Resistance of Organic Coatings to the Effects of Rapid

Deformation (Impact) 2.g. SSPC-VIS-1 Visual Standard for Abrasive Blast Cleaned Steel 2.h. Naval Ships Technical Manual Chapter 631, Preservation of Ships in Service 2.i. ISO 8502-3 Assessment of dust on steel surfaces prepared for painting (pressure sensitive tape method) 2.j. CSA Z245.20-02 External Fusion Bond Epoxy Coating for steel pipe Cathodic Disbondment Test 3. APPENDICES:

APPENDICES

APPENDIX TITLE (PAINTING)

1 QA INSPECTION FORM - ENVIRONMENTAL READINGS 2 QA INSPECTION FORM - SURFACE SOLUBLE SALT CONDUCTIVITY LOG 3 QA INSPECTION FORM SURFACE PROFILE LOG 4 QA INSPECTION FORM DRY FILM THICKNESS MEASUREMENTS 5 CHECKPOINTS & MILESTONES COMPLETION & SIGN OFF LOG 6 PAINT APPLICATION EQUIPMENT & PAINT CONSUMPTION LOG

7 QA INSPECTION FORM TEST FOR ASSESSMENT OF SURFACE CLEANLINESS

APPENDICES

APPENDIX TITLE (POWDER COATING)

8 APPLICATION DATA FOR POWDER COATING SYSTEM FOR CHEVRON LOUVERS

ENCLOSURES

ENCLOSURE TITLE

1 SURFACE CONDUCTIVITY TESTING PROCEDURE 2 PHOTOGRAPHS OF LOUVER FLANGE SPACER

4. REQUIREMENTS:

2Gas Turbine Ships Bolted Chevron Louvers Installation and Inspection Instruction August 14, 2007

4.1 SAFETY: Accomplish the safety precautions as specified by local instructions, Section 2 of Ref. 2.h, and the job order during the removal, preservation, and installation of gas turbine bolted air intake and exhaust chevron louvers.

4.1.1 Comply with all applicable Occupational Safety and Health Standards during the removal, preservation,

and installation of gas turbine bolted air intake and exhaust chevron louvers. 4.1.1.2 Personnel shall be adequately informed of and understand hazardous material hazards and the necessary protective measures (by way of hazard communication training), proper disposal techniques

and procedures, and access to Material Safety Data Sheets (MSDSs). 4.2 WORK NOTICE: The contractor shall post the notice at the ships quarterdeck or other designated

location for each job or separate area at least four hours, but not more than 24 hours, prior to the start of work. The notice shall contain the following information: ships name and hull number, work item number, compartment or frame number, identification of hazard, date and time of work process and identification of engineering and work practice controls. Deliver notification of work planned for a weekend or Monday following that weekend to the Commanding Officers representative not later than 0900 on the Friday immediately preceding that weekend. Deliver notification of work planned on a federal holiday and on the day following the federal holiday to the Commanding Officers representative not later than 0900 on the last working day preceding the federal holiday.

4.3 QUALITY ASSURANCE REQUIREMENTS: 4.3.1 REQUIREMENTS FOR COATED ITEMS: Surface preparation that consists of burn-off and / or abrasive

blasting shall be accomplished by certified personnel. Powder coating systems shall be applied by certified personnel. Checkpoints and final inspections shall be signed off by certified coating inspectors. Implementing contractors shall have the capabilities to complete the following tests in an in-house qualified laboratory and prequalify their process to the following:

Salt Spray Testing (ASTM B117) 5000 Hrs Cathodic Disbondment (CSA Z245.20-02) 8+ Impact (ASTM D2794) 100 in/lb Hydraulic Pull Adhesion (ASTM D4541) 3000 lbs/in Cure Test (MEK 10 Double Rubs) No softening/discoloration Cross Hatch Adhesion (ASTM 3359A) 5A Hardness (ASTM 3363) Excellent Gloss (ASTM D523) Semi Gloss (as per manf. spec) Thickness As per this procedure 4.3.2 COATING SPECIALIST TRAINING: The implementing contractor shall maintain a training program for

coating specialists working on the project. The program shall include minimum training requirements and provide for adequate records verifying the completion and currency of training for each coating specialist involved in surface preparation and application of coatings. Documentation shall be maintained verifying that only qualified personnel are used for preservation work. Training shall include all burn-off, blasting, and painting/powder coating application techniques and procedures appropriate to the surface preparation and coating materials being used.

4.3.3 COATING INSPECTOR TRAINING: Documentation shall be maintained verifying that only qualified

coating inspectors are used for inspecting preservation work. Training shall include all techniques and procedures appropriate to inspecting the surface preparation and coating application being used. These techniques and procedures include determining the acceptability of surface preparation prior to commencement of powder coating application; the degree of compliance with burn-off and blasting procedures appropriate to the surface preparation and coating materials being used; and the acceptability of finished products IAW established standardized acceptance criteria.

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4.3.4 COATING INSPECTOR RESPONSIBILITIES: Coating inspectors are responsible for providing reasonable confidence that material storage, surface preparation, powder coating/painting application, and curing are accomplished IAW the manufacturers requirements. These responsibilities require the coating inspector to: inspect material storage facilities; ensure all inspection equipment requiring calibration certification is certified under organization metrology calibration programs; perform in-process inspections of surface preparation, powder coating/painting application operations and verify successful completion of checkpoints in the application process; and inspect and accept or reject final coating systems.

Gas Turbine Ships Bolted Chevron Louvers Installation and Inspection Instruction August 14, 2007

4.3.5 DEVIATIONS: All surface preparation and coating applications shall be IAW delineated guidance herein.

Any deviation will require NAVSEA approval and Contracting Regional Maintenance Center (or representative) sign-off.

4.3.6 A TYCOM / NAVSEA authorized representative will provide QA oversight of this process. Notification of

all checkpoints prior to accomplishing the checkpoint is MANDATORY. 4.3.7 This instruction provides the requirements for using zinc rich epoxy primer followed by a TGIC

polyester topcoat (MIL-PRF-24712, Type IV). In addition to the requirements of MIL-PRF-24712, Type IV, the TGIC coating used for the topcoat shall conform to the additional performance requirements as follows:

PROPERTY TEST METHOD RESULT

Color FED-STD-595, Color No. 26270

Hardness Pencil: Eagle Turquoise ASTM D3363 Excellent

Impact ASTM D2794 100 in/lb

Humidity Resistance ASTM D2247 1000 hours Excellent

Abrasion Taber Abrasion CS-10

1000G load ASTM D4060

70 mg (max.)

Water Immersion Resistance ASTM D870 500 HOURS Excellent

Overbake Resistance 200% OVERBAKE No visible change

UV Resistance QUV 313 Lamp 800-1000 hrs Less than 1 macadam

Outdoor Resistance FLORIDA 45 SOUTH 60% gloss retention after 36 months (min.)

4.3.7.1 Coatings manufacturer will supply a Certificate of Compliance (COC), certifying each product meets the

requirements of MIL-PRF-24712, Type IV. COC shall identify product name, product number, batch number, date of manufacture, maximum shelf life, and expiration date.

4.3.8 A COC for each product shall be submitted by the Contracting Regional Maintenance Center to the

TYCOM. 4.4 RECORD KEEPING: 4.4.1 RECORD KEEPING DURING SURFACE PREPARATION / COATING APPLICATION: A permanent record of environmental conditions, surface preparation, powder coating/paint application

operations shall be maintained on applicable Appendices. 4.4.1.1 Powder Coating infor