Protective Coatings Technician – 1999 to today

• PETRONAS and IMM initiated the IMM Blaster & Painter Certification

& IMM Coating Inspector Certification Programs to improve the skills of

the blasters & painters

• The scheme is aimed at improving the quality of workmanship thereby

reducing overall costs.

• In the Malaysian EP industry, the total cost from rework, in service repair

and total recoating is estimated at a staggering RM45m annually.

• In the offshore, associated costs like scaffolding and work boat/barge hire

costs 3 times as much (~Rm 150 million annually) to support these

operations

• The lesson learnt by all asset operators/owners is premature failures not

matching the system’s lifespan capability are often encountered. Root

cause analysis by manufacturers and industry research attributed up to

70% of it to surface preparation and application weakness.

PETRONAS REQUESTS IMM TO REVAMP THE PROTECTIVE COATINGS TECHNICIAN

TRAINING PROGRAM

Protective Coatings Technician – 1999 to today (contd..)

• Much of the coating rework was attributed directly or indirectly to…

– Poor QA/QA practices (~30%)

– Poor workmanship (including poor surface preparation) due to inexperience, unprofessional and

uncertified applicators (~60%)

– Paint failure due to poor paint performance (~5%)

– Others (~5%)

• An in depth analysis of IMM certification revealed that the older certification had

gaps which needed to be addressed, especially in the following areas…

– Change certification duration from an indefinite period to 5 years recertification

– Update and expand teaching material to incorporate new technologies and industry best practices

– Put in additional levels of qualification to help differentiate between various levels of skills and

experience

– Add thermal spray and other specialist application to the curricula

– Bring workmanship quality up to international standards

– Added emphasis on HSE, QA/QC, and workmanship

– Added Bahasa Malaysia as a language of delivery for those weak in English

– Added checks and balance to examination & qualification process

COATINGS COMMITTEE RENEWED FOCUS ON BLASTER PAINTER TRAINING

- Emergency Committee Meeting Appointed New Chairman, Vice Chairman & Committee Members On April 10th 2015

- Blaster Painter Sub- Committee Formed July 10th

2015

- Thermal Spray Coatings (TSC) Sub-Committee Formed July 10th 2015

INTRODUCING THE REVISED

PROTECTIVE COATINGS TECHNICIAN

TRAINING PROGRAM

Proposed New Protective Coatings

Technician Program Overview

• Blaster and Painter • Replaces Blaster Level 1, Painter Level 1

• Pre-requisite 12 months relevant experience – familiarity with the equipment

• Language proficiency (written & oral) Bahasa Malaysia or English

• 4 days draining & 1 day assessment

• Blaster and Painter, Lead • Replaces Blaster Painter Supervisor

• Pre-requisite –Blaster and Painter with 5 years experience

• 2 days training & 1 day assessment

• Blaster and Painter, Supervisor• Pre-requisite – Lead Blaster Painter with minimum 10 years experience

• 1 day theory & 1 day assessment

• Thermal Spray Applicator• Blaster painter lead certification

• 2 days practical and 2 days practical training

Proposed New Coatings Inspector

Program Overview

• Level 1 – Assistant Coatings Inspector

• Level 2 – Coatings Inspector

BLASTER AND PAINTER TECHNICIAN

TRAINING COURSE

Blaster & Painter Training & Assessment Schedule

Day 1 – Theory Training (Blasting)

Day 2 – Practical Training (Blasting)

Day 3 – Theory Training (Painting)

Day 4 – Practical Training (Painting)

Day 5 – Theory & Practical Assessment

(Blasting & Painting)

Blaster and Painter Training Program

Surface Preparation1.IMM Introduction

2.The importance of Corrosion Control

3.Basic Corrosion Science Explained

4.The Standards

5.The Substrates

6.Methods of Surface Preparation

7.Dry Air Abrasive Blasting in Depth

8.Abrasives

9.Recycling of Expendable Abrasives

10.Common misconceptions and mistakes Q&A

Coating1. Paint Technology

2. Paint Application

3. Application Technique

4. Coating Breakdown

5. Quality Control

6. Safety & Health

TRANSITION PLAN

(Blaster Painter ‘Go Live’ September 2016)

• Exiting Certified Blaster Painter has to certify under new blaster painter program by 31st December 2017

• Blaster painter refresher every 5 years, recertification every 10 years

• Blaster Painter Lead, Blaster Painter Supervisor, TSA to be advised in due course