SOHAR REFINERY IMPROVEMENT PROJECT

SRIP

Method Statement for Blasting and Painting/Coating

For Approved Third Party Outside Refinery Area
(HERTEL)
Document No: BEC-OFD0137-MS-008,REV.3

BEC Project Number : OFD0137

DPJV Contract Number :120476 / JI-02022

Package Number : 2 & 6

3 21/Feb/2015 Issued for Approval SSA SJN GVA

2 10/Feb/2015 Issued for Approval

1 1/Feb/2015 Issued for Approval

0 15/Jan/2015 Issued for Approval

Rev. Date Description Originator Checker Approver DPJV

Bahwan Engineering Co LLC, PO Box 703, PC 112, Sultanate of Oman

Tel: +968 24597510, Fax: +968 24597511 www.bahwanengineering.com
 Method statement for Blasting
Sohar Refinery Improvement Project – SRIP
and Painting/Coating
Doc Ref :BEC-OFD0137-MS-008, Rev-1 Project No: OFD0137

INDEX

1.0 Purpose

2.0 Scope

3.0 References

4.0 Abbreviations

5.0 Manpower

6.0 Equipment

7.0 Measuring Instruments

8.0 Sequence of activities

9.0 Inspection

10.0 Safety precautions

11.0 Attachment

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 Method statement for Blasting
Sohar Refinery Improvement Project – SRIP
and Painting/Coating
Doc Ref :BEC-OFD0137-MS-008, Rev-1 Project No: OFD0137

1. OBJECTIVE

The purpose of this Method Statement is to establish, monitor and control all activities involved for
Surface preparation and painting/coating for (UG/AG)piping for (package number 2 &6)in order
to meet project specification, reference codes andstandards.

2. SCOPE

This method statement covers minimum requirements for surface preparation, Coating / painting to
be done for Sohar Refinery Improvement Project (SRIP).

3. REFERENCES

 S-00013A0-102 : General Specification for External Coating of Underground Piping

 S-000-53A0-001 : Specification for surface preparation, Painting and Lettering

 SSPC SP 1 : Solvent Cleaning Method

 SSPC :Surface Preparation of Steel Structure Painting Council

 ISO 8504 :Preparation steel substrate before application of paints and related products –
Surface preparation Methods. Part 1-3

 ISO 4624 : Paint and Varnish - Pull off Test Adhesion

 ISO 2409 : Paint and Varnish – Cross cut Test

 ISO 2808 : Paint and Varnish – Determination of film thickness

 Paint Manufacturers Technical Data Sheet

 Material Approval Sheet for Paints and Abrasives

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 Method statement for Blasting
Sohar Refinery Improvement Project – SRIP
and Painting/Coating
Doc Ref :BEC-OFD0137-MS-008, Rev-1 Project No: OFD0137

4. ABBREVATIONS

HSE - Health & Safety and Environment

QA/QC- Quality assurance/Quality control
DFT - Dry Film Thickness
NDFT - Nominal Dry Film Thickness
FBE - Fusion Bond Epoxy
WFT - Wet Film Thickness
CURE - The process of hardening of applied paint.
MSDS - Material Safety Data Sheet
CQP - Contractors Quality Plan
PSI - Pounds per square inch
Kpa - Kilo Pascal
ASTM- American society for Testing and Materials
ISO - International Organization for Standards

5. MANPOWER

1. Construction Manager
2. HSE Advisor
3. QC Inspector
4. Painting Supervisor
5. Painting Foreman
6. Spool coordinator
7. Blasters
8. Painters
9. Helpers

6. EQUIPMENTS

 For Blasting - Air Compressor, Blasting Pots, Blasting Hoses with Nozzels, Blasting
Masks, Aprons and Goggles, Dead man Handle, high pressure pump & accessories, Air
Receivers & Air Filters, Etc.
 For Painting – Air Compressor, Spray Painting Machine, Spray Guns, Pressure
regulators, Hose Pipes, Pneumatic Paint Agitator, masks etc.

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 Method statement for Blasting
Sohar Refinery Improvement Project – SRIP
and Painting/Coating
Doc Ref :BEC-OFD0137-MS-008, Rev-1 Project No: OFD0137

7. MEASURING INSTRUMENTS

The measuring Instruments used for the Inspection for the surface preparation and
painting measurements shall be verified by the Coating Inspector for calibration status of
the records and due date of calibrations.

The following Instruments shall be used :

 Whirling Hygrometer
 Humidity meter / Dew Point or RH Calculator
 Magnetic Metal Temperature Gauge
 Thermometers
 Hypodermic needle Pressure gauge
 Anchor Profile Micrometer
 WFT / Comb Gauge
 Coating Thickness Gauge / DFT Gauge
 Pinhole Detector wet sponge
 Pull of Adhesion test and cross cut adhesion test
 Testexx tape

8. SEQUENCE OF ACTIVITIES

 Measurement of weather conditions and recorded during Blasting and Coating/painting

 Steel Temperature - 30 above dew point
 Relative Humidity – Below 85 %
 Cleaning, Blasting, Coating/Painting shall not be carried out in unsuitable conditions like
Air borne dust or sand, rain, fog, mist or when there is free moisture on the surface.
 Environmental conditions shall be verified and recorded prior to Blasting.
Coating/Painting
 When there is likelihood that weather conditions will change in 2 hrs, such that the above
conditions apply.
 Material Selection for Blasting and Coating/Painting and approved by DPJV
 Blasting Abrasive Grit shall be approved by DPJV
 Copper Slag for Carbons steel Pipes and fittings and Garnet for SS and Alloy Steel
Pipes and fittings shall be used
 The Abrasive material used for blasting shall be visually inspected . The material shall be
free from moisture due to condensation, rain water, oil, grease, soil and stones ingress
and salts etc.
 Physical and chemical analysis and particle size certificate shall be made available from
abrasive supplier for each batch.

Paint Coating Material:

 The type of Coating/Paint material shall be selected as per contractor requirement and
submitted for approval.

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 Method statement for Blasting
Sohar Refinery Improvement Project – SRIP
and Painting/Coating
Doc Ref :BEC-OFD0137-MS-008, Rev-1 Project No: OFD0137

 The painting materials shall be used as per the approved Material Approval Sheet.
 The Coating material shall be inspected for the type, Batch No., Mfg and Exp. Dates, and
recorded.
 All Paints and Thinners shall be stored in a closed container as per Manufacturers
recommendations specified in MSDS.
 Paint Material shall be consumed on first in first out basis,
 MSDS shall be available for all paint products.

Blasting : (Surface Preparation)

 Before blasting pipe spools including running length pipes are to be identified for heat
number, drawing number and spool numbers hard stamped on aluminium tags which are
to be securely tied to spools with wires.
 Spool Numbers taken from spool drawings and heat numbers taken from pipes, fittings
etc.
 Spools shall be checked to ensure that the surface is free of oil, grease, foreign materials
and any substrate defects.
 Contaminations like dust or dirt, moisture shall be removed with clean dry compresed
air. If the extent of dirt is more, water washing and sponge scribbling shall be carried out
to be remove it. Grease & oil contamination shall be removed with suitable solvent and
detergent wash shall be carried out to remove to contamination. And finally the substrate
shall be dried using clean water / compressed air.
 Air compressor shall deliver clean and dry air. Accumulated water droplets shall be
drained from the seperators or filters periodically. Air delivered from compressor shall
be checked for that it is free of oil and moisture by blotting paper test.
 Before blasting check surface that it should be completely dry and free from burrs, weld
spatter, flux, loose scale, dirt, oil, grease and any other foreign mater.
 Surface preparation shall be in accordance with the minimum preparation grade to ISO
8501-1. Refer to S-000-53A0-001, paragraph 3.3 for comparison of ISO grades.
 The required surface profile shall be achieved as per paint manufacturer
recommendations. The surface roughness shall be in the range 35-70 microns and shall
be measured by testex tapes and profile micrometer.
 After the specified standard has been achieved all dust, debris and abrasive residues shall
be removed from the blasted or hand and power tool cleaned surface and the surface
shall be painted with suitable primer before contamination or flash rusting starts.
 Surface preparation in the prefabrication shop or site paint shop shall be by blast
cleaning. Surface preparation at the jobsite shall be by hand or power tool cleaning only,
unless dictated otherwise by paint manufacturer. Blast cleaning at job site is only
allowed after approval by contractor.
 The abrasive blasting shall be carried out at 80 to 100 psi.
 After surface preparation and before commencing any coating work, the surface shall be
checked for the following :
 The surface profile shall be measured by using a calibrated surface profile gauge. The
surface roughness shall be in the range of 35 to 70 microns for painting and 40 to 100
microns for coating. The results shall be recorded.
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 Method statement for Blasting
Sohar Refinery Improvement Project – SRIP
and Painting/Coating
Doc Ref :BEC-OFD0137-MS-008, Rev-1 Project No: OFD0137

 Any Blasted surface that cannot be painted within the same working day or flash rusting
occurred due to delays between blasting and Painting shall be given a sweep blast before
painting.
 Areas where blast cleaning is practically not possible shall receive a power tool cleaning
to a visual standard in accordance with SSPC-SP3 (ST3)

PAINTING / COATING

 Paint system to be applied shall be as per the Respective approved Material Approval
Sheet.
 Underground piping shall be coated according to specification S-000-13A0-102
Rev.R1C2.
 Above ground piping shall be painted according to Specification S-000-53-A0-001 Rev.
4.
 All Paint and Coating material shall be stored as per manufacturers recommendations.
Shelf live and pot life shall be regularly monitored.
 The respective paint system shall be selected and applied as per specification S-000-
53A0-001 Rev. 4. Attachment 1.0
 Paints which are supplied as two components in separate containers, shall be mixed just
before use and shall be applied within the time limits (pot life) specified by the
manufacturer.

NOTE:Products from different manufacturers shall not be used in the same coating
system.

Painting / Coating Application:

 Painting / Coating activities shall be started only after the inspection of blasting has been
cleared.
 After blasting the surface shall be blown off with clean dry compressed air to remove all
dust and embedded abrasive particles.
 Site weld edge portions and adjacent width of 50 mm shall be masked with appropriate
tape after surface preparation and prior to painting.
 Strip coating shall be done on all hard to reach areas which cannot be painted effectively
by spray painting, such as corners, angles, welding joints, flanges brackets, etc. to ensure
they have the specified dft. This shall be done prior to application of each coat.
 Subsequent coats of paint shall be applied with necessary drying time and over coating
intervals as per paint manufacturer’s recommendations.

Paint application shall be executed as method as follows:

 Paint application shall be by airless spray on blast cleaned surfaces.

 Air liners and pots shall be thoroughly cleaned before and after each use.
 Parallel passes should cover the overlapping of the previous other passes.
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 Method statement for Blasting
Sohar Refinery Improvement Project – SRIP
and Painting/Coating
Doc Ref :BEC-OFD0137-MS-008, Rev-1 Project No: OFD0137

 Spray painting shall be done by competent painters.

 On complex structures, touch painting repairs and where the spray painting
methods cannot be applied shall be done by rollers or brushes.

9. INSPECTION

 The applied coating shall be of uniform color, free of any defects detrimental to its
quality, free of deleterious defects such as runs, sags wrinkles discontinuities and
contamination.
 All inspection shall be carried out in accordance with approved inspection and test plan
 The results of all measurement shall be recorded in the inspection report.
 Wet Film thickness (WFT) spot checks shall be carried out during the dourse of painting
operation to ensure that film thickness is maintained. This shall be done according to the
procedure described in ISO 2808, method No. 1A Comb Gauge
 The DFT of the applied paint shall be checked with calibrated DFT Gauge.
 The dry film thickness of the completed coating system shall be equal to or greater than
the specified Nominal Dry Film Thickness (NDFT).
 The dry film thickness of the individual coating layers shall be equal to or above 80% of
the specified nominal dry film thickness. The number of readings below NDFT shall be
less than 20% of the total number of DFT readings taken.
 If coating is performed over the existing paint layers, the DFT of the existing coating
shall be measured before application of the next layer of coating so that the thickness of
the new layer of coating can be determined.
 After full curing of the top coat, holiday testing shall be carried out using high voltage
holiday detector method in accordance with NACE SP-0274, to ensure the top coat is
free from coating breakdowns and holidays. The result of such test shall be documented.
 Coating / Painting activity including holiday / pinhole detection, Painting / Coating
Inspection Report shall be issued by the QC Inspector (Painting)
 Adhesion Test(where required)

The adhesion test shall be performed as follows:

 A lattice pattern with either six or eleven cuts in each direction (cross Cut) is made in the
applied coating to the substrate until the cuts penetrate down to the steel the cuts shall be
spaced approximately 2mm away from each other.

 A pressure sensitive tape shall be pressed on the lattice pattern.

 The pressure sensitive tape shall be firmly pulled from the lattice pattern and the lattice
pattern shall be submitted to a visual inspection for determination of the obtained rate.

 Rate 5B (the edges of the cuts are completely smooth; none of the squares of the lattice is
detached) or rate 4B (small flakes of the coating are detached at the intersections; less than
5% of the area is affected)

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 Method statement for Blasting
Sohar Refinery Improvement Project – SRIP
and Painting/Coating
Doc Ref :BEC-OFD0137-MS-008, Rev-1 Project No: OFD0137

10.0 SAFETY PRECAUTIONS

 All blasting / painting equipments are to be in good working condition.

 All blasting equipment compiles with the safety regulations. Blasting equipment are earthed
and conductive hoses used to prevent built-up of static electricity.
 Disposal of waste shall be made as per waste management system
 Fixed scaffolding or staging shall be used where required for surface preparation and
painting and shall comply with the safety regulations
 When painting is carried out in enclosed spaces, as adequate ventilation shall be provided
 All potential sources of ignitions shall be strictly controlled
 Storage of chemicals shall be as per manufacturers recommendations

11.0 ATTACHMENT

 JHA

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