1. SCOPE:
This Method Statement is described to carry out abrasive blasting and coating works in shop and touch-up/repair works of weld joints in the field for Piping at Buildings, plants and refinery.
2. PURPOSE:
The purpose of this Method Statement is to ensure that the coating works for Piping are executed in accordance with Buildings, plants and refinery Coating Philosophy Summary and the recommendation of paint manufacturer.
3. REFERENCES SPECIFICATION:
3.1 Schedule “Q”: Quality Requirement.
3.2 ISO 8501-1 : Joint Surface Preparation Standard (NACE/SSPC) for Abrasive Blast Cleaning.
3.3 SSPC-PA-2 : SSPC Method of Measurement of Dry Paint.
3.4 SAES-H-001 : Coatings Selection & Application Requirements for Industrial Plants & Equipment.
3.5 SAES-H-002 : Internal and External Coatings for Steel Pipelines and Piping.
3.6 SAES-H-100 : Coating Materials & Application Requirements for Industrial Facilities.
3.7 SAES-H-101 : Approved Protective Coating System for Industrial Plants & Equipment’s.
3.8 SAES-H-101V : Approved Saudi Aramco Data Sheets- Paints & Coating.
3.9 SAES-H-102 : Safety Requirements for Coating Applications.
3.10 SAES-H-002V : Approved Saudi Aramco Data sheet for the pipeline & piping coating.
4. COATING PERSONNEL & JOB RESPONSIBILITIES:
4.1 Crew Supervisors, Blasters, Sprayers and Roller/Brush Painters shall have JCC, in the case of not having JCC of coating personnel an RFI shall be raised to seek approval and obtain JCC as per performance qualification of coating personnel.
4.2 Project Engineer is responsible to receive all documents including Drawings, Site Instructions, Change Orders, etc. From the authorized representative of client. He will communicate the same to project team. He will ensure that Operation Supervisor, QC inspector and Safety inspector are familiar with this work procedure, QA/QC Procedure and safety requirements at site. He will be overall authority at site and coordinate with authorized representative of client.
4.3 Operation Supervisor is responsible for overall operations at site including all stages of inspection that are required to be coordinated with QC Inspector. He will be aware of all sequences of abrasive blasting and coating works including the safety requirements for the respective activity. He will ensure that all the Foremen working under him are properly communicated with work instructions including the safety requirements for the respective activity.
4.4 QC Inspector is responsible for overall QA/QC activities and documentation. He will carry out all the required inspection, prepare QC reports and coordinate with client QA/QC representative for stage sign off where needed as per “Inspection and Test Plan” (ITP).
4.5 QC Manager is responsible for overall compliance with project specification/MS, ITP, coordinating client representatives.
4.6 QC Supervisor is responsible to ensure QC Inspectors are familiar with ARAMCO Standards, the applicable Quality Control Procedure including ITP (Inspection and Test Plan). He will coordinate with authorized QA/QC representative of client.
4.7 Safety Officer is responsible to enforce the project safety rules and regulations at site and coordinate with client safety representative where needed. He is assigned at site when member of operation crew exceeds 50 nos. Otherwise, operation supervisor undertakes his responsibility and does the needful.
4.8 Foremen are responsible for the activities assigned to them. They will be familiar with project specification, safety requirements and QA/QC procedure as applies to the assigned activities. They will ensure that skilled workers working under them are properly communicated with work instructions including the safety requirements for the respective activity.
4.9 Skilled workers are trained in their respective field such as abrasive blasting, spray painting, driving, etc. They will be made aware of the safety and quality requirements of work assigned to them. They will strictly abide by the work instructions given to them by Foremen.
4.10 Semi skilled workers are trained in their respective field such as brush painting, power tool cleaning, masking, etc. They will be made aware of the safety and quality requirements of work assigned to them. They will strictly abide by the work instructions given to them by Foremen.
4.11 Unskilled workers are there to assist and work with skilled and semi skilled workers. They will be made aware of the safety and quality requirements of work assigned to them. They will strictly abide by the work instructions given to them by Foremen.
5. EQUIPMENT/TOOLS:
All equipment and tool to be used shall conform to ARAMCO Safety Requirements as per SAES-H-102. All pressure gauges and relief valves shall be calibrated and Air Receiver shall be hydro tested by Approved Saudi Aramco Inspection Company. RFI shall be raised for coating equipment inspection and valid calibration certificate shall be submitted to CONTRACTOR QC. The calibration frequency will be 6 month. Extra QC instruments shall be maintained at site as spare.
The compressed air supply shall be checked and approved by performing blotter test at the start of each shift to make sure that air compressor, auxiliary receiver and hoses are free from condensed water and oil.
5.1 Air Compressor 750cfm with valid calibration certificate for relief valve.
5.2 Air Compressor 350cfm with valid calibration certificate for relief valve.
5.3 Air Receiver with ASME Stamp and valid calibration certificate for relief valve.
5.4 Conventional Blast Unit.
5.5 Spray Unit.
5.6 Forklift 5 tons with valid test certificate and also with PWAS.
5.7 Forklift 7 tons with valid test certificate and also with PWAS.
5.8 Truck with valid registration and MVPI.
5.9 Site Paint store insulated and fitted with air conditions.
6. PROCEDURE:
6.1 PAINTING YARD:
The entire abrasive blasting and coating works shall be carried out at Daewoo painting yard.
6.1.1 WORKSHOP:
This workshop is designed for all persons who play a role in developing Safe Work Method Statements (SWMS) for high risk construction work. The course will guide you through writing SWMS, in a simple and effective format and provides participants with the skills and knowledge required to completed SWMS.
BLASTING WORKSHOP:
Blasting shop will be dimension of 15 x 30 m. Bottom surface of work shop will be a concrete with smooth surface .Work shop will maintain all the safety measures like Proper ventilation, Illumination, etc. Blaster will work inside the workshop with proper PPE as per ARAMCO requirement. We will make proper housekeeping and Dust control
PAINTING WORKSHOP:
Painting shop will be dimension of 15 x 30 m. Bottom surface of work shop will be a aggregate for dust control .Work shop will maintain all the safety measures like Proper ventilation, Illumination, etc. Painter will work inside the workshop with proper PPE as per ARAMCO requirement. We will make proper housekeeping and Dust control.
6.2 HANDLING:
Pipes those are delivered to painting yard for abrasive blasting/surface preparation and coating works must be free from weld spatters, projection grinded off if any, properly marked or tagged or punched for identification.
The pipe delivered shall have caps or any other suitable end protectors at both ends.
The pipe will not be stored on ground/soil. The timbers will be used for temporary storage.
Forklift arms will be padded with carpet to minimize damage to the coated areas.
The painting stands made of Carbon steel will be used for abrasive blasting and coating works for piping.
Painted surfaces shall not be handled until the paint has dried thoroughly. An extra care will be given to avoid damages of the coated surface during transportation, loading/un-loading works.
6.3 MASKING OFF/TEMPORARY PROTECTION :
Surface not to be coated shall be protected using masking tape/duct tape during coating application works.
The tagged identification marks will be masked off with duct tape before coating application works.
An attention will be given to the tagged identification marks that those are not lost during shop activities. In case of loss SUBCONTRACTOR person in charge will immediately consult with CONTRACTOR to arrange a new tag.
6.4 SURFACE PREPARATION:
Surface preparation will be carried out as per ARAMCO standards and recommendation of coating manufacturer.
CARBON STEEL SURFACE
Garnet (#30-60 mesh) will be used for carbon steel piping/supports.
STAINLESS STEEL SURFACE
Use non chlorinated solvent in order to remove oil, grease & soil
Use non-metallic grit (Garnet 30/60 mesh) to perform sweep blasting
The surface shall not be blasted when the surface temperature is less than 30 °C above the dew point, when relative humidity is greater than 85%, or when there is possibility that the blasted surface will be subject to wetting.
Oil, Grease and other contaminants shall be removed from the steel surfaces by solvent cleaning (SSPC-SP1) prior to blasting of steel surface. Compressed dry air will only be used to blow-off or de-dust the blasted or primed or intermediate applied surfaces prior to any coating application. All cleaned surfaces shall be primed with in 4 hours to avoid contamination. If the prime coat cannot be applied with in 4 hours, the surface preparation work for the surfaces shall be repeated, before Priming.
6.5 COATING APPLICATION:
General weather conditions, relative humidity, surface temperature and dewpoint shall be checked prior to coating.
Coating shall be applied when relative humidity will be less than 85%.
Surface temperature should be less than 500 °C and minimum 30 °C higher than the dew point or as per manufacturer’s recommendation.
Care shall be used to ensure the coating application stay within the recommended parameters, particularly film thickness.
Coating shall be applied in an even, uniform film, allowing coating to wet the surface, thin and multiple passes with 50% overlapping to achieve a uniform film and ultimately the proper final thickness.
Coating shall not be applied in rain, fog, mist, past storm, strong winds or when frost or moisture has formed on the surface to be pained.
If it is raining either during or immediately after the paint application, the proper step, such as repainting, shall be taken. Spool welding joints up to Primer coat shall be applied for 2coats/3coats system.
6.6 MIXING:
All components shall be thoroughly mixed as recommended on the Manufacturer’s Date Sheet and shall be filtered by mesh filter (size as per Manufacturer Data Sheet).
Coating materials shall be mixed thoroughly. Catalysts or thinners shall be added and the materials shall be used or discarded strictly as per manufacturer’s advice.
Mechanical mixers such as stirrers, paddle mixers, can vibratos, can shakers; capable of thoroughly mixing the components together shall be used whenever required. Pressure pots shall be equipped with mechanical mixers where required as per manufacturer’s instructions. Small quantities of coating (2 gallons and less) can be mixed if needed.
Mixing and thinning shall be done in a well ventilated place where there are no open flames.
Paint Data Sheet shall be posted at mixing Area and only trained personnel shall mix the paint.
6.7 POT/SHELF LIFE:
The maximum usable pot life of mixed product and shelf life shall be complied as per manufacturer’s recommendations.
6.8 THINNER:
The addition of thinners and the right volume shall only be added only as per manufacturer’s recommendations.
Gasoline, kerosene or gas oils shall never be added into the paint.
6.9 APPLICATION METHODS:
Application equipment such as spray equipments shall be adjusted and controlled to produce a smooth, uniform without orange peel or dry overspray at all times.
The application can be made by one or a combination of the methods such as brushing and airless spraying. Written company approval should first be secured prior to usage of brush or roller if needed to be substituted for spray application.
6.10 APPLICATION TECHNIQUES:
Each coat shall be applied at the dry film thickness required range in the coating system as described in item 7 this procedure. The maximum dry film thickness shall be in accordance with the paint manufacturer’s recommendations.
Application personnel shall have sufficient working experience in coating works with valid Coating Job Clearance card (JCC).
The distance between spray gun and the surface is usually 300mm to 400mm; however the distance can be adjusted in reference to be requirement of the paint material and or manufacturer’s instructions. The trigger of the gun shall be pulled fully open during spraying and be kept on right angle.
Re-coating intervals and temperatures specified on the paint Manufacturer in the Data Sheets should be strictly followed.
Paint finishes should have no sags, runs, or defects and should have uniform appearance.
6.11 FINISH GOODS/QUALITY RELEASE:
The finish product area shall be identified and the rubber lining or suitable material shall be provided between supports and coated paipes to avoide any damages.
The finish goods will be released only after having verified that coating works have been inspected and accepted by client.
All identification marks will be inspected prior to release of finished goods. In case of faded or removed, will be reinstated as above.
6.12 PAINT SYSTEM :
The applicable APCS to be used in Saudi Jazan refinery terminal project for piping systems and equipment’s are APCS-1A, APCS-1B, APCS-1C, APCS-2A, APCS2C, APCS-11A, APCS-11C APCS-17A, and APCS-26.
APCS-1A Epoxy Coating System for Atmospheric Service (with Inorganic Zinc Primer)
APCS-1B Epoxy Coating System for Atmospheric Service (wit Epoxy Primer)
APCS-1C Epoxy Coating System for Atmospheric Service (with Zinc-Rich epoxy primer)
APCS-2A Phenolic Epoxy Coating System for General Immersion Service (Self-Priming)
APCS-2C Phenolic Epoxy Coating System for Immersion Service, at temperatures up to 120°C
APCS-11A High temperature coating system for atmospheric service between 150°c to 400°c
APCS-17A Inorganic zinc rich , Solvent based
APCS-26 Mastic epoxy coating ( Self Priming)
7. MATERIAL:
7.1 BLAST ABRASIVE:
Garnet will be used as blast abrasive.
7.2 COATING MATERIAL:
Coating Material shall be used as per company approval in engineering specification for blasting and painting. the paint shall be contained in a tightly sealed container.
All paint cans shall be clearly marked or labeled to shown their paint identification, date of manufacture & expiry, batch number, colour code/RAL No. and special instructions; all of which must be legible at the time of their use. Only approved paint materials from M/s Hempel Paints (APCS 1A,1B,1C,2A,2C,17A,11A,11B & 26 & M/s International ( APCS 11C) will be used. Company approval will be taken prior to use any coating material.
7.3 STORAGE OF PAINTS :
- Paints shall be stored in accordance with any local laws or regulations, or both. In principle, paints shall be stored in an independent warehouse/container. However, only a short period of outdoor storage may be allowed when provisions for weather protection and provisions for cover from direct sun light are made.
- Paint shall not be stored together with other dangerous and inflammable materials.
- All paints shall be stored in a tightly sealed condition, and never stored in, or exposed to the open air.
- The oldest paints shall be used first after they have been delivered from the manufacturer’s warehouse.
- Material Safety Data Sheets shall be kept in “MSDS” Box available with the paint container.
Paints and Thinners shall be stored in well ventilated building at storage temperature as recommended in manufacturer’s data sheet. - Temperature of inside the Paint container must be maintained as per MSDS.
- A paint storage container shall be with good ventilation, air conditions, temperature reading device and its log sheet/book, fire extinguisher, warning signs such as “ No Smoking”, “No Open Flames” and “Storage of Flammable Materials”, etc.
- Storage condition of paint materials should be monthly jointly inspected with client.
7.4 WASTE MATERIAL TREATMENT :
7.4.1 PAINTING AND BLASTING WASTE
A suitable number of suitable trash containers shall be provided as various locations on site and be clearly marked. All containers shall regularly remove emptied and cleared.
7.4.2 LIQUID WASTE
Sanitation at the sub-contractor office & pipe spool fabrication area shall be ensured by installation of appropriate toilet facilities and storage holding tanks. Collection and removal of waste shall be done via sewer vacuum system. Discharge of waste collected by vacuum truck shall be at approved Saudi Aramco provided on site disposal area.
8. FIELD TOUCH UP/REPAIR PROCEDURE:
8.1 Surface Preparation shall be as follows:
8.1.1 Weld Joints for above 10 dia inch pipe, non-prepared surfaces like flanges, valves and damaged area which display sign of corrosion shall be abrasive blasted as per pipe coating system. Surface profile shall be the same as specified in the coating system of weld joints pipe.
Surface profile shall be measured as per ASTM-4417, method C, ISO-8503-1.
8.1.2 Weld Joints for below 10 dia inch pipe, non-prepared surfaces like flanges, valves and damaged area which display sign of corrosion shall be cleaned using power tools. Surface Cleanliness shall be as per SSPC-SP11 (Power Tool Cleaning to Bare Metal). Profile rang shall be 20 micron to 25 micron.
8.1.3 Damaged coating and pin point rusting area shall be cleaned by hand tool (Wire brush, Sand paper). Repair area shall be roughened and feathered. The feathered edges shall be approximately 1” (2.5 cm) in width.
8.2 Coating Application shall be as follows:
8.2.1 The coating material shall be mixed and applied in accordance to the coating manufacturer’s latest published data sheet. These data sheet shall be present at the job site during blasting and coating activity.
8.2.2 Blasted weld joints and damaged area may be painted by airless spray.
Welding joint shall be given a brush applied stripe coat prior to spray. Roller application shall be carried out if the quantity of weld joints is very few.
8.2.3 Power tool cleaned weld joints and damaged area shall be painted by brush or roller. Care shall be used to achieve required and specified film thickness.
9. COLOR CODING/MARKING/STENCILING:
9.1 Color coding/marking/stenciling procedure shall be submitted separately prior to start the stenciling job at site.
10. SAFETY: JOB SAFETY ANALYSIS (JSA)
11.0 DOCUMENTATION
11.1 Document control shall include and not limited to the following:
Quality control Equipment Kit & materials Certificates and data sheet
Criteria specification and standards.
Quality control equipment Check Sheet
In-Process (Inspection Sheet)
Paints/Coatings and Equipment Log
Project documentation shall be submitted to the client for review.
12.0 WORK PROCEDURE SEQUENCE:
Blasting, Painting and Rectification Procedure | Method Statement