- PURPOSE
- SCOPE
- REFERENCES
- RESPONSIBILITIES
- PROCEDURE
- INSPECTION AND TESTING
- SAFETY PRECAUTION
- ATTACHMENT
1.0 METHOD STATEMENT FOR TOUCH-UP / REPAIR PAINTING
This method statement outlines the general requirements for the touch-up/repair of painted surfaces of steel structures, galvanized surfaces and process piping.
2.0 SCOPE
This procedure covers the minimum requirements on the surface preparation and application for the touch-up/ repair painting of damaged external surfaces of structural steel, galvanized surfaces and process piping.
3.0 REFERENCE
• 09-SAMMS-101 Qualification Requirements for Stand Alone Self-Priming Epoxy Mastic Coatings
• SAES-H-100 Coating Materials and Application Requirements for Industrial Facilities
• SAES-H-101 Approved Protective Coating
• SAES-H-101V Approved Saudi Aramco Data Sheets – Paints and Coatings
• Manufacturer’s Recommendation
• AWS D1.1 Structural Welding Code
• ASME IX Welding and Brazing Qualification
• SSPC-SP1 Solvent Cleaning
• SSPC-SP2 Hand Tool Cleaning
• SSPC-SP3 Power Tool Cleaning
• SSPC-SP11 Power Tool Cleaning to Bare Metal
• S-000-13A0-001 Supplementary Specification for External Coating
4.0 RESPONSIBILITIES:
Site Manager:
Ensure the full implementation of this Method Statement and identifies the HSE requirements and maintained sufficient resources for the effective accomplishment of the touch-up/repair painting.
Construction Manager
Secure that the work areas are in safe working condition and monitor properly from time to time the implementation of safety procedure, requirements and assuring that all safety equipment and tools are present
at working site and shall be properly color coded.
Painting Supervisor
Ensure full compliance of all painters regarding the execution of work in accordance with Saudi Aramco Project requirements and specifications. Confirm the availability of all materials, tools, equipment, and required personnel who will carry out the work.
Quality Control Manager
Ensure the full implementation of the required minimum quality control procedures and maintain the required documentation as per applicable Saudi Aramco Inspection and Test Plan for the final acceptance and handover of the system.
Quality Control Inspector
Conducts daily surveillance and inspections as necessary in accordance with this procedure and prepares quality control records and secure final acceptance documentation which is required for final handover.
Safety Officer
Check the work areas and monitor from time to time in the implementation of safety procedure and assuring that all safety equipment are properly color coded.
5.0 PROCEDURE
5.1 General Requirements
5.1.1 All painting materials to be use shall be approved by Saudi Aramco and must be supplied by approved vendors.
5.1.2 All painting system to be use shall be as per project specifications and requirements approved by Saudi Aramco.
5.1.3 Every possible precaution shall be taken to ensure that the damaged surface(s) shall be thoroughly clean, dry, free from condensation, moisture, dust, oil, grease, rust, dirt and other contaminants before the application of the touch-up process.
5.1.4 Any paint found to be incorrectly applied shall be removed and repainted to the appropriate painting requirement.
5.1.5 Surface preparation shall be carried out by hand or power tool cleaning. This shall be followed by dry solvent cleaning prior to painting. Only qualified painters are allowed to perform painting works.
5.1.6 Where the damaged surface being repaired lies adjacent to a previously coated surface, the cleaning shall extend to the surrounding coating by a minimum of 25mm on all sides and the edges shall be “chamfered” to ensure continuity of the patch painting.
5.1.7 When using brushes or rollers, ensure that a smooth coat, as uniform in thickness as possible, is obtained with no deep or detrimental brush marks.
5.1.8 Paint shall be worked into all crevices and corners. Runs and sags shall be brushed out immediately during paint application.
5.2 Painting Materials
5.2.1 Storage, thinning, mixing and handling of paint materials shall be in accordance with the Paint Manufacturer’s recommendation.
5.2.2 All paint materials and solvents shall be supplied by Saudi Aramco approved vendors and shall be in the paint manufacturer’s original containers, durably and legibly marked with clear description of the contents. This shall include the specification number, the color reference number, the method of application for which it is intended, the batch number, date of manufacture, the shell life expiry date and the paint manufacturer’s name or recognized trademark.
5.2.3 Different brands or different make of paints shall not be inter mixed. Similarly, mixing of different brands or generic types of paint material is not permitted.
5.2.4 The manufacturer’s pot life requirements shall be strictly and diligently followed. The same shall be said for the minimum and maximum over-coating time as recommended by paint manufacturer.
5.2.5 Only thinners as specified by the paint manufacturer shall be used. Mixing and thinning directions as furnished by the paint manufacturer shall be followed. Statutory requirements for levels of volatile organic compound are to be met.
5.3 Surface Preparation
5.3.1 General
For optimum paint performance, surfaces to be painted shall be completely dry and free from burrs, weld spatter, flux, rust, loose scale, dirt, dust, grease, oil and other foreign matter deleterious and harmful to paint. After preparation of substrate surface, any generated dust or dirt shall be removed and a layer of primer applied before any corrosion or recontamination occurs, normally within four (4) hours after cleaning. Surface preparation shall be subjected to inspection before the primer coat is applied to ensure all traces of dust and foreign matter have been removed by brushing, blowing with dry clean compressed air or vacuum cleaning.
5.3.2 Pre-Cleaning of Surface and Solvent Cleaning
This cleaning process is mandatory before further cleaning or surface preparation. Prior to the actual cleaning operation, surface contaminants such as oil, grease, hydrocarbon, etc. shall be removed preferably by degreasing with approved suitable degreaser or solvent cleaning according to SSPC SP1. The degreased surface shall be further washed or rinsed down with fresh water to remove all traces of the degreaser chemicals. The surface shall be allowed to dry thoroughly before proceeding with any further painting work. This process also applies to all metal surfaces to be painted that do not require power tool cleaning.
5.3.3 Hand and Power Tool Cleaning
Manual cleaning shall be performed using hand wire brushes or mechanically operated tools in accordance with ISO 8504-3 (Hand and Power Tool Cleaning). Where welds occur within these areas or when these areas cannot accommodate power discs, power brush cleaning shall be applied. If the surface being prepared lies adjacent to a coated surface which is not to be refurbished, the power tool cleaning shall overlap the coated surface by at least 25mm. The minimum requirement for successful coating application is SSPC-PC3 at the time of coating. Care shall be taken care to ensure that the substrate surface does not become polished during power tool cleaning.
5.4 Paint Application
5.4.1 General
Before application of any further painting of material, all damages to previous paints shall be repaired. All loose paints shall be removed to a firm edge. Any surfaces to be painted shall be dry and rendered dust free prior to application of primer coat. This can be accomplished by blowing off the surface with clean dry air or using a vacuum cleaner together with a clean dry stiff brush. The prepared surfaces shall be examined for traces of smudge, oil, grease or other contamination. Surface areas with inadequate coating thickness shall be thoroughly cleaned and if necessary abraded and additional compatible coats (system wise) shall be applied.
5.4.2 Mixing and Thinning
All painting materials shall be thoroughly stirred in a pressure pot with a power mixer for a time sufficient to thoroughly remix the pigments and vehicles. Sufficient agitation to maintain good mixing shall be applied until the product is used. Paintings containing heavy or metallic pigments that have a tendency to settle shall be kept continuous suspension in the pressure pot by a mechanical agitator or stirrer if during mixing/stirring air is entrapped in the product, sufficient time should be allowed for air bubbles to escape, before application is started. This is to reduce the risk of pin-holing of the painting layer to be produced. Thinner shall not be added to primer unless necessary for proper application according to paint manufacturer’s recommendation. The type of thinner used must comply with the same. If the painting material requires the addition of catalyst, the pot life under application conditions shall be clearly stated on the label. The pot life shall not exceeded. When the painting material pot life limit is reached the same shall be discarded.
5.4.3 Other Miscellaneous Requirement
Paints shall not be applied when:
a. Incomplete surface preparation or oil, grease and dust still present on substrate to be painted.
b. The surface temperature is less than 3°C above Dew point.
c. The relative humidity of air is greater than 85%.
d. The metal substrate temperature is higher than that recommended by the paint manufacturer for application.
e. There is a likelihood of an adverse change in weather conditions within two (2) hours after application that would result in a drastic drop in air temperature below those as specified above and quality finish of the paint application.
f. There is a deposition of moisture in the form of rain, condensation, etc. upon the surface.
g. Each coat of paints is not dry.
5.5 Application Method
5.5.1 General
Paintings shall be uniformly applied without runs, sags, solvent blisters or other blemishes. All blemishes and other irregularities shall be repaired or completely removed and recoated. Special attention shall be paid to crevices, corners, edges, weld lines, bolt heads, nuts and small brackets to apply the specified minimum dry film thickness by brush or roller application to completely cover all surfaces. Edges of existing painting shall be feathered towards the substrate prior to over-coating. Primers should not be over-coated with the second coat paint until the specified minimum over-coating time is achieved. Inter-coat contamination shall be minimized by maintaining proper cleanliness and by applying the intermediate and finish coats within the over-coating time recommended by the paint manufacturer. If contaminants are present, they shall be removed before applying succeeding coats.
5.5.2 Brush Application
Paint brushes used shall be of a style and quality that will permit proper and appropriate application of paint. Good quality hog bristle is preferred and nylon or other synthetic bristle types are prohibited. Round or oval brushes are considered most suitable for rivets, bolts, irregular surfaces, etc. Wide flat brushes are suitable for large flat areas but not to exceed width of 120mm. Brushes shall be kept in good condition at all times and discarded if damaged or excessively worn. The brushing shall be done so that a smooth coat, as uniform in thickness as possible is obtained. There should be no deep or brushed out. During application of each coat, all areas such as corners, edges, welds, small brackets, bolts, nuts and interstices shall receive additional coating material to ensure that these areas have at least a minimum specified dry film thickness (OFT) and to ensure continuity of coatings.
5.5.3 Roller Application
Rollers shall only be used on relatively large surface areas provided that the first primer coat of paint is applied by brush and its use in accordance to Paint Manufacturer’s instructions. Rollers shall be manufactured from a good quality “carpet pile” or lamb’s wool.
5.6 Painting and Coating System
All painting and coating system applied shall be as per project specifications approved by Company.
6.0 INSPECTION AND TESTING
Inspections and testing shall be conducted and recorded in accordance with the Saudi Aramco Typical Inspection Plan. Reports and record shall be documented as per the applicable Saudi Aramco Inspection and Checklist/Test Report.
7.0 SAFETY PRECAUTION
7.1 Approved work permit shall be obtained prior to the start any painting works.
7.2 Work execution shall be carried out in accordance with this method of statement.
7.3 Painting crew must carry out a safety risk assessment prior to the start of any new activities.
7.4 The necessary manpower inclusive of supervisory staff, tools, equipment, materials, and other resources required must be made available and ready to use.
7.5 Workers shall be provided with and wear their PPE’s needed for work.
7.6 Manlift equipment, if required shall be tested and certified by the Saudi ARAMCO Equipment Inspection Division.
7.7 Only certified manlift operator(s) shall be allowed to operate the manlift equipment.
7.8 Sufficient lightings shall be provided if work is done at night time. Work at night shall be approved by client.
8.0 ATTACHMENT
• Job Hazard and Risk Assessment (JHRA)
• Vendor’s Painting Specification for Steel Structures
• Painting Manufacturer’s Technical Data Sheet
• Painting Manufacturer’s Safety Data Sheet
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