x st 2002vessel iternalcoating

8/9/2019 X ST 2002Vessel IternalCoating

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INTERNAL COATINGS FOR VESSELS IN WET H2S SERVICE

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Doc X-ST-2002

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THIS IS A CONTROLLED DOCUMENTNO UN-AUTHORISED MODIFICATIONS.

INTERNAL COATINGS FOR PRESSUREVESSELS IN H2S SERVICE

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This document is dual language. Ensureboth versions are modified.

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0 10-05-09 62 KR VK DLK

REV DATE PAGES BY CHK MGR CONST REL MAINT OPS

REVISIONS PRELIM APPROVALS FINAL APPROVALS


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REVISION DESCRIPTION SHEET

REV. PARA. REVISION DESCRIPTION

0 ALL/

ADOPTED CHEVRON SPECIFICATION COM-SU-5014-D DATED

SEPTEMBER 2008 PER REQUEST FROM TCO RELIABILITYMECHANICAL INTEGRITY CONSULTANT"

COM-SU-5014-D 2008 .


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TABLE OF CONTENTS

1. SCOPE 4

2. REFERENCES 5

3. ACCEPTABLE COATING SYSTEMS AND BRANDS 7

4. GENERAL 8

5. SAFETY PRECAUTIONS 10

6. AREAS TO BE COATED 11

7. SURFACE PREPARATION 12

8. ORGANIC COATING APPLICATION AND CURING 17

9. THERMAL SPRAY COATING APPLICATION 22

10. INSPECTION 24


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1. SCOPE

1.1. This specification covers surface preparation, application, and inspection of thin

film organic, thick film, specialty (e.g. Belzona), and thermal spray coatingsintended for protection of new and existing vessels against wet H2S cracking.

1.2. The Company shall specify the specific coating systems to be used and thespecific areas to be coated.


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2. REFERENCES

1) Protective coatings shall comply with all applicable RoK codes and regulationson surface preparation, coating application, storage, handling, safety, andenvironmental requirements, including the recommendations of SSPC-PA Guide3.

2) The following documents are referenced herein and are considered part of thisspecification.

3) Use the edition of each referenced document in effect on the date of thepublication of this specification.

4) Any discrepancies or conflicts among the documents above and with TechnicalRequirements shall be called to the attention of the Company for resolution.

2.1. Company Documents

COM-EF-844 TCO Coating Inspection Report Form

2.2. Industry Codes and Standards

American Society for Testing and Materials (ASTM)

E337 Standard Test Method for Measuring Humidity with a Psychrometer(the Measurement of Wet- and Dry-Bulb Temperatures)

D4285 Standard Test Method for Indicating Oil or Water in Compressed Air

D4417 Standard Test Methods for Field Measurement of Surface Profile ofBlast Cleaned Steel

D4541 Standard Test Method for Pull-Off Strength of Coatings Using PortableAdhesion Testers

Society for Protective Coatings (SSPC)

PA 1 Shop, Field, and Maintenance Painting of Steel

PA 2 Measurement of Dry Coating Thickness with Magnetic Gages

PA Guide 3 A Guide to Safety In Paint Application

SP 1 Solvent CleaningSP 5 (NACE No 1) White Metal Blast Cleaning

SP COM Surface Preparation Commentary for Steel and Concrete

Substrates

VIS 1 Guide and Reference Photographs for Steel SurfacesPrepared by Dry Abrasive Blast Cleaning


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QP 1 Standard Procedure for Evaluating Painting Contractors (FieldApplication to Complex Industrial Structures)

National Association of Corrosion Engineers (NACE)

SP0178 Design, Fabrication, and Surface Finish Practices for Tanks andVessels to Be Lined for Immersion Services

SP0188 Discontinuity (Holiday) Testing of New Protective Coatings onConductive Substrates.


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3. ACCEPTABLE COATING SYSTEMS AND BRANDS

3.1. Requirements

3.1.1. Only the specified coating systems and accepted brands shown inTable 1shall be used. Alternatives shall be reviewed by the Companyand accepted in writing.

3.1.2. On the bid, the Contractor shall clearly indicate the material (bothmanufacturer and product name) to be used.

3.1.3. All coatings shall be provided to the jobsite in the original manufacturercontainers.

3.1.4. The Contractor shall only use coatings which complying with RoK airpollution regulations.

3.2. Thermal Spray Powder/Wire Certification

3.2.1. For thermal spray coatings, the coating applicator shall providecertified analysis of the powder or wire material to be applied.

3.2.2. The certification shall include the nominal alloy type, a detailedanalysis of the actual chemistry (along with the required limits for eachelement), and the particle size distribution.

3.2.3. Powder/wire samples shall be obtained at random by a Companyrepresentative any time during the job and may be subjected topositive materials identification (PMI) testing.

3.2.4. Contractor shall be required to qualify their procedure.

a) Qualification testing shall be performed prior to contractsettlement.b) Procedure will need to be re-qualified if the operator, sprayprocess, or spray materials is changed.


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4. GENERAL

4.1. All contractors and sub-contractors that perform surface preparation orcoating application shall be certified by the Society for Protective Coatings(SSPC) to the requirements of SSPC QP 1 prior to contract award, and shallremain certified while accomplishing any surface preparation or coatingapplication.

4.2. The Contractor shall follow all directions on the coating manufacturer's datasheets and shall have the current version of these data sheets available at thejob site.

4.3. If there is a conflict between the requirements of this specification and thedata sheets it shall be brought to the attention of the Company coating

representative/inspector and resolved to his/her satisfaction.

4.4. The Contractor shall furnish all materials, labor, equipment, and incidentalsrequired to meet this specification.

4.5. Sufficient floodlight or spotlights shall used to provide good visibility duringabrasive blasting, coating application, and inspection.

4.6. The Company may, at its option, require the Contractor to have a technicalrepresentative from the coatings manufacturer present to assist and witnessthe initial application of each coating system. The Contractor shall obtainfurther technical assistance from the coatings manufacturer when problems

arise or when the Company requests such assistance.

4.7. The Contractor and the Company representatives shall hold a pre-jobconference to discuss all aspects of the specification.

a) Particular emphasis shall be placed on job safety, environmentalregulations, plant rules, surface preparation, coating application, andinspection.

b) Company representatives shall include TCO Coatings Inspector andReliability Engineering representative.

4.8. There must be a NACE certified coating inspector present during the entire jobprocess who will:

a) Ensure that proper procedures are followed.

b) Will document all aspects of the job including, but not limited to thefollowing:

1. Temperature

2. Humidity

3. Surface preparation

4. Condition of coating, dehumidifying, and curing equipment

5. Cure time6. Film thickness


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4.9. Inform Company plant support and inspection personnel of any performanceissues that affect coating quality.


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5. SAFETY PRECAUTIONS

5.1. Contractor shall comply with all RoK safety regulations.

5.2. Contractor shall comply with all TCO safety procedures and instructions.

5.3. Contractor shall review the information on hazards and safety procedures inSSPC-PA Guide 3 prior to beginning work.

5.4. Deleted.

5.5. The coatings used shall be within the local maximum limit for volatile organiccompounds (VOC).

5.6. The coating manufacturer's recommended precautions regarding toxicity andsafe handling of all coating materials shall be followed.

5.7. Adequate ventilation shall be provided during all work and for at least fourhours after coating application, to keep solvent concentrations within safe,non-explosive limits. Vapors shall be removed by use of an air eductor, ratherthan by air blown into the tank.

5.8. All blast pots must be equipped with properly installed pressure relief devices.Both the blast pot and the pressure relief device must have proof of inspectionand certification.


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6. AREAS TO BE COATED

6.1. The Company shall specify the areas to be coated and the coating systems to beused for each area.

6.2. The temperature and other limitations of the Company-acceptable coatings areprovided inAppendix A.

6.3. For new vessels, all nozzle and seam welds shall be coated at minimum.

6.4. For existing vessels, as many of the following areas as possible shall be coatedwithin the allowed time frame for the shutdown (in descending priority):

a) Weld repaired areas, regardless of location

b) Nozzle welds

c) Seam welds

d) Visibly blistered base plate (blisters shall first be assessed by a CompanyReliability Engineer)

e) Any areas not listed above that were grit blasted for whatever reason

6.5. Coating shall take place only after all required repairs, welding, heat treatmentsand inspections have been completed.

6.6. In no case shall visible cracking or blisters be coated without the written reviewand acceptance of a Company Reliability Engineer.

6.7. Extent of coating coverage for nozzle and seam welds shall be:

a) For vessels up to 1" thick: Stripe coat the welds so that the coatingextends at least 3" either side of the weld centerline.

b) For vessels greater than 1" thick: Stripe coat the welds so that thecoating extends at least three times the vessel thickness, either side ofthe weld centerline. Example: if a vessel is 1.5" thick, the coating shallextend 4.5" either side of the weld centerline.

c) For the ID nozzles and seamless piping: Coat up to 1" or whatever ispractical.

d) For all cases: The coating does not need to more than 6" either side ofthe weld centerline. Example: for a three inch vessel, the 3X rule wouldsay that we need to extend the coating 9" either side of the centerline, butthe overriding rules says we need to coat this vessel only 6" either side ofthe weld centerline.


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7. SURFACE PREPARATION

7.1. Responsibility

7.1.1. The Coating Applicator is responsible for assuring that the surface is inthe proper condition for coating.

7.1.2. This includes light grinding, abrasive blasting, and other mechanicalmeans.

a) Feather grinding to remove weld splatter and burrs, and to roundoff sharp edges may be required to ensure proper coatingthickness.

b) The coating contractor shall employ persons who are skilled ingrinding.

c) Any grinding on a coded vessel shall be performed by a contractorwho is certified to build/repair coded vessels. All grinding atpressure boundaries shall be inspected by an API 653 or 510inspector.

7.1.3. At no time may the Coating Applicator perform arc gouging or otherforms of hot cutting on the vessel.

7.1.4. Surface preparation performed by the Coating Applicator shall notincrease the depth of gouges, grooves, pits, or other local thin areas.

7.2. Preparation for Abrasive Blasting

7.2.1. Sharp edges, such as those occurring in rolled structural membersSharp edges, such as those occurring in rolled structural members aswell as those resulting from flame cutting, welding, etc., shall beremoved by any suitable method such as a soft grinding wheel beforeabrasive blasting and application of any coat of paint (refer to SSPC-SP COM or NACE SP0178).

7.2.2. Neither welding, nor grinding, including cosmetic grinding, is permittedon the pressure resisting components and welds of pressure vessels

and piping after hydrostatic testing, unless reviewed and accepted inwriting by the Company.

7.2.3. All surfaces to be coated shall be clean of all contaminants that wouldaffect the integrity of the coating system.

a) Prior to surface preparation, the surfaces shall be cleaned, asnecessary, to remove all oil, grease, dirt, salts or other foreignmaterial.

b) This cleaning shall be by appropriate detergent and/or solventcleaning.

c) Detergent or solvent cleaning shall be performed as outlined in

SSPC-SP 1.d) Solvents used to clean stainless steel shall be free of substances

such as chlorides, sulfur, halogens, or metallic pigments.


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7.2.4. The presence of oil shall be checked by shining a black light on thesteel surface.

7.2.5. Test surfaces to be coated prior to abrasive blasting or surfacepreparation for chloride, sulfate, and nitrate salt contamination usingthe CHLOR*TEST test kit or equivalent.

a) Test sites shall be selected to be representative of the surface asa whole.

b) Test at the rate of three tests for the first 90 m2 or part thereof,and one test for each additional 280 m2 or part thereof.

(1) For immersion service, the following are the maximum acceptablelevels:

a. Chloride - 3 g/cm2

b. Nitrate - 5 g/cm2

c. Sulfate - 10 g/cm2

(2) For non-immersion service, the following are the maximumacceptable levels:

a. Chloride - 5 g/cm2

b. Nitrate - 10 g/cm2

c. Sulfate - 15 g/cm2

d. Salt contaminated surfaces will require high-pressure water

washing (minimum 21 MPa) using a solution of water andCHLOR*RID soluble salt remover or Company approvedequivalent.

e. Test and treat surface as required until test results are lessthan or equal to the limits listed in Section 7.2item 5b.

7.3. Abrasive Blasting

7.3.1. To the best extent possible, blasting shall be confined to only thosezones specifically requiring wet fluorescent magnetic particle (WFMT)inspection and subsequent coating application.

7.3.2. All abrasive blasted surfaces shall be blasted in accordance with theSSPC or NACE blast specified on the manufacturer's data sheet.

7.3.3. The anchor pattern shall be as specified on the manufacturer's datasheet.

7.3.4. Abrasive blast cleaning shall be performed with a clean, sharp gradeof abrasive.

a) Only dry, grit-type abrasives shall be used.

b) Grain size shall be suitable for producing the specified anchorprofile.

c) All abrasives shall be free of dust, dirt, and other foreign matterand shall be kept dry at all times.


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7.3.5. Silica or other abrasive substancesontaining more than 1% crystallinesilica shall not be used as an abrasive blasting material.

7.3.6. If automatic blasting equipment is used, the abrasive mix of 75% gritand 25% shot shall be maintained so that a consistently sharp profileis produced.

7.3.7. The compressed air used in any cleaning method shall be free ofwater and oil.

a) Adequate separators or traps and dryers shall be provided andproperly maintained and shall be emptied regularly of water andoil.

b) The air supply shall be tested daily for cleanliness using ASTM

D4285.

c) Prior to the start of blasting, the Contractor shall select anappropriate blast air pressure with abrasive and mesh size toattain the specified anchor pattern.

d) The Contractor shall demonstrate to the Company that theselected nozzle pressures and abrasive shall provide the specifiedanchor pattern by blasting a representative piece of steel andmeasuring the anchor pattern using Press-O-Film tape orCompany-reviewed and accepted equal as described in ASTM D-4417 Method C.

e) Any change in nozzle pressure, abrasive or mesh size shall bequalified in the same way prior to the change.

f) Blast air pressure shall be a minimum of 95 psig unless thedemonstration test proves acceptable otherwise.

7.3.8. Weld areas shall be feather ground, chipped or wire brushed asnecessary prior to blasting to remove rust, residual flux and weldspatter.

a) Feather grinding at weld toes may be required to avoid excessivecoating build-up.

b) The coating contractor shall employ persons who are skilled insurface preparation.

c) Any grinding on a coded vessel shall be performed by a contractorwho is certified to build/repair coded vessels. All grinding atpressure boundaries shall be inspected by an API 653 or 510inspector.

7.3.9. Steel surface slivers, laminations, laps, scabs or seams exposed byblasting shall be reported to the Company, investigated, and repairedon any portion of the steel to be painted by the Contractor using rulesfrom the applicable code for repairs prior to coating. All such areasshall be re-blasted prior to coating.

7.3.10. Blasting shall be performed in dry weather. Dry blast cleaningoperations shall not be conducted on surfaces exposed to rain, waterspray, or any other moisture.


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7.3.11. Abrasive blast cleaning shall not be performed when the ambient orsubstrate temperature is less than 5F (3C) above the dew pointtemperature.

a) Dew point temperature shall be determined by sling psychrometerin accordance with ASTM E337 or equivalent electronic device, atthe location where the work is being performed.

b) Substrate temperature shall be determined with a surfacethermometer.

7.3.12. Blast cleaned surfaces that show evidence of rust bloom or that havebeen left uncoated overnight shall be re-cleaned to the specifieddegree of cleanliness prior to coating.

7.3.13. After blasting and immediately before spraying, dust, and looseresidues shall be removed by brushing, blowing off with clean dry air,or vacuum cleaning.

7.3.14. Blasting shall be accomplished so that previously painted surfaces arenot contaminated by abrasive or blast wastes.

7.3.15. No inhibitive washes intended to prevent rusting shall be used afterblasting.

7.3.16. A minimum of four inches around the edge of blasted areas shall beleft unprimed unless adjoining a coated surface.

a) Subsequent blasting shall continue a minimum of one inch into theprimed surfaces.

b) These requirements are to ensure that no coating is applied overunblasted steel.

c) All loose, cracked, or damaged coating shall be removed and theadjacent sound coating feathered back approximately 2 inches(50 mm) to form a uniform and smooth surface.

d) Feathering shall be done by hand or power sanding with a gritwheel or sandpaper.

7.3.17. When the coating is damaged down to the steel, spot cleaning isnecessary.

a) These damaged areas shall be cleaned by abrasive blasting.b) After the metal surface has been cleaned, the edge of the

surrounding coating shall be feather-edged to remove all cracked,loose or damaged coating.

c) Feather-edging shall be accomplished by power or hand sandingwith a grit wheel or sandpaper.

d) The prepared surface shall be free of loose, burnt, or blisteredcoating.

e) Repaired areas require re-profiling of the steel.

7.3.18. Welding undercut and porosity shall be repaired prior to application ofintermediate coat.


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7.3.19. All blast cleaned surfaces shall be inspected for proper cleaning priorto painting. SSPC-VIS 1 shall be used as a visual standard forconfirming the degree of surface cleanliness.

7.3.20. The anchor profile shall be verified in accordance with ASTM D4417Method C using either course or extra-course replica tape and aspring loaded micrometer.


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8. ORGANIC COATING APPLICATION AND CURING

8.1.1. Abrasive Blasting

8.1.2. Application shall be in accordance with SSPC-PA 1, the coatingmanufacturer's published application instructions, MSDS's, and therequirements specified herein.

8.1.3. All application equipment shall be as recommended by the coatingmanufacturer, shall be clean and in good condition, and shall besuitable for applying the coating as specified.

8.1.4. The number of coats to be applied shall never be fewer than thenumber of coats required by this specification and the technicalrequirements and shall have individual coat dry film thicknesses notless than the minimum thickness specified.

a) Wet film thicknesses are to be verified at the start of work (until thepainter is familiar with the paint and work) with a wet film thicknessgauge.

b) Thickness requirements shall be met with each coat and totalthickness shall not be "madeup" in any one coat.

8.1.5. Coatings shall be applied within the environmental conditions shown inthe coating manufacturer's data sheets.

8.1.6. No coating shall be applied when any of the following conditions arepresent:

a) When the ambient or surface temperatures are above or belowthe manufacturer's recommended temperature limits.

b) If the ambient or substrate temperature is less than 5F (3C)above the dew point temperature.

1) Dew point temperature shall be determined by sling psychrometerin accordance with ASTM E337 or equivalent electronic device, at

the location where the work is being performed.

2) Substrate temperature shall be determined with a surfacethermometer.

8.2. Materials

8.2.1. Coating materials shall be furnished in the manufacturer's unopenedcontainers, clearly identifiable, and shall be kept covered, clean andprotected.

8.2.2. Materials older than manufacturer's recommended shelf life shall not

be used.

8.2.3. All solvents used for thinning shall be as recommended by the coatingmanufacturer.


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8.2.4. All materials shall be handled and stored in accordance with themanufacturer's latest published instructions and SSPC- PA 1 Article5.1.

8.3. Mixing and Thinning

8.3.1. All components shall be thoroughly mixed as per recommendationsnoted in the manufacturer's data sheets.

a) All mixing shall be done in clean containers, free from traces ofgrease, other paints or contaminants.

b) Containers shall be kept covered to prevent contamination by dust,dirt or stain.

c) Paint shall be mechanically mixed in full batches.

8.3.2. Multi-component coatings, shall have the components accuratelymeasured according to the manufacturer's directions.

8.3.3. Mixing of partial kits is not acceptable.

8.3.4. Thinning shall not exceed the allowable volatile organic compound(VOC) level for the coating used.

8.4. Shelf and Pot Life

8.4.1. Materials that have exceeded the coating manufacturer'srecommended shelf life shall not be used.

8.4.2. The coating manufacturer's recommended pot life shall not beexceeded. When this limit is reached, the spray pot shall be emptied,cleaned, and new material mixed.

8.5. Spray Application

8.5.1. Contractors applicators shall be skilled in the proper applicationtechnique for each coating.

a) Proper equipment, per the coating manufacturer's data sheets,shall be used.

b) Applicators or equipment failing to meet this requirement, to theCompanys or the coating manufacturer's satisfaction, shall beremoved from coating application.

8.5.2. Contractors Spray guns, lines, and pressure pots shall be cleanedprior to adding new material.

8.5.3. The air caps, nozzles and needles shall be those recommended bythe coating manufacturer for the material being sprayed.

8.5.4. Moisture traps or separators shall be installed between the air supplyand the pressure pot.


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8.5.5. The drain valve shall be kept open slightly to permit continuousdraining of any condensate during operations.

8.5.6. Operating pressures shall comply with the recommendation of thecoating manufacturer.

8.5.7. All pressure pots shall be equipped with pressure regulators andgauges.

8.5.8. Paint shall be applied in a uniform layer, with 50% overlapping of theprevious pass.

8.5.9. During application, the spray gun shall be held perpendicular to thesurface being painted.

8.6. First Coat Application

8.6.1. The specified coating system shall be applied within 4 hours from thetime that surfaces are cleaned and before rusting, discoloration, orsurface contamination occurs.

8.6.2. All coatings shall be applied 6 hours prior to the vessel reaching dewpoint.

8.6.3. Surfaces to be coated shall be clean, dust-free, and dry beforeapplication of any coating and shall meet applicable hand, power toolor abrasive blasting surface preparation requirements before

application.

8.6.4. Care shall be exercised to prevent overspray, spillage or application ofcoatings to surfaces for which they are not intended.

8.6.5. Skips, sags, and drips are to be repaired.

8.7. Top-Coating

8.7.1. Each coat of paint shall be of contrasting color to indicate extent ofcoverage.

8.7.2. All coatings shall be allowed to dry for at least the minimum timerecommended by the paint manufacturer, considering temperatureand humidity, before applying succeeding coats.

8.7.3. Maximum overcoat time shall be limited to the manufacturer'srecommendation.

a) When the maximum overcoat time has been exceeded, Contractorshall perform additional surface preparation as agreed to byCompanys representative.

b) Additional surface preparation shall include, but not limited to,hand sanding, pressure washing, mist coat application, degreasing

or re-blasting.8.8. Film Thickness


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8.8.1. Wet film thickness shall be checked during the application of eachcoat to assure the specified dry film thickness (DFT) will be met.

8.8.2. The DFT of each coat shall be checked in accordance with theprocedures defined by SSPC-PA 2 using a magnetic gage that hasbeen properly calibrated.

8.8.3. All gages shall be adjusted to compensate for the substrate effect priorto application of any coating.

8.9. Defects

8.9.1. All coatings shall be free of defects such as runs, sags, pin holes,voids, blisters, wrinkles, mud cracking and bubbles.

8.9.2. Where film thickness does not meet specifications and/or defects(holidays) are found, the Contractor shall take corrective action at noadditional cost to the Company. These corrections shall be to thesatisfaction of the Company.

8.9.3. Dry spray and overspray shall be removed.

8.9.4. The DFT of each coat shall not be outside the specified range.

8.9.5. All coatings shall be checked for amine blush prior to application of thesecond coat or to making any repairs.

8.9.6. Blush shall be removed prior to top coating.

8.10. Touch-Up

8.10.1. Prior to application of any coat, all defects and damage to the previouscoat(s) shall be repaired. Damage to finished work shall be thoroughlycleaned and recoated.

8.10.2. Damaged areas shall be spot blast cleaned or power tool cleaned asnecessary to restore any exposed steel to its original degree ofcleanliness.

a) All loose, cracked, and damaged coating shall be removed and theadjacent sound coating feathered back approximately 2 inches (50mm) to form a uniform and smooth surface.

b) Feathering shall be done by hand or power sanding with a gritwheel or sandpaper.

c) The prepared surface shall be free of loose, burnt, or blisteredcoating.

8.10.3. Unless specified otherwise, the coating used for repair shall be thesame as the original and shall have the same DFT.

8.11. Brush or Roller Application

8.11.1. Company review and written acceptance is required before brush orroller application can be substituted for spray application.


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8.11.2. Belzona 1391 and 1591 can only be applied by trowel.

8.11.3. Inaccessible and restricted areas which prevent spray application of

paint at the proper inclination angles shall be boxed in and sealwelded prior to paint application. This requires engineering review andacceptance so as to avoid welding on a pressure boundary.

8.11.4. All welds which cannot be properly spray coated shall be brush orstripe coated with an accepted coating before applying successivespray coats over the primer coating.

8.11.5. Brushes shall be of a style and quality that will enable properapplication of the coating.

8.11.6. Brushing shall be done so that a smooth coat with uniform thickness is

obtained. When applying coatings with a brush, multiple coats may berequired to achieve the specified millage.


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9. THERMAL SPRAY COATING APPLICATION

9.1. Thermal Spray Coating Requirements

9.1.1. Do not preheat carbon steel above 300 F (150C) or stainless steelabove 212F (100C) for longer than a minute.

9.1.2. If masking is to be done, a shadow mask shall be used to avoidcreating a square edge. All coating edges shall be tapered. Anexample of a shadow mask is shown in Figure 1.

Figure 1: Example of a shadow mask and a square edge.

9.1.3. In difficult to access areas (i.e. areas where the correct angle of attackcannot be obtained by the spray gun operator), at least three ASTMD4541 adhesion tests with a Type IV fixed alignment tester shall be

used.

a) Tests shall be conducted up to 3000 psi (20.7 MPa) maximum.

b) If any of the three measurements are below 3000 psi (20.7 MPa),the coating in this limited access area shall be removed and re-applied.

c) The Company reserves the right to adhesion test any area duringthe project.

9.1.4. Electric Arc and High Velocity Continuous Combustion (HVCC)processes.

a) The wire feeder potential shall be calibrated at the beginning ofeach shift.

b) Wire diameters shall not exceed 2 mm.

c) Wire sizes larger than this can lead to inconsistent wire feeding.

d) Rotometers shall be calibrated at the start of each shift to thespecific gas being used.

9.2. High Velocity Ox Fuel (HVOF) Processes Only

9.2.1. Rotometers shall be calibrated by either a mass flow meter or a critical

flow meter.

9.2.2. Powder feedstock shall be used immediately after opening thecontainer, or else it shall be heated at 100C (212F) for at least 5


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hours prior to used. Powder from containers opened for more than twodays shall not be used.

9.2.3. Particle size of powders shall be greater than 10 microns.

9.2.4. Any sooting shall be documented.

a) The spray applicator shall specify what measures they have forpreventing sooting and controlling the fuel-oxygen ratio.

b) When sooting does occur, the spray applicator shall apply thesemeasures until sooting ceases.


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10. INSPECTION

10.1. General

10.1.1. The Contractor shall perform all inspection necessary to ensure thatsurface preparation and coating application complies with therequirements of this specification.

a) The indicated records shall be kept daily and shall be submitted tothe Company at least weekly.

b) TCO Coating Inspection Form (xx-xx-xxxx), shall be used torecord this information.

c) All records shall be kept current and shall be submitted to theCompany upon demand, or at least weekly, and at the completionof the job for verification to the Companys satisfaction.

10.1.2. Companys authorized inspector(s) shall be given adequate noticeprior to the start of surface preparation and coating application so thatthey can witness the work.

10.1.3. The Companys authorized inspector shall have the option to witnessor repeat any of these functions as necessary.

10.1.4. All materials, equipment, and work shall be available to Companysauthorized inspector(s) at all times. Companys authorized inspector(s)

shall have access to the work site during the progress of the work andthe right to conduct any inspection or testing deemed necessary toensure that the coatings are properly applied.

10.1.5. All instruments used in inspection activities (e.g., thermometer,pyrometers, hygrometers, thickness gauges, profile gauges, andholiday detectors) shall be supplied by the Contractor in properworking order and calibrated prior to use.

10.2. Compressed Air and Abrasive

10.2.1. The cleanliness of compressed air supply used for blast cleaning,

pneumatic tools, and spray equipment shall be checked for oil andwater contamination in accordance with ASTM D4285.

a) All lines shall be tested separately.

b) Testing shall be performed at the beginning and end of each workshift and at not less than four-hour intervals.

c) In the event that contamination is discovered, all necessarycorrective actions shall be made and the air supply re-tested.

d) Surfaces that are determined to have been blasted withcontaminated air shall be cleaned with solvent and re-blasted withclean air and abrasive.

e) Coatings that are determined to have been applied usingcontaminated air shall be removed and reapplied using clean air.


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10.2.2. Re-circulated shot and grit used for abrasive cleaning shall be testedfor the presence of oil by immersing in water and checking for oilflotation.

a) Tests shall be made at the start of blasting, at four-hour intervalsthereafter, and at the end of blasting.

b) If oil is evident, contaminated abrasive shall be replaced withclean abrasive and re-tested before proceeding.

c) All steel blasted since the last satisfactory test shall be re-blasted.

10.3. Environmental Conditions

10.3.1. The following shall be checked and recorded at the beginning of eachday's operation and several times during the application process:

a) Ambient temperature

b) Relative humidity

c) Dew point

d) Moisture-free surface

e) Temperature of the surface to be coated

10.3.2. These recordings shall be compared with criteria stated in Section 8.1item 5 of this specification and the manufacturer's data sheets. If anycriterion is exceeded, coating shall not be applied.

10.4. Surface Preparation Inspection

10.4.1. Immediately prior to priming, blasted surfaces shall be inspected bythe following methods to verify that the specified surface preparationhas been achieved:

10.4.2. The anchor pattern shall be verified using Testex Inc. "Press-O-Film"tape as described in ASTM D4417 Method C. The measurementsshall be recorded on the Coating Inspection Record.

10.4.3. The degree of cleanliness shall be verified by comparison to SSPC-VIS 1. The cleanliness shall be recorded on the Coating Inspection

Record.

10.5. Surface Preparation Inspection

10.5.1. Dry film thicknesses shall be measured using a Microtest magneticfilm thickness gauge or Company-reviewed and accepted equal inaccordance with SSPC-PA 2.

a) The dry film thickness gauge shall be calibrated to the Companyssatisfaction at the beginning of coating work and thereafter,regularly and whenever the Company requests recalibration.

b) Calibration shall be made by comparison with the dry film

thickness measured on known standards such as a micrometer-measured paint film or National Bureau of Standards CalibrationCoating Inspection Record for each coat as work proceeds as wellas for the total thickness of each finished coating system.


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c) The film thickness for each coat shall be within the manufacturer'sspecified range.

10.5.2. The entire surface of internal linings shall be inspected for holidays perNACE SP0188. When testing hard-to-get-at locations aroundappurtenances and nozzles, a small sponge attachment shall be used.

10.5.3. Areas containing holidays shall be locally abrasive blasted to baremetal, recoated with the same system and retested for holidays.

10.5.4. Areas containing holidays shall be locally abrasive blasted to baremetal, recoated and re-inspected.

10.5.5. All areas found to contain runs, overspray, pinholes, sags and/or othersigns of improper application shall be repaired in accordance with the

manufacturer's recommendations at the Contractors expense.

10.6. Inspection by Company

10.6.1. All work shall be subject to Company inspection.

10.6.2. The Companys inspectors shall be given at least two days' noticeprior to the start of surface preparation or coating application so thatthey can witness the work.

10.6.3. Work shall not proceed past each of the inspection hold points definedbelow without the review and acceptance of the Companys

inspectors.

a) The Companys inspectors shall ensure that all necessaryinspections are carried out at each hold point.

b) The inspection hold points shall be:

1. Completion of surface preparation, prior to primer application.

2. Completion of application of each coat (primer, intermediate andTop-Coat).

3. Holiday detection and repair (internal linings and splash zonecoatings only).

4. Final acceptance of completed coating work.

10.6.4. Companys inspectors shall have the right to condemn any materials,equipment or work not in compliance with this specification.

10.6.5. All necessary corrective actions shall be performed by the Contractorat Contractors expense.

10.6.6. Scaffolding, beam clamps, or any other equipment which will interferewith or damage coating shall not be used.

10.6.7. Contractor shall provide safe access to all areas for inspection by

Company.

10.6.8. Contractor shall maintain the area to prevent contamination ofcoatings. Contractor shall, for example, wet down dusty fabrication


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and painting areas including the surrounding grounds when dryconditions are experienced.

10.6.9. Prior to final coating acceptance, Contractor shall wash the entireplatform with fresh water and apply a finish coat to areas stained andcontaminated by grinding, weld spatter, general traffic, etc.

10.7. Coating Manufacturer's Representatives

The coating manufacturer's representatives shall have access to the worksite during the progress of the work to perform any inspection and testingdeemed necessary to ensure that the coatings are properly applied.


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APPENDIX A- RECOMMENDED COATINGS FOR WET H2S SERVICE VESSELS

Thin Film Epoxy Coatings:These coatings are acceptable for continuous service temperatures up to 82C (180F) andare resistant to steam outs up to the temperatures listed in Table 1 below. Check with eachcoatings manufacturer for specific chemical resistance.

All these coatings require a SSPC-SP 5 white metal blast with an anchor profile of 2-3 mils.Cure time is required prior to placing these coatings into service (consult manufacturer'sdata sheets).

Thick Film Coatings:

These coatings are acceptable for continuous service temperatures up to 82C (180F) andare resistant to seam outs up to the temperatures listed in Table 1 below. Thick film coatings

are easier to apply on substrates in existing service that have excessive surface profile dueto past corrosion.

All these coatings require a SSPC-SP 5 white metal blast with an anchor profile of 3-5 mils.Cure times very prior to placing these coatings into service (consult manufacturer's datasheets).

Specialty Coatings:

These coatings are typically used for smaller coating jobs or touch-up coating of existingvessels and have the highest temperature resistance. These coatings shall be appliedstrictly according to manufacturers specifications.

These coatings require a SSPC-SP 5 white metal blast with an anchor profile of 3-4 mils.

Cure time is required prior to placing these coatings into service (consult manufacturer'sdata sheets).


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Table 1: Acceptable Coating Brands for Wet H2S Service (Sheet 1 of 2)

Manufacturer

/ Coating

Coating

Type

Total

DFTSteam

Out VOC

Cure to

Immersion

Singleor Multi-

LayerComments

Ameron-Amercoat 91

EpoxyNovolac(ThinFilm)

12 mils 365F 410 g/L 7 Days 2 Coats Also a good performer inhigh pressure testing.Formerly called ValsparV9. Best used for newconstruction.

Belzona 1391 SpecialtyCoating

24-30mils

410F 0 g/L 2-14Days

1 Coat Trowel applied. Effectivein amine environments.Requires postcuring for maximumproperties.

Belzona 1521 Specialty

Coating

25-40

mils

365F 0 g/L 1-5 Days 2 Coat Resistant to amines

and sour gases.


32-40mils

410F 0 g/L 1 Day 1 Coat Trowel applied. Resistantto Amines and sourgases.


20 mils 365F 0 g/L 2 Coat Resistant to Aminesand sour gases.

CarbolinePhenoline1205

EpoxyNovolac(ThinFilm)

15 mils 300F 259 g/L 4-21Days

2 Coats Use for new construction.

CarbolinePhenoline 368WG

ModifiedPhenolic(ThinFilm)

14 mils NR 288 g/L 1-14Days

2-3Coats

Use for new construction.

SigmaPhenguard930aSigmaPhenguard940a

EpoxyPhenolic(ThinFilm)

4 mils

4 mils

420F 315 g/L 5-14Days

2-3Coats

Good experiences withthe Sigma series coatingsin Pascagoula wetH2S service vessels.

a. Formerly Phencoat 7409 primer and Phenguard 7436 topcoat.


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Thermal Spray Coatings:

These coatings are acceptable for continuous service temperatures in excess of 260C(500F) and are fully resistant to steam outs. The coating shall be applied in multiple coatswithin the coating material manufacturer's limits. Consult Company if the manufacturerrecommends less than 15 mils (0.38 mm) or more than 40 mils (1.02 mm) thickness.Manufacturers of the thermal spray systems have published thickness limits for theircoatings. These coatings require a SSPC-SP 5 white metal blast with an anchor profile of2.5-5.0 mils. Cure time is generally not required prior to service but may be needed whensealer coats are applied. A sealer shall be applied over the electric arc thermal spraycoating, but is not required for HVOF coatings. Application of the sealer shall be permanufacturer's guidelines. Conventional coatings or paints shall not be substituted forsealers. Sealers are made of very solvent-thinned organic coatings and have much lowerviscosity than conventional organic coatings.

This enables them to permeate through the coating pores more effectively. The purpose of

the epoxy sealer is to seal surface porosity that might allow corrosive fluids to penetrate thecoating and attack the substrate. When penetration occurs, the build-up of corrosion productat the substrate can cause the coating to spall.

Thermal Spray Brands

Hastelloy C family or Inconel 625 material applied by twin wire arc or Com-Arc ExcalliburProcess (system used by Metalspray United) or Jetstar (used by Amstar SurfaceEngineering) is required.


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1. 32

2. 33

3. 35

4. 36

5. 38

6. 39

7. 41

8. 47

9. () 53

10. 55

,


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1.

1.1 , ,, (: Belzona) , .

1.2 , , .


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2.

1. , , , , 3SSPC-PA.

2. , .

3. , .

4. , , .

2.1

COM-EF-844

2.2

(ASTM)

E337 ()

D4285

D4417 ,

D4541

(SSPC)

1 ,

2

3

SP 1

SP 5 (NACE No 1)


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SP COM

VIS 1 ,

QP 1 , ( )

(NACE)

SP0178 , ,

SP0188 ( )


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3.

3.1

3.1.1 , 1. .

3.1.2 ( , ), .

3.1.3 .

3.1.4 ,

3.2 /

3.2.1 , , , .

3.2.2 , ( ) .

3.2.3 / . (PMI).

3.2.4

a) .

b) , ,.


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4.

4.1 , , (SSPC), SSPC QP1, .

4.2 .

4.3 , / , /.

4.4 , ,, .

4.5 , .

4.6 . .

4.7 .

a.

, , ,.

b. .

4.8 , NACE,:

a. .

b. ,, , :

1.


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2.

3.

4. ,

5.

6.

4.9 , .


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5.

5.1 .

5.2 .

5.3 , 3 SSPC-PA.

5.4 .

5.5 ().

5.6 .

5.7 . , .

5.8 , . , .


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6.

6.1 , , .

6.2 ,, .

6.3 .

6.4 , ,

()a.

b.

c.

d. ( )

e. , , -

6.5 , , .

6.6 .

6.7 :

a. 1 : ,

3 .

b. 1 : , , 3-, . :1,5 , 4,5 .

c. : 1 .

d. : 6-


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. : , 3-, 9

, , 6.


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7.

7.1

7.1.1 , , , .

7.1.2 , .

a)

.b) ,

.

c) , / . , , , , API 653 510.

7.1.3 ,

, .

7.1.4 , , , , , .

7.2

7.2.1 , , ,

.., , , , - (. SSPC-SP COM NACESP0178).

7.2.2 , , , , , .

7.2.3 , , , .


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a) , , , .

b) /.

c) SSPC-SP 1.

d) , , ,, .

7.2.4 .

7.2.5 , CHLOR*TEST .

a. .

b. 90 . , 280 . .

(1) :

a. 3 /2

b. 5 /2

c. 10 /2

(2)

:

a. 5 /2

b. 10 /2

c. 15 /2

d. , , (21) -CHLOR*RID , .

e. ,


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,5b 7.2.

7.3

7.3.1 , (WFMT) .

7.3.2 , , SSPC NACE, .

7.3.3 , .

7.3.4 .

a) .

b) .

c) ,

. .

7.3.5 , 1% .

7.3.6 , 75% 25% .

7.3.7 , , .

a. , .

b. ASTMD4285.

c. , .


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d. ,

Press-O-Film, ASTM D-4417,.

e. , .

f. 95/2., , ,

.

7.3.8 , , .

a. , .

b. ,

.c.

, / . , , , API 653 510.

7.3.9 , , , , .

, . .

7.3.10 . , ,-.

7.3.11 ,

50F (30C).

a) ASTM


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E337 .

b) .

7.3.12 , , , , .

7.3.13

, .7.3.14

, .

7.3.15 -, , .

7.3.16 ,

.a.

.

b. , ,.

c. , , 2 (50 ) .

d. .

7.3.17 .

a. .

b. , ,

,.


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c. .

d. , .

e. .

7.1.18 .

7.1.19 .

SSPC-VIS 1.

7.1.20 ASTM D4417, , .


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8.

8.1

8.1.1 SSPC-PA 1; , ; (MSDS) , .

8.1.2 , ,.

8.1.3 , , , .

a) () .

b) , , ,

.

8.1.4 , .

8.1.5 , :

a. , .

b. 50F (30C).

1) ASTM E337 .

2) .


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8.2

8.2.1 , , .

8.2.2 , , .

8.2.3 , , .

8.2.4 , 5.1 SSPC-PA 1.

8.3

8.3.1 , .

a) , , .

b) , .

c) .

8.3.2 .

8.3.3 .

8.3.4

(), .

8.4

8.4.1 , , .

8.4.2 , .

, .


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8.5

8.5.1 ,

, .

a) .

b) , , .

8.5.2 ,

, .

8.5.3 , .

8.5.4 .

8.5.5 .

8.5.6 .

8.5.7 .

8.5.8 50%-.

8.5.9 .

8.6

8.6.1 4 , .

8.6.2 6 .

8.6.3 , ,

, , - , .


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8.6.4 , , , .

8.6.5 , .

8.7

8.7.1 ,.

8.7.2 ,, .

8.7.3 .

a) ..

b) , , , , ,

.

8.8

8.7.1 ().

8.7.2 -, SSPC-PA 2, .

8.7.3 .

8.9

8.9.1 , , , , , ,.

8.9.2 ,/ (),

. .


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8.9.3 .

8.9.4 .

8.9.5 .

8.9.6 .

8.10

8.10.1

() . , .

8.10.2 .

a) , ,

2 (50 ) .

b) .

c) ,.

8.10.3 , , ,

.

8.11

8.11.1 .

8.11.2 Belzona 1391 1591 .

8.11.3 , ,


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. , ,

, .

8.11.4 , , .

8.11.5 .

8.11.6

, . , , .


53/62


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9.2 ( )

9.2.1 , .

9.2.2 , , 100C ( 212F ) 5 . ,.

9.2.3 10 .

9.2.4 .

a) , , , -.

b) , - , .


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10.

10.1

10.1.1 , .

a) - .

b) (--).

c) .

10.1.2 () () - , .

10.1.3 -

, ,.

10.1.4 , () -() . () () , () -.

10.1.5 , (:

, , , , ) .

10.2

10.2.1 , , , ASTM D4285.

a) .

b) .


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c) , .

d) , , .

e) , , , .

10.2.2 () , -

, .

a) , .

b) , , .

c) ,

,.

10.3

10.3.1 :

a)

b)

c)

d)

e)

10.3.2 ,5 8.1 , . -.

10.4

10.4.1 , , .


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10.4.2 Testex Inc. Press-O-Film ASTM D4417, .

.

10.4.3 SSPC-VIS 1. .

10.5

10.5.1 Microtest

, SSPC-PA 2.

a) , .

b) , ,, ,

, .

c) , .

10.5.2 NACE SP0188. .

10.5.3 , , .

10.5.4 , , .

10.5.5 , , , , / -

, .


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10.6 ,

10.6.1 .

10.6.2 , , .

10.6.3 .

a) , .

b) :

1. .

2. (, ).

3. ( ).

4. .

10.6.4 , , .

10.6.5 .

10.6.6 , - , .

10.6.7

.

10.6.8 . , , , , .

10.6.9 , ,, .

10.7


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,

.


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, ,

:

820C (1800F ) , 1 . .

SSPC-SP 5 2-3 . (. ).

:

820C (1800F ) , 1 . , , .

SSPC-SP 5 3-5 . (. ).

:

..

SSPC-SP 5 3-4 . (. ).


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1:

/

Ameron-Amercoat 91

(

)

12 3650F 410 / 7 2 . Valspar V9. .

Belzona 1391

24-30

4100F 0 / 2-14 1

.

. .

Belzona 1521

25-40

3650F 0 / 1-5 2

.Belzona 1591

32-40

4100F 0 / 1 1

. .

Belzona 5891

20 3650F 0 / 2 .

CarbolinePhenoline 1205

(

)

15 3000F 259/

4-21 2 .

CarbolinePhenoline368 WG

()

14 288/

1-14 2-3 .

SigmaPhenguard930

a

SigmaPhenguard940a

()

4

4

4200F 315

/5-14 2-3

Sigma , , .

. Phencoat 7409 Phenguard 7436


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:

2600C (5000F ) . , . , 15 (0,38) 40 (1,02). . SSPC-SP 5 3-5 . , , , . , , .

. . , , , .

. , - . .

:

Hastelloy C Inconel 625 Com-ArcExcallibur Process (, Metalspray United) Jetstar (Amstar Surface Engineering).