HYDROBLASTING AND COATING PROCEDURE

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 TABLE OF CONTENTS

1. PURPOSE 4
1.1 INTRODUCTION 4
1.2 SCOPE 4
2. SURFACE PREPARATION AND CLEANINESS 6
2.1 REFERENCES 6
2.1.1 Revisions 6
2.1.2 Compliance 6
2.1.3 Conflict of Information 6
2.1.4 Reference Documents 6
2.2 SOURCE AND QUALITY OF WATER 6
2.3 PLANNING ACTIVITIES 7
2 SAFETY GUIDELINES 9
3.1 HAZARD IDENTIFICATION AND CONTROL 9
3.2 JOB SAFETY ANALYSIS 9
3.3 PERSONAL PROTECTIVE EQUIPMENT (PPE) 10
3.4 EQUIPMENT 10
3 SAFE HOUSEKEEPING 13
4 HYDROBLASTING EQUIPMENT REQUIREMENTS 14
5 PAINTING AND COATING 16
6.1 INSPECTION OF EQUIPMENT 16
6.2 INSPECTION OF EQUIPMENT 16
6.3 ATMOSPHERIC CONDITIONS 17
6 SURFACE PREPARATION 18
7.1 ATMOSPHERIC CONDITIONS 18
7.2 REMOVAL OF CONTAMINANTS 18
7.3 REMOVAL OF WELD SPATTER 18
7.4 COMPRESSED AIR 18
7.5 POWER-TOOL CLEANING 18
7.6 HAND-TOOL CLEANING 18
7.7 SOLVENT CLEANING 19
7.8 HYDROBLASTING AND POWER-TOOL / HANDLE CLEANING INSPECTION 19
7 PAINT MIXING AND THINNING 20
8 PAINTING AND COATING APPLICATION 21
9.1 GENERAL 21
9.2 COATING OF NEW CONSTRUCTION 21
9.3 PAINT APPLICATION 22
9.3.1 Spray Application 22
9.3.2 Airless Spray Application 23
9.3.3 Brush Application 23
9.3.4 Critical Internal Coating 23
9.3.5 Protection Cleaning 24
9.4 DRYING/CURING 24
9 INSPECTION AND TESTING 25

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 10.1 GENERAL 25
10.2 CHECKING ENVIRONMENTAL CONDITIONS25
10.3 VISUAL CHECK FOR SURFACE PREPARATION AND FINISHED COATING
25
10.4 FILM THICKNESS MEASUREMENT 25
10.5 HOLIDAY TEST 26
10.6 REPAIR OF DAMAGED AREAS 26
10 SAFETY 28
11 QUALITY RECORD AND INSPECTION REPORT 29
12 REVISION NOTE 30
13 APPENDIX A: VISUAL SURFACE PREPARATION REQUIREMENTS 31
14 APPENDIX B: TYPICAL PRESSURIZED WATER-JETTING SYSTEMS 32
15 APPENDIX C: HYDROBLASTING OPERATION CHECKLIST 33

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1. PURPOSE
This document describes the procedure, safety requirements and the method used for
the surface preparation and painting of steel structures in the FPSO. It also provides
safety guidelines for the protection of maintenance and operators from injury while
working with the hydro-blaster and coating materials and equipment. Typical steel
structures to hydro-blasted in the FPSO are decks, outer hulls, internal ballast tanks,
storage tanks etc.

1.1 INTRODUCTION
The use of hydroblasting equipment is a potentially hazardous activity. Special
precautions shall be taken in order to operate the equipment safely and effectively.
The category of hydroblasting equipment is specified below in accordance with NACE
No. 5 / SSPC-SP12.
Equipment
Pressures Application
Category
Hydroblasting with low
Class A 1,000–5,000 psi litre / min
pressure and volume
Hydroblasting using high
Class B 5,000–10,000 psi litre / min
pressure and volume
Hydroblasting using very
Class C 10,000–30,000 psi litre / min
high pressure and volume
Hydroblasting using ultra-
Class D Above 30,000 psi litre / min
high pressure and volume
Table 3.1: Equipment Category

Incorporated shall apply low pressure and volume Class A hydroblasting in accordance
with the requirements of NACE No. 5 / SSPC-SP12 to remove all loosed coating,
dust / dirt, oil, grease etc. prior to re-coating of hull, tanks, decks and other steel
structures of the FPSO. Category A equipment will be operated by a single individual
who shall be an experienced mechanic.

1.2 SCOPE
This Guideline provides guidance for the operation of hydroblasting equipment. It
describes methods for eliminating or reducing hazards and risks associated with
hydroblasting.
This Guideline provides guidance for:

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a. high pressure hydroblasting systems pressurized by positive displacement pumps
with an output capability greater than 400 bar litres/minute;
b. high pressure hydroblasting operations carried out at pressures above 200 bar and
includes hydroblasting operations involving the use of additives and abrasives if
applicable; and
c. hydroblasting operations below 200 bar where there is a foreseeable risk of injury
to operators or other persons.
This procedure applies to all Sons Incorporated personnel performing general
hydroblasting operations and painting / coating or working in the immediate area
where hydroblasting operations are occurring. Therefore, all personnel who have
the need to perform hydroblasting on the FPSO working with Sons Incorporated
shall use this Guideline.
Supervisors of personnel operating hydroblasting equipment shall ensure that the
requirements of this Guideline are followed by their respective work crews.

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2. SURFACE PREPARATION AND CLEANINESS
The surface steel structures shall be prepared to meet the requirements of one of the
four visual conditions prior to recoating stated below in accordance with NACE No. 5 /
SSPC-SP12. All deposits of oil, grease, and foreign matter shall be removed by
hydroblasting with clean fresh water. No abrasive shall be used during hydroblasting
operations of FPSO except otherwise advised and approved by the CLIENT.
Application of rust inhibitor shall be applied where necessary after approval by the
CLIENT.
The entire surface to be prepared for coating shall be subjected to a cleaning method
in accordance NACE No. 5 / SSPC-SP12 and shall conform to the requirements of
WJ-2 Appendix A.

2.1 REFERENCES
2.1.1Revisions
Only the latest issues of the relevant standards, codes and project specifications
referenced shall be applied to the work being performed.

2.1.2 Compliance
This procedure shall be in accordance with CLIENT standards and procedure.

2.1.3 Conflict of Information

In the event of any conflict between this procedure and CLIENT’s Standard, CLIENT
Standard shall be followed.

2.1.4 Reference Documents

REF DOCUMENT NUMBER TITLE

[1] AS/NZS 4233.1 High Pressure Water-jetting Systems

[2] Joint Surface Preparation Standard: Surface Preparation
NACE No. 5 / SSPC-SP12
and Cleaning of Metals by Water-jetting Prior to Recoating

2.2 SOURCE AND QUALITY OF WATER

The fresh water to be used for hydroblasting operation shall be sufficient purity and
quality that it does not impose additional contaminants on the steel surface being

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 cleaned and does not contain sediments or other impurities that are destructive to the
proper functioning of water-jetting equipment.
Potable water source, suitable for human consumption from the FPSO that satisfy
mechanical filtration down to 5 or 10 microns shall be used for the hydroblasting
operations. In order to prevent sediment of pumps and damage, filtration systems are
used on the inlet water side of the pump. CLIENT shall advise the source of water to
be used if CLIENT observe that the quality of water in the FPSO is not sufficient for
hydroblasting activities. The following shall be considered if detergents or inhibitors
are will used during hydroblasting operation.
a. Any detergents or other types of cleaners used in conjunction with water-jetting
shall be removed from surfaces prior to applying a coating.
b. Compatibility of the detergents with the special seals and high-alloy metals of the
water-jetting equipment shall be carefully investigated to ensure that hydroblasting
machines are not damaged.
c. Hydroblasting equipment and coating manufacturers shall be consulted to ensure
compatibility with equipment if inhibitors to be used.
Immediately prior to the application of the coating, Sons Incorporated shall ensure that
the hydro-blasted steel surface does not contain the specific amount of chloride
content (μg/cm2) more than allowed by the CLIENT and the method of testing shall be
as agreed upon by both parties. As a minimum, the chloride content shall be less than
7 μg/cm2 in accordance with SSPC-SP12 / NACE No. 5.

2.3 PLANNING ACTIVITIES

Sons Incorporated personnel shall work in conjunction with CLIENT operation
personnel to establish the following prior to commencement of hydroblasting work.
i. Provide proper location for setup of equipment
ii. Verify hydroblasting equipment set-up does not interfere with plant, equipment or
operations.
iii. Ensure electrical equipment in the work area has been isolated and protected from
water ingress.
iv. Sons Incorporated personnel shall ensure that the appropriate Work Permit or
Isolation Permit is applied for and obtained prior to Hydroblasting work commencing
(in accordance with site procedures). Work shall commence with the appropriate
Work Permit
v. Review procedures to ensure the minimum requirements are met.

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vi. Ensure hydroblasting equipment is in good operational condition and safety features
are functional. Equipment must comply with the requirements of AS/NZS 4233.1 and
NACE No. 5 / SSPC-SP12.
vii. Maintenance to coordinate with Operations regarding the selection of a location for
the equipment and to ensure spacing requirements are met.
viii. Maintenance Supervisor shall verify the completion of items on Appendix C and that
appropriate signage is in place.
ix. Contractor to ensure personnel operating the equipment are appropriately trained
and follow established procedures.
x. All operators engaged in Class A and Class B Hydroblasting operations should carry
an immediately accessible, waterproof medical alert card outlining:
 Possible nature of injuries and post-accident infection s that can be caused by high
pressure water jetting;
 Provide details of immediate first-aid treatment until medical treatment can be
arranged; and
 Provide the name/s of medicos who should be contacted for expert medical advice.

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2 SAFETY GUIDELINES
3.1 HAZARD IDENTIFICATION AND CONTROL
Hydroblasting is an activity with significant inherent hazards. If work tasks are
approached inappropriately, significant risks with the potential for serious injury,
including fatality are possible. A hazard identification and control philosophy shall be
adopted to significantly reduce the risk of exposure and the potential for personal
injury.
Therefore, hydroblasting activities shall be approached with a risk control hierarchy
approach:
1. Firstly, where possible, hydroblasting activity is to be avoided and other methods of
cleaning reviewed for practicality (e.g. chemical cleaning).
2. Secondly, remotely controlled mechanical cleaning devices shall be considered in
order to separate the operator from the high pressure water hazards.
3. Thirdly, only experienced operators shall be used when manual hydroblasting is
applicable
4. Appropriate safety procedures shall be followed and minimum mandatory PPE be
worn throughout the period of hydroblasting operation.
5. When manual flexi-lance cleaning of exchanger tubes is required, fail safe (anti-
withdrawal) devices attached to the equipment shall be used to prevent the lance
exiting the tube in an uncontrolled manner.
6. The manual use of hydroblasting equipment shall only be utilized as a last resort
where the use of other automated or mechanical equipment cannot be used.

3.2 JOB SAFETY ANALYSIS

A documented Job Safety Analysis (JSA), Task Hazard Analysis (THA) and the Permit
to Work programme shall identify if any additional or specialised personal protective
equipment that are necessary for the execution of hydroblasting activities. This
includes but is not limited to energy isolation of equipment, confined space entry,
correct body positioning for tasks, using shotguns, flex lancing, rigid lancing, line
moling, and use and installation of anti-withdrawal safety devices as a minimum is
required to be recorded and attached during request for Work Permit. As a minimum,
the following activities shall be considered when carrying out JSA and THA:
 A written energy isolation procedure shall be put in place to effectively de-energize
and isolate water cleaning and cutting equipment when it is being serviced,

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 repaired, installed, relocated, or any time anyone could be exposed to the high
pressure water stream.
 Job plans must be established for all Hydroblasting activities before work
execution. As a minimum, this should include basic job steps, parameters,
safeguards, and a list of the equipment that will be utilized to facilitate the
hydroblasting work required.
 Use a pre-job check list/ job safety analysis (JSA) to help identify all job hazards
and ensure the safe execution of the job with the crew.
 The pre- job check list/ JSA shall be initiated and reviewed with the crew initially
and any anytime there is a change in job scope, an instance of an unsafe
condition, additional personnel added to the job, or at each and every personnel
shift change.

3.3 PERSONAL PROTECTIVE EQUIPMENT (PPE)

The PPE worn by operators of hydroblasting equipment shall reflect the activities
being performed. Whatever the nature of the job, the following PPE is mandatory for
operators or those within the blasting area when hydroblasting:
 Hard hat
 Mono Goggles
 Face shield
 Hearing protection
 Heavy duty rain suit or hydroblasting suit
 Protective gloves (dependent on the material / substance being handled or
exposed to and the hazard and risk presented to the operators)
 Hydrojet safety rubber boots (with built in metatarsal protection) with steel toe
caps
 Other equipment as required if a hazardous chemical is involved.

3.4 EQUIPMENT
As a minimum, the following safety precautions shall be taken to safeguard equipment
prior to and during hydroblasting operations. These include:
a. The hydroblasting equipment area must be barricaded using red barricade tape
with white lettering stating " DANGER: HIGH PRESSURE WATER JETTING
EQUIPMENT IS IN USE". Barricade tape should extend out 10 metres (30 feet) in
all directions from blasting equipment. Hoses extending from equipment to blasting
area should be surrounded by barricade tape and signs.

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b. If it is not possible to isolate the prescribed area, sturdy barriers/ panels must be
placed or erected to shield operations.
c. The pumping unit shall be equipped with a safety valve and/or rupture disc capable
of rapidly relieving the full capacity of the pump. These safety devices should be
checked to ensure a tag is attached indicating they have been properly tested and
are operational. Checking of safety devices shall be daily prior to start of work.
d. The pumping unit should be located to minimize the length of hoses required.
Considerations should be given to the distance from operating equipment. A safe
location will be selected that does not require running hoses through an active
access way or work area. Care will be taken to protect hoses from damage by
vehicular traffic, hot lines/equipment, or external abrasion.
e. The operating pressure of the high pressure hose and fittings should not exceed
1/3` of the rated pressure. Hoses should be inspected before each job and tested
every three months at 125 percent of rated pressure. Hoses shall be tagged with
the latest test date and test pressure.
f. Hydroblasting equipment shall be grounded to minimize static electricity build-up.
g. Quick connect/disconnect fittings are not permissible for use for hydroblasting.
Hose connections shall have a secondary joining mechanism to prevent whipping if
the connection is broken.
h. Minimum length of the shotgun barrel (nozzle) is 120cm (48-inches). The minimum
length of entire shotgun is 165 cm (66-inches).
i. When lancing, a foot or hand operated fail safe control with guard should be
manipulated by the lance operator. In some operations such as lancing exchanger
tubes or line moleing another person must be used to assist with the lance or hose.
Only the lance operator (person nearest the working end of the lance) should
operate the fail-safe device.
j. Shotguns shall be equipped with double-action switches. The double-action
switches should be positioned so that both the operator's hands are required to
initiate high pressure water flow.
Note: A dump valve which will immediately dump all the water pressure when the
control is released is the only approved fail safe control.

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3 SAFE HOUSEKEEPING
During and completion of the job, it is the responsibility of the crew to maintain good
housekeeping practices on the job site. This includes, but is not limited to;
a. the elimination of slip, trip and fall hazards including proper hose placement
b. Proper disposal of trash, contaminated PPE and chemical/product wastes
generated from the cleaning service.
c. Use of barricades and signs when performing hydro-blasting work. Adequate
barricades and signs shall be in place to protect personnel when approaching all
ends of the equipment being cleaned.
d. All high pressure hoses should be routed and protected in a manner that prevents
vehicular damage and personnel exposure to the hoses. When possible, roadways
should be barricaded for vehicular and pedestrian traffic where high pressure
hoses cross roadways.
e. All equipment being cleaned shall be shielded against flying debris/chemicals that
could pose a potential injury or exposure to someone.

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4 HYDROBLASTING EQUIPMENT REQUIREMENTS
Pressure pumps used by hydroblasting equipment shall be equipped but not limited
with the following;
i. A rupture disc assembly or PSV rated at minimum of 1.2 times the maximum
operating pressure (M.A.W.P.) of the system’s weakest component. Note: The
maximum operating pressure is typically referred to as MAWP by hydroblasting hose
and equipment manufacturers.
ii. A pressure gauge with the full range of system capability must be verified operable
and must be visible to the equipment operator line
iii. Dump line must be secured so that it does not whip when active.
iv. All rigid lance assemblies shall include use of a minimum 3’ (feet) shroud to protect
the employee handling the end of the rigid or stiff lance.
v. The construction of the Shroud (e.g. double S.S. braided) shall be sufficient enough to
help ensure the safety of the employee against serious injury from the potential of a
high pressure hose rupture.
vi. The hose Shroud must be inspected for inner and outer integrity (e.g. excessive wear
and breakdown of reinforcement wire braiding) at a minimum on a quarterly basis.
vii. High pressure hose end fittings, connection fittings and couplings shall be
manufactured to be compatible with the hose.
viii. Only fittings marked with the Maximum Allowable Working Pressure (MAWP) shall be
used. Fittings designed for pressure less than the service pressure of the pump shall
never be used in a higher pressure application.
ix. Pipe thread connections shall not be used at pressures greater than 15,000 psi
x. An anti-Withdrawal Device must be used on all flex lance, rigid lance and line moling
jobs. The anti- withdrawal devices must be securely attached to the equipment being
cleaned.
xi. Anti-withdrawal devices used on tube sheets when flex lancing or rigid lancing must
include use of a snorkel that does not exceed 1’’ (inch) clearance from the tube-sheet.
xii. In vertical tube sheet applications, to prevent the potential of a water-cut to the foot,
that gap (between snorkel and tube sheet) must be protected from the lance operator
by utilizing some type of physical barrier e.g. 4”x4”x12” (inches) piece of angle iron or
a 2”x4”x12” (inches) board. In addition to use of anti-withdrawal devices when line
moling, a Stinger must be attached to the end of the nozzle, that is at least 1½ times
the I.D. of the piping being cleaned.
xiii. The combined length of the hose connection, stinger, and nozzle shall be a minimum
of 1.5 times the diameter of the pipe being cleaned unless the pipe being cleaned has
a "T" then the combined length shall be 3 times the diameter of the largest pipe.

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 There is a minimum total length for hydro-blasting guns. The minimum total length of
a hydro-blasting gun (hand operated control valve, lance and nozzle resembling a gun
layout) shall be 66 inches from the shoulder pad to the nozzle.
xiv. A moleing device or lance shall require a minimum 2 feet end identification when a
pipe flange is available.
xv. If no flange or other means to secure anti-reversal device is used, the hose/lance
shall require a 2 feet end identification marking and a 4 feet end identification marking
of a different colour or different pattern. The hydro-blasting system shall not be
operated above the lowest working pressure of any of its components. A system is not
to be operated above the lowest working pressure (40% of the burst pressure) of any
of its components.

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5 PAINTING AND COATING
6.1 INSPECTION OF EQUIPMENT

The following painting and coating inspecting equipment shall be kept available during
hydroblasting and painting operations:
i. A temperature gauge and a hygrometer
ii. Surface temperature thermometer
iii. Wet film thickness gauge (25µm to 3 mm)
iv. Dry film thickness gauge (for DFT measuring 25 µm to 5 mm)
v. Holiday detector (carbon impregnated neoprene or rolling spring types of
electrodes)
vi. Crest voltmeter (for daily calibration of holiday detector)
vii. Roughness inspecting instrument
viii. Spark leak detector (for shrink sleeve)
ix. The above inspecting equipment shall be checked periodically (especially for the
wet film thickness gauge).

6.2 INSPECTION OF EQUIPMENT

The equipment below shall be used in addition to hydroblasting equipment and shall
be in accordance to material manufacturer’s recommendation and as approved by
FPSO Owner.
a) Power tool cleaning equipment
b) Air spray equipment
c) Airless spray equipment (necessary)
d) Brushes
e) Masking Tape
f) High density battery powered light for internal coating
g) Ventilation equipment
h) All the equipment shall be ready and checked as being in good working order prior
to and during blasting and coating operations and shall be kept in a sufficiently
clean condition to avoid surface and/or coating contamination.
i) Blasting materials shall be ready and checked as per the project requirements and
standards. Especial for the moisture content shall be less than 2%, radius shall be
around 0.5mm~1.5mm for 95% of blasting materials, sieve diameter shall be

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 around 40~48 sieve/m 2 for radius 1.2mm materials and 372~476 sieve/m 2 for
radius 0.3mm materials, for other requirements materials shall meet project and
standard requirements.

6.3 ATMOSPHERIC CONDITIONS

The applicator shall measure the ambient conditions at regular intervals prior to and
during blast cleaning and coating, and keep records of prevailing temperature,
humidity and dew point. No surface preparation or application of material may take
place when steel surface temperatures are less than 3C above the dew point or
above 5C at the time of coating.

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6 SURFACE PREPARATION
Surface preparation shall be in accordance with per paint manufacturer’s instruction
and project specification with hydroblasting, power tool, hand tool or solvent cleaning.
Surface preparation shall be done in accordance with NACE No.5 / SSPC-SP12 and
project specifications as approved by the CLIENT. Abrasives shall not be used except
otherwise stated by the CLIENT.

7.1 ATMOSPHERIC CONDITIONS

Alternative surface preparation methods may be used when hydroblasting is unsafe or
impractical due to surface geometry and inaccessible.

7.2 REMOVAL OF CONTAMINANTS

All organic substance such as oil grease and other contaminants shall be removed in
accordance with per specification prior to hydroblasting operations.

7.3 REMOVAL OF WELD SPATTER

All rough welds, burrs and sharp surface projections shall be ground smooth and all
weld spatter shall be removed prior to hydroblasting operations.

7.4 COMPRESSED AIR

The compressed air supply used for surface preparation must be of sufficient pressure
and volume to prepare the surface to the degree specified and shall be free of oil and
water.

7.5 POWER-TOOL CLEANING

Power-tool cleaning shall be to a visual standard in accordance with ISO 8501-1 St 3.
Power-tool cleaning shall be done using abrasive or wire-type power discs.
Power-tool cleaning shall extend a minimum of 25mm distance into adjoining coated
surfaces.
7.6 HAND-TOOL CLEANING
Hand-tool cleaning is the least effective of the surface preparation methods, but it may
be used for touch-up/repair maintenance with certain surface-tolerance coating
systems. Hand-tool cleaning shall be a visual standard in accordance with ISO 8501-1

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 St 2. Cleaning shall be done with brushes, scrapers, sanders or other hand impact
tools.

7.7 SOLVENT CLEANING

Solvent cleaning shall be done in accordance with SSPC-SP1 “Solvent Cleaning’ on
the surface examined for the presence of oil or grease.

7.8 HYDROBLASTING AND POWER-TOOL / HANDLE CLEANING INSPECTION

After hydroblasting, surface profile shall be checked with the roughness inspecting
instrument and the result shall meet project requirement and standard. The total
hydroblasting quality shall be checked by photo comparison method.

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7 PAINT MIXING AND THINNING
Paint shall be mixed in accordance with manufacturer’s instruction and as per
specification.
a. Mixing method shall be applied in accordance with the paint manufacturer’s
recommendation.
b. All pigmented paint shall be strained after mixing except where application
equipment is provided with strainers. Strainers shall be of a type to remove only
skins and undesirable matter but not to remove the pigment.
c. Where a skin has formed in the container, the skin shall be cut loose from the sides
of the container, removed and discarded. If the volume of such skins is more than
2% of the remaining paint, the paint shall not be used.
d. Mixing in open containers shall be done in a well-ventilated area away from sparks
or flames.
e. Dry pigments which are separately packaged shall be mixed into paints in such a
manner that they are uniformly blended and all particles of the dry powder are
wetted by the vehicle.
f. Paint shall not remain in spray pots, painter buckets, etc., overnight, but shall be
stored in a covered container and re-mixed before use.
g. Catalysts, curing agents, or hardeners which are separately packaged shall be
added to the base paint only after the latter has been thoroughly mixed. The proper
volume of the catalyst shall then be slowly poured into the required volume of base
with constant agitation.

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8 PAINTING AND COATING APPLICATION
9.1 GENERAL
a. Painting / coating shall be applied in accordance with the paint manufacturer’s
instructions and this procedure, whether air spray, airless spray or brush.
b. Field painting on steel surfaces. Surface preparation shall be finished in
accordance with this procedure before application of primer.

9.2 COATING OF NEW CONSTRUCTION

Coating application on new construction shall conform to the following:
a. Field painting on shop coating. Any previously applied shop coating must be dry and
free of dirt, oil, and other contaminants.
b. Damaged areas of shop applied coatings shall be touched-up with the same type of
paint as the shop unless otherwise specified. This touch up shall include cleaning
and painting of field connection welds or rivets, and all damaged or defective paint
and rusted areas.
c. Shop coated steel members shall preferably be field painted after erection of such
members is completed. Steel members may be field painted on the ground before
erection, provided such painting is touched-up where damaged, with the same
number of coats and types of paints after erection. The top coat shall be applied
after erection.
d. When the type of paint for field coating is not specified, it shall be approved and
verified whether the paint to be used is compatible with the shop applied coat(s).
e. Surfaces (other than contact surfaces) of fabricated assemblies that is accessible
before erection but which will not be accessible after erection shall receive all field
coats of paint before erection.
f. All field welds and all areas within 4 inches of welds shall be cleaned before
painting, using surface preparation methods at least as effective as those specified
for the structure itself; all welds shall either be blast cleaned, or thoroughly power
brushed.
g. Cold-tangled belt will be used as per the project requirement. Blasting shall be done
before start construction of cold-tangled belt. Priming paint shall be done according
to the cold-tangled belt vendor specification before start cold-tangled belt. Gluing
shall be done tight and without bubble. Wrapping shall be finished immediately once

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 gluing is finished and the overlap joint is about 20-25mm. Leak hunting(electric)
shall be checked after wrapping and the final shaped rubber shall be done if
necessary as per the vendor specification. Prior to field coating, the finish coat shall
be removed from the overlap area.
h. Shrink sleeve will be used as per the project requirement. Blasting and rust cleaning
shall be done and meet the Sa 2.5 requirements. Groove shall be prepared at the
pipe port and the slope shall be no more than 30 degree. After construction every
shrink sleeve shall be checked, the surface shall be smooth and no bubble, the
connection joint between pipe groove and shrink sleeve shall be tight, no gap and
carbonization. Filling port shall be checked by spark leak detector within pinhole
inspection method and the pinhole defects shall be fixed.

9.3 PAINT APPLICATION

9.3.1 Spray Application
All spray application of paint whether air, or airless spray, shall be in accordance with
the following:
1) The equipment used shall be suitable for the intended purpose, shall be capable of
properly atomizing the paint to applied, and shall be equipped with suitable pressure
regulators and gauges. The equipment shall be maintained in proper working
condition at all times.
2) Paint ingredients shall be kept uniformly mixed in the spray pots or containers
during paint application either by continuous mechanical agitation or by intermittent
agitation as frequently as is required.
3) Paint shall be applied in a uniform layer with a 50% overlap at the edges of the
spray pattern, and 20 - 25 cm away from the surface.
4) All runs and sags shall be removed immediately or the coating shall be removed
and the surface repainted.
5) Brush or daubers shall be painted for cracks, crevices, blind areas of all rivets and
bolts, and all other inaccessible areas.
6) Paint manufacturer’s instructions regarding pot life, drying /curing intervals between
successive coats and final curing periods before assembly or transport, shall be
followed.

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7) Each layer of paint shall be allowed to dry for a period of time within the limits
prescribed by the paint manufacturer, before the next layer is applied.
8) No coating shall be applied to edges prepared for field welds or within 50mm of
these edges, except for a prefabrication or welding (shop) primer which shall be
limited to a maximum 25 microns.
9.3.2 Airless Spray Application
1) Airless or high pressure spray application of paint shall be in accordance with all of
the provision of this specification and in addition shall comply with following:
2) The air pressure to the paint pump shall be adjusted so that the paint pressure to
the gun is proper for optimum spraying effectiveness in accordance with paint
manufacturer’s recommendation.
3) The trigger of the gun should be pulled fully open during all spraying to insure
proper application of paint.
4) Airless paint spray equipment shall always be provided with an electric ground wire
in the high pressure line between the gun and the pumping equipment. Further, the
pumping equipment shall be suitably grounded to avoid the build-up of any
electrostatic charge on the gun. The manufacturer's instruction is to be followed
regarding the proper use of the equipment.
9.3.3 Brush Application
1) Brush application shall be done in areas which cannot be properly sprayed and for
touch up maintenance where spray application is not practical.
2) Brush shall be of a type and size which permits proper application of paint. Round
or oval brushes are most suitable for irregular surfaces such as bolts, weld, pitted
steel, etc. Wide flat brushes shall be used for large flat areas.
3) Paint shall be worked into all corners and crevices.
4) Rugs and sags or other defects will not be permitted
9.3.4 Critical Internal Coating
1) For critical internal coating of tanks /and vessels. All crew supervisors,
hydroblasting personnel and paint coating Applicators shall be fully conversant
with all aspects of the hydroblasting and coating operations. All equipment such as
lighting, air extractors shall conform to safety requirements.

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 2) The method of application used shall be governed by the coating manufacturer’s
recommendation for the particular coating being applied. Method of application
shall also be considered by the immediate vicinity where work will be carried out.
3) Warning notes shall be clearly paint specified on the external surface of all
internally coated vessels: “INTERNALLY COATED – DO NOT WELD – HANDLE
WITH CARE”.
9.3.5 Protection Cleaning
1) After hydroblasting, materials shall be kept in a dry and clean space and shall be
painted at the required time. Once there is pollution appeared or flash rust on the
surface, blower or hand cleaning shall be used to clear the impurities. For the
serious pollution flash rust cannot be cleaned, and no painting shall be carried out
and surface or materials shall be re-cleaned and inspected before painting.
2) After painting/coating materials shall be kept in a clean and no pollution situation
to prevent any secondary pollution. Once the secondary pollution is taken,
materials shall be resent for blasting as un-blasted materials.

9.4 DRYING/CURING
1) All drying and re-coat times shall be that specified by manufacturer.
2) Curing shall conform to the manufacturer’s recommendations. Force curing shall
only be done in accordance with manufacturer’s recommendations.
3) Paint shall be protected from rain, condensation, contamination until dry to fullest
extent practical.
4) No paint shall be subjected to immersion before it is thoroughly dried or cured.

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9 INSPECTION AND TESTING
10.1 GENERAL
It shall be the responsibility Morrison and Sons Incorporated to conduct the test and
inspection as follows in accordance with per paint manufacturer’s application
instruction and project specification. The following tests shall be performed at start-up
and at specified intervals.

10.2 CHECKING ENVIRONMENTAL CONDITIONS

Before commencing work on surface preparation and coating, the atmospheric
temperature and relative humidity shall be measured in order to determine the dew
point. Relative humidity readings shall be measured a maximum of every 2-hour
interval.
Following determination of the dew point, the steel surface temperature shall be
measured at regular 2-hour intervals. The steel surface temperature shall be 3ºC or
more above the dew point during surface preparation as well as during coating. During
coating operations.

10.3 VISUAL CHECK FOR SURFACE PREPARATION AND FINISHED COATING

1) All coatings shall be visual checked for compliance with the specified surface
cleanliness finish standard and freedom of contamination before coating
application.
2) The finished coating surfaces shall be of uniform color and free from pinholes,
peeling, sags, and runs. etc.

10.4 FILM THICKNESS MEASUREMENT

The dry film thickness of individual coats and of the total coating system shall be
checked at 5 random locations over areas representative of the work in progress.
There shall be a check of at least one area on each horizontal, vertical and curved
surface. For internal coating of tanks and vessels, a minimum of 10 random areas
shall be checked.
1) With the exception of areas such as welds, crevices, etc. the specified minimum dry film
thickness shall not be exceeded by more than 50%.

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2) Dry film thickness shall be measured with a coating thickness gauge suitable for given
type of coating thickness range and substrate material (magnetic or nonmagnetic).

10.5 HOLIDAY TEST

Holiday test is required for the internal lining of tanks and vessels. Internal linings shall
be holiday free. Holiday testing is not a standard requirement for externally pained
surfaces.
1) Holiday detection shall be carried out using equipment acceptable to CLIENT on
surfaces which are at ambient temperature and free from moisture. If the surface
temperature is above 195F (90C). Holiday detection shall not be conducted.
2) The electrode used for locating holidays shall have direct contact with the coating,
(with no visible gaps) and provide complete coverage of the whole coated surface.
For epoxy coating systems carbon impregnated neoprene or rolling spring types of
electrodes shall be used.
3) The travel rate of the detector electrode shall not exceed 1 feet /secs (0.3m/s) and
shall not be allowed to remain stationary while the power is on.
4) Voltage will be determined according to material applied and manufacturer’s
requirement.
5) All holidays, imperfections and damaged areas shall be clearly identified immediately
with a waterproof marker. All markings shall be sufficiently distant from the holiday,
imperfection or damaged area to allow surface preparation and patching to take
place without detriment to the adhesion of the coating.

10.6 REPAIR OF DAMAGED AREAS

Damaged painting and coating, and/or coating which does not pass the holiday
detection test shall be repaired and retested to the satisfaction of the CLIENT.
1) The coating materials used for repair and maintenance shall be the same as the
original materials.
2) The surface preparation method for repair will depend upon the size of areas to be
coated and the repair coating materials required.
3) The area of the coating damage or holiday, along with the adjacent area of coating
for a minimum of 25 mm on all sides shall be thoroughly prepared / abraded.
4) The painting repair method shall be as per paint manufacture’s specifications.

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5) Repair coating shall be applied so that the final coat overlaps the surrounding sound
coating for a minimum 25 mm.

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10 SAFETY
Safety in hydroblasting and painting operations is paramount. Both operators and
supervisors must be fully conversant with all safety requirements associated with
hydroblasting and cleaning, scaffolding and access platforms, ventilation in enclosed areas,
as per project safety manual.
All spraying equipment shall be earthed, all high lines checked daily, operators shall wear
all approved safety equipment at all times when spraying operations are in progress, and
warning signs erected when blasting work is in progress.

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11 QUALITY RECORD AND INSPECTION REPORT
Daily reports shall be assured on all painting activities and recorded on blasting / painting
inspection reports. These records shall be maintained and monitored by QC engineer who
together with CLIENT shall sign on all inspection reports
The inspection report shall be filled up by QC engineers, in which the content shall reflect
status of the inspections and quality in truth. Project Quality Plan shall contain the forms of
the construction quality record and the inspection report.

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12 REVISION NOTE
This procedure shall be revised if CLIENT deemed necessary for the purposed work it is
prepared and upon completion of project, a review of new construction practice / new site
information or as requested by the CLIENT.

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 Morrison and Sons
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PROJECT:

13 Appendix A: Visual Surface Preparation Requirements

Surface Description of
Cleaned Surface Appearance Description of Flash Rusted Surface
Requirements Cleaned Surface
Surface shall be cleaned to a finish; free of all
visible rust, dirt, previous coatings, mill scale, and
Steel surface exhibits no visible flash rust Cleaned to bare
WJ-1 foreign matter when viewed without
when viewed without magnification. substrate
magnification. Discoloration of the surface may
be present.
Steel surface exhibits light, small
Surface shall be cleaned to a dull, mottled finish;
quantities of a yellow / brown rust layer on
free of all visible oil, grease, dirt, and rust except
the steel substrate when observed or
for randomly dispersed stains of rust, tightly Very thorough or
viewed without magnification. The rust or
WJ-2 adherent thin coatings, and other tightly adherent substantially
discoloration may be evenly distributed or
foreign matter when viewed without cleaned
present in patches, but it is tightly adherent
magnification. The staining shall be limited to a
and not easily removed by lightly wiping
maximum of 5% of the surface.
with a cloth.
Steel surface exhibits a moderate layer of
Surface shall be cleaned to a dull, mottled finish;
yellow / brown rust that obscures the
free of all visible oil, grease, dirt, and rust except
original steel surface when viewed without
for randomly dispersed stains of rust, tightly
magnification. The rust layer may be Thoroughly
WJ-3 adherent thin coatings, and other tightly adherent
evenly distributed or present in patches, cleaned
foreign matter when viewed without
but it is reasonably well adherent and
magnification. The staining shall be limited to a
leaves light marks on a cloth that is lightly
maximum of 33% of the surface.
wiped over the surface.
Steel surface exhibits a layer of heavy
red / brown rust that hides the initial
Surface shall be cleaned to a finish; free of all surface condition completely, viewed
visible oil, grease, dirt, dust, loose mill scale, without magnification. The rust may be
WJ-4 loose rust, and loose coating when viewed evenly distributed or present in patches, Lightly cleaned
without magnification. Any residual material shall but the rust is loosely adherent, easily
be tightly adherent. comes off, and leaves significant marks on
a cloth that is lightly wiped over the
surface.
Morrison and Sons
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PROJECT:
 Morrison and Sons
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PROJECT:

14 Appendix B: Typical Pressurized Water-jetting Systems

 Morrison and Sons
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PROJECT:

15 Appendix C: Hydroblasting Operation Checklist