Petroleum Development Oman L.L.C.

UNRESTRICTED Document ID : SP-1246

April 2010 Filing key : xxxx

Specification for
Painting and Coating of
Oil and Gas Production Facilities

PART 3

MAINTENANCE OF
COATING SYSTEMS

Keywords:

Coating
Compatibility
Defects
Inspection
Maintenance
Painting
Repair
Renovation
Refurbishment
Scale of rusting
Surface preparation

This document is the property of Petroleum Development Oman L.L.C. Neither the whole nor any part of this document may be disclosed
to others nor reproduced, stored in a retrieval system, or transmitted in any form by any means (electronic, mechanical, reprographic
recording or otherwise) without prior written consent of the owner.
Specification for Painting and Coating of Oil and Gas Production Facilities – Part 3 Version 2

Version No. Date Author Scope / Remarks

ERD-48-01 Jan 89 ETH/5 Original ERD Document
SP-1246 Ver.0 May 2002 OTT/11 Updated and in new PDO format
SP-1246 Ver.1 July 2003 TTO/11 For Issue
SP-1246 Ver.2 April2010 UEC/121 For Issue

INSTRUCTIONS TO USER
Make sure this is the latest issue of this specification. Refer to the EMDS for the last issue date.

Where this Specification refers to DEPs and International Standards, it refers to the issues that were in-use when
the author wrote this Specification. Exceptions are references to specific issues. If you use DEPs or
International Standards with this Specification, make sure you use the relevant issues.

Do not change this Specification without approval. Only the Custodian, the Corporate Functional Discipline
Head (CFDH) who owns this Specification, can give approval for changes. If you think the Specification is not
correct, write your comments on a copy of the User Comment Form. The form is the last page of this
Specification.

SP-1246 2 April 2010

Specification for Painting and Coating of Oil and Gas Production Facilities – Part 3 Version 2

Contents

1 Preface .............................................................................................................................................5
1.1 Background ...................................................................................................................................................... 5
1.2 Applicability .................................................................................................................................................... 5
1.3 Language and Units of Measurement .............................................................................................................. 6
2 Introduction ....................................................................................................................................7
2.1 General............................................................................................................................................................. 7
2.1.1 Scope ....................................................................................................................................................... 7
3 Maintenance Painting and Coating Repair ...............................................................................8
3.1 General............................................................................................................................................................. 8
3.2 Maintenance Painting Philosophy.................................................................................................................... 8
3.3 Assessment of Old Coating.............................................................................................................................. 8
3.3.1 Coating Surveys ....................................................................................................................................... 8
3.3.2 Extent of Surface Corrosion..................................................................................................................... 9
3.4 Types of Coating Maintenance ........................................................................................................................ 9
3.4.1 Preventive Cleaning ................................................................................................................................. 9
3.4.2 Spot Repair .............................................................................................................................................. 9
3.4.3 Renovation ............................................................................................................................................... 9
3.4.4 Refurbishment.......................................................................................................................................... 9
3.4.5 Paint Colours ......................................................................................................................................... 10
3.5 Repair of Coatings ......................................................................................................................................... 10
3.5.1 Defective and Damaged Coatings .......................................................................................................... 10
3.5.2 Margin of Sound Existing Coating ........................................................................................................ 10
3.5.3 Loss of Gloss in Topcoats ...................................................................................................................... 11
3.5.4 Stainless Steel Substrates Coating ......................................................................................................... 11
3.5.5 Repair of Galvanised Steel Surfaces Coating ........................................................................................ 11
3.5.6 Repair of Pipelines and Flowlines Coating ............................................................................................ 11
4 Inspection ......................................................................................................................................12
4.1 Visual Inspection of the Old Coating............................................................................................................. 12
4.2 Classifying Surface Condition ....................................................................................................................... 12
4.3 Testing the Mechanical Properties of the Old Coating .................................................................................. 15
4.3.1 Measuring Thickness of the Old Coating .............................................................................................. 15
4.3.2 Adhesion (including intercoat) of the Old Coating ................................................................................ 15
4.3.3 Embrittlement of the Old Coating.......................................................................................................... 15
4.3.4 Under Rusting or Insufficient Surface Preparation Prior to the Original Painting................................. 15
4.3.5 Defects in Vessel and Tank Internal Coatings ....................................................................................... 15
4.3.6 GRE Lining............................................................................................................................................ 16
4.4 Detection and Removal of Surface Salts........................................................................................................ 16
4.4.1 Test for Salt Contamination ................................................................................................................... 16
4.4.2 Removal of Soluble Salts and Conductivity Tests ................................................................................. 16
4.5 Coating Compatibility.................................................................................................................................... 16
4.5.1 Overcoating Existing Coating Systems.................................................................................................. 17
4.5.2 Paint Applicability ................................................................................................................................. 17
5 Selection Guide for Maintenance Painting Schedules ...........................................................18
5.1 Schedule Selection ......................................................................................................................................... 18
6 Related Business Control Documents .......................................................................................22
7 Appendix A Glossary of Definitions, Terms and Abbreviations ..........................................23
7.1 Standard Definitions ...................................................................................................................................... 23
7.2 Abbreviations ................................................................................................................................................. 24
8 User Comment Form...................................................................................................................25

SP-1246 3 April 2010

Specification for Painting and Coating of Oil and Gas Production Facilities – Part 3 Version 2

Tables

Table 3 Degree of Rusting ............................................................................................................................................. 9

Table 4a Repair & Maintenance Requirements for External Coatings .......................................................................... 10
Table 5b Repair and Maintenance Requirements for Internal Coatings ........................................................................ 10

SP-1246 4 April 2010

Specification for Painting and Coating of Oil and Gas Production Facilities – Part 3 Version 2

1 Preface
1.1 Background
This Specification SP-1246, covers the minimum requirements for protective painting and coating systems,
materials and application methods for the internal and external surface of steel structures and equipment within
the oil and gas production facilities.

Relevant structures and equipment include aboveground and buried onshore tanks, vessels, in-station pipework,
structural steel, and electrical and mechanical equipment.

Whilst the Specification is directed predominantly at protection of onshore oil and gas installations, it also
covers external protective coating of marine facilities such as jetties, mooring buoys, barges and launches.

Internal surfaces of pumps, valves and other mechanical equipment requiring special protective treatments, are
not dealt with in this Specification. For further guidance consult UER/CFDH Materials and Corrosion.

The external coating of new pipelines and existing pipelines requiring rehabilitation are covered in the
alternative Specifications and procedures listed below.

GU-368 Guidelines For The Protection Of Buried Sections Of Surface Laid Pipelines/Flowlines
PR-1180 Procedure for Qualification of Pipeline Rehabilitation Coating Systems
DEP 31.40.30.31-Gen. Technical Specification for External Polyethylene and Polypropylene Coating for Line
Pipe
DEP 31.40.30.32-Gen. Technical Specification for External Fusion-bonded Epoxy Powder Coating for Line
Pipe
DEP 31.40.30.37-Gen External Field Joint And Rehabilitation Coatings System For Line Pipe .

1.2 Applicability
All coating work shall be carried out in accordance with this Specification. If a variance is required then
approval in writing from the Custodian UER/CFDH Materials and Corrosion is required.

This Specification is not applicable retroactively.

This specification does not apply to concrete structures. For concrete structures in corrosive environment
consult UER/CFDH Materials and Corrosion.

This is Part 3 of a five part Specification and must be read in conjunction with Parts 1, 2,4 and 5.

PART 1 specifies technical and related requirements. This Part includes performance tests and acceptance
criteria for assessing the acceptability of paint/coating/lining systems for each service specified in Parts 2 and 3.

PART 2 contains recommended protective coating systems for the following categories with respect to new
construction painting/coating activities:

- External surfaces of carbon steel structures, piping and equipment, onshore and marine
- External surfaces of buried carbon steel structures, piping and buried sections of above ground
flowlines and pipelines (except Class I and Class II pipelines)
- Internal surfaces of tanks and vessels
- Stainless steel and galvanised piping and equipment
- Areas beneath insulation
- Specialist applications

This Part also gives descriptions of the generic types of paint used for new construction projects. The
descriptions apply equally to the maintenance paint systems presented in Part 3.

SP-1246 5 April 2010

Specification for Painting and Coating of Oil and Gas Production Facilities – Part 3 Version 2

Protective coatings for new pipelines based on Polyethylene (PE), Polypropylene (PP) or Fusion Bonded Epoxy
(FBE), are not covered in this Specification but the general good practices described in this volume are equally
applicable to the coating of line pipe.

PART 3 contains recommended maintenance coating systems for the following categories with respect to
location and painting/coating activities and inspection of old coatings:

- External coatings on carbon steel structures, piping and equipment, onshore and marine
- External coatings of below ground carbon steel structures and piping including Class I and
Class II pipelines
- Internal coated surfaces of tanks and vessels
- Stainless steel and galvanised piping and equipment

PART 4 contains the general requirements for surface preparation and application of coatings to the categories
stated in Parts 2 and 3. This Part contains HSE advice and general inspection requirements.

PART 5 Contains the list of approved coating systems and is a live document that will be updated by UER.
This includes coating systems that have been grandfathered in.

New Projects

PARTS 1, 2 and 4 apply in their entirety to new projects where painting and coating activities are carried out at
site or in the shop.

For painting and coating of package items, carried out prior to delivery to site or to existing facilities, the
requirements, stated in PARTS 1 and 4, apply in their entirety, whilst those of PART 2 apply where applicable.

Maintenance

Where maintenance painting is to be done, PDO’s technical requirements are stated in PART 1 and those
sections of PARTS 3 and 4 as appropriate, dependent upon the Scope of Work.

1.3 Language and Units of Measurement

This specification uses and requires the use of the International System (SI) units of measurement in all
documentation. Paint film thickness are expressed in microns, 1micron is 0.001mm.

SP-1246 6 April 2010

Specification for Painting and Coating of Oil and Gas Production Facilities – Part 3 Version 2

2 Introduction
2.1 General
This Part of Specification SP-1246 is intended to facilitate the maintenance of coated steel structures in PDO oil
and gas facilities and for those inspecting such structures. Regular inspection and timely maintenance of
existing coatings generally proves attractive by saving unnecessary costs for total removal of existing coating
and enabling relatively sound old coatings to continue to usefully contribute to the further protection of the
structure.

It is therefore advisable to have maintenance carried out as soon as the first signs of serious degradation become
apparent, such as chalking, cracking, flaking, rust spotting etc.

Vendors proposed repair systems will be considered by the UER CFDH of materials and corrosion provided
they are compatible with existing systems.

2.1.1 Scope

This Specification covers the minimum requirements for maintenance painting of coated steel structures in PDO
oil and gas facilities.

This Specification is intended for use by Petroleum Development Oman LLC in specifying maintenance
painting and coating requirements.

This specification covers repair to pipelines covered by the above specifications, procedures and guidelines.

Cases not covered in this Specification shall be discussed with the Document Custodian UER/CFDH Materials
and Corrosion.

SP-1246 7 April 2010

Specification for Painting and Coating of Oil and Gas Production Facilities – Part 3 Version 2

3 Maintenance Painting and Coating Repair

3.1 General
This Specification will allow Engineers and Inspection/Vendor personnel to select the appropriate PDO
approved maintenance painting and coating system for existing steel structures and to include the correct
painting and coating specifications in their maintenance contracts. The proposed maintenance system will
require approval by PDO.

For the selection of painting and coating systems for new construction projects, refer to Part 2 of this
Specification.

3.2 Maintenance Painting Philosophy

The repair and rehabilitation of existing protective coatings comprises two types of activity:

Large-scale maintenance required because extensive breakdown of the existing protective system has impaired
the continued technical integrity of the structure. Localised repairs are not economically justified and the
structure will need to be treated in line with the requirements for new construction, given in Part 2 of this
Specification.

Local coating repair to correct premature deterioration through ageing and corrosion processes.

To determine the correct course of action, it is necessary to establish:

- the nature and extent of coating deterioration by assessing the condition of the existing coating
- the appropriate maintenance coating system

This can be done by visual assessment in accordance with ISO-4628 and then by applying the appropriate
maintenance coating system depending on the level of deterioration determined from the visual assessment.
If required, the old coating system can be further inspected and the mechanical properties of the coating
determined. This particularly applies to old coatings that have been in immersion service inside tanks and
vessels where a full inspection is required.

3.3 Assessment of Old Coating

The precise condition assessment of old coatings and the resulting consequences for maintenance are of great
importance for successful coating repair and rehabilitation. The following sections, together with the industry
pictorial reference standards, contain details of possible conditions of old coatings, testing methods and advice
as to what should be done in individual cases.

The assessment should be performed prior to starting maintenance work, particularly if trial areas have to be
applied in order to find the most suitable coating for the individual contract.

The methods used to assess the condition of protection coatings on buried pipelines will differ from those used
to examine the deterioration of paintwork on accessible structural and advice should be sought from
UER/CFDH Materials and Corrosion.

3.3.1 Coating Surveys

Equipment and structure, identified for coating maintenance, shall be cleaned to a standard sufficient for the
effective inspection of the coated surface. Cleaning may be performed using fresh water, detergents, light
scraping or sweep blasting.

Representatives of the Materials and Corrosion Department shall estimate the amount of coating damage and the
extent of corrosion of the underlying surface. Where required, Inspectors shall assess the quality of the
remaining coating by carrying out tests for coating thickness, adhesion and presence of holidays.

SP-1246 8 April 2010

Specification for Painting and Coating of Oil and Gas Production Facilities – Part 3 Version 2

For buried pipelines the results from the DCVG survey can be used to identify the areas that require coating
repair. Repairs may also need to be carried out at dig sites used to verify the internal condition of the pipeline.

3.3.2 Extent of Surface Corrosion

The amount of surface rusting associated with coating breakdown that is visually observed may be
quantitatively assessed by referring to the degree of rusting as specified in the international comparative
standard, ISO 4628-3.

Table 1 Degree of Rusting

Degree of Rusting Area Rusted
%
ISO 4628-3 European rust scale ASTM 610
Ri 0 Re 0 10 0
Ri 1 Re 1 9 0.05
Ri 2 Re 2 7 0.5
Ri 3 Re 3 6 1.0
Ri 4 Re 4 4 <10
Ri 5 Re 5 1 to 2 >10

Whilst the ISO Standard is the one most appropriate to PDO operations, the alternative previously used
European and American standards are shown for comparison.

The degree of rusting is applicable only to carbon and low alloy steels. The degree of corrosion and coating
deterioration observed on buried structures shall be checked with representatives of UER.

The particular nature of coating breakdown on high alloy and stainless steels makes these criteria irrelevant for
assessing deterioration.

3.4 Types of Coating Maintenance

3.4.1 Preventive Cleaning

Where there has been no coating breakdown (ISO 4628-3 grade Ri 0), it is usually sufficient to adopt a
programme of regular washing to preserve the integrity of the coating system. Periodic removal of salts, dirt,
oil, grease etc by hosing with fresh water or detergents where necessary will reduce the aggressive impact of the
environment and extend the period before coating rehabilitation.

3.4.2 Spot Repair

For a paint film that, apart from a few isolated rust spots, is sound and well-adherent with less than Ri 3 or
better, the locally corroded areas may be spot cleaned and touched up with a compatible coating to full film
thickness. All corrosion products should be removed and the interface between the cleaned and sound areas
properly prepared.

3.4.3 Renovation

Where the degree of rust spotting is more extensive and reaches between Ri 3 and less than Ri 4 and the
remaining coating is in a sound condition as in 3.4.2 above, then the same surface preparation should be
adopted but a full top coat should be applied over the entire surface. For internal coating systems Ri 2 and
below can be renovated.

3.4.4 Refurbishment

For external coating systems that show coating damage over Ri 4, the coating will need to be completely
removed and a new protective system applied in accordance with the requirements for new construction in Part
2 of this Specification. For internal coating systems that show more than level Ri 3 of deterioration then the
coating will need to be completely removed and a new system applied.

SP-1246 9 April 2010

Specification for Painting and Coating of Oil and Gas Production Facilities – Part 3 Version 2

Tables 2a & 2b below summarises the typical types of coating maintenance based on the existing coating
condition.

Table 2a Repair & Maintenance Requirements for External Coatings

Paint Surface Condition Rust Scale Maintenance Minimum Recommended
(ISO 4628- Type Surface Treatment
3) (ISO 8501-1)
Contaminated Ri 0 Preventive -
No corrosion cleaning
<1% of surface corroded Ri 3 Spot repair St 2 / Sa 1
>1% of surface corroded Ri 3 Renovation St 3 / Sa 2½
< 10% of surface corroded Ri 4 and Refurbishment Sa 2½
Ri 5

Table 3b Repair and Maintenance Requirements for Internal Coatings

Paint Surface Condition Rust Scale Maintenance Minimum Recommended
(ISO 4628- Type Surface Treatment
3) (ISO 8501-1)
Contaminated Ri 0 Preventive -
No corrosion cleaning
<1% of surface corroded Ri 3 Spot repair St 3 / Sa 2½
>1% of surface corroded Ri 3 Removal & As required for new
replacement construction

3.4.5 Paint Colours

The colours of alternate paint coats of the generic and proprietary systems listed in Schedules of Section 5 of
this Specification should be contrasting.

The finish colours of paint systems and the colours for piping identification/banding and safety shall be as
specified in Section 3.6 of Part 1 of this Specification.

3.5 Repair of Coatings

3.5.1 Defective and Damaged Coatings

Scraping, abrading, wire brushing or sweep blasting shall be used to remove coatings that are defective or have
been damaged, during handling or exposure. Once a suitable surface has been obtained, it shall be overcoated
with a repair coating in line with the Coating Schedules contained in this Specification.

Damaged areas of primer or exposed underlying substrate shall be spot blasted to bare metal. In sensitive or
inaccessible locations, mechanical cleaning, using power wire brushes or needle guns may be used in preference
to grit blasting. Surface preparation, coating application and inspection shall generally be in accordance with the
requirements of Part 4 of this Specification. For large scale repair work a Method Statement and ITP shall be
submitted to PDO for approval.

3.5.2 Margin of Sound Existing Coating

For a distance of 25mm, the edges of sound coating adjacent to the damaged area, shall be feathered to a fine
tapered interface by sanding or abrasive cleaning, taking care not to damage the underlying intact coating. The
repair coating shall be applied to the existing sound in accordance with the Manufacturer’s instructions.

SP-1246 10 April 2010

Specification for Painting and Coating of Oil and Gas Production Facilities – Part 3 Version 2

3.5.3 Loss of Gloss in Topcoats

The surfaces of topcoats that have lost their gloss due to over exposure shall be cleaned and overcoated in
accordance with MPS-1.

3.5.4 Stainless Steel Substrates Coating

The need to repair the coatings on stainless steel will depend on the result of a visual inspection of the existing
coating (including the condition of any insulation). The degrees of rusting given in Table 1 are not applicable to
stainless steel substrates. Consult UER/CFDH Materials and Corrosion for further advice.

3.5.5 Repair of Galvanised Steel Surfaces Coating

Areas of slightly damaged galvanising shall be lightly power tool cleaned to ISO 8504-3 St 3 and treated with
two coats of an approved zinc-rich epoxy primer in line with the requirements of the Schedules in this
Specification. Larger areas shall be blast cleaned to ISO 8501-1 Sa 2½. Note repair of coated galvanised steel is
in accordance with MPS-6.

3.5.6 Repair of Pipelines and Flowlines Coating

For the repair of pipeline coatings in service one of the approved systems specified in PR-1180 or heat
shrink sleeves shall be used as appropriate to the type of defect and coating type as shown in the table below.
This is not applicable to shop/site repair of new line pipe coatings.
Table.3 Buried Structures Repair Options

Coating Defect Repair

Pipelines
FBE/CTE
Small damaged area <30cm wide
Large damaged area > 30cm wide
3 Layer Minor defect /pinhole < 25cm2
Polyethylene (PE)
Small damaged area > 25cm2
< 30cm wide
Large damaged area > 30cm wide
3 Layer
Polypropylene (PP)
Small damaged area < 30cm wide
Large damaged area > 30cm wide
Blast to Sa 2½.
Heat shrink sleeve
PR-1180 approved coating
PERP patch repair
PE Heat shrink sleeve
PR-1180 approved coating with PE
heat shrink sleeve overlap of 150mm
minimum to the existing coating
PP Heat shrink sleeve
Use a series of PP heat shrink sleeves
with an overlap of 50mm to cover the
damaged area. Overlap the existing
coating to a minimum of 150mm.

For areas where coating has been removed for UT verification then the repair shall be treated as a large
damaged area.

Care should be taken not to damage the parent coating when applying the heat to shrink the sleeve. Heat
shrink sleeves shall be approved in accordance with DEP 31.40.30.37 and shall suite the service temperature
for which they are to be used.

SP-1246 11 April 2010

Specification for Painting and Coating of Oil and Gas Production Facilities – Part 3 Version 2

4 Inspection
4.1 Visual Inspection of the Old Coating
Visual inspection gives a first indication of the condition of the old coating and will provide information as to
whether application of a maintenance coating is technically feasible and economically viable.

Below summarises the visual observations that may indicate the initial stages of coating breakdown. Such
warning signs include:

 general rust formation,

 local rust attack resulting from mechanical damage, typically of edges, in crevices and
corners, at weld seams and in corrosion traps,
 local rust spots on films that are too thin or porous,
 rust creep from damaged areas,
 rust staining on adjacent equipment/structures,
 flaking of the substrate or between coats,
 blistering,
 cracking of the paint film

4.2 Classifying Surface Condition

Table 3, below gives guidance for the assessment and classification of the surface condition of existing coating
systems categorised from the initial visual appearance of coating defects.

SP-1246 12 April 2010

Specification for Painting and Coating of Oil and Gas Production Facilities – Part 3 Version 2

Table 4 Summary of External Coating Defects - Visual Inspection, Likely Causes and Maintenance
Type of Defect Visual Likely Causes Maintenance Action Maintenance Surface Preparation Repair Extent
Standard Consequences

Contaminated old Exposure to contaminants,
coating infrequent cleaning.
Chalking and film ISO 4628-6 Corrosion, atmospheric attack
thickness reduction
Rust spots ISO 4628-3 Salt contamination
Pinholes, porous film or damages
Deterioration (by stresses)
Mill scale or remnants or rust
Grit inclusions
Pitting
Insufficient dry film thickness
Blistering ISO 4628-2 Soluble salts present under or
between coats
Cathodic over protection
Contaminants, grease present
High temperature or thermal
gradient
Contact with chemicals, solvents,
water condensation
Solvent retention in coating
Cracking, checking ISO 4628-4 Hard coating on top of a soft
and flaking ISO 4628-5 coating (checking)
Dried or brittle oil-based top coat
(cracking / flaking).
Detached/disbonded Coating lifting at corners, edges,
coating angles, weld seams etc.
Intercoat contamination or
incompatibility
Cathodic over protection
Internal stresses due to excessive
thickness or temperature changes
Remove deposits, dust, grease,
oil, salts algae etc.
Remove deposits, contaminants
Check presence, wash with
fresh water
Feather edges of damages
Thoroughly abrade
Abrade/blast clean mill scaled
or rusty areas
Remove by chipping/abrading
Grind out and fill pits
Reinstate DFT
Check presence, wash with
fresh water
Adjust CP, select resistant
system
Check, clean, degrease
Confirm coating heat
resistance, insulate
Protect coating, select resistant
coating
Use correct DFT and/or
overcoating times
Check underlying material
Abrade checked paint and
change paint system
Change paint system
Improve surface design,
smooth out sharp edges/corners
Check specification, change
paint system
Adjust CP, change paint system
Check total DFT
Application of appropriate
coatings after surface cleaning
Application of appropriate
coatings after surface cleaning
Reinstate DFT
Local coating repair for
damaged areas up to 10% total
Repair possible after removal
of blisters and surrounding
damaged coating
Indicate stress and brittleness
Usually restricted to small local
areas. Total re-coat only
required where disbondment is
extensive
Thorough bristle brush scrubbing
with detergents, fresh water wash
Thorough bristle brush scrubbing
with detergents, fresh water wash
Depending on future exposure,
power tool clean to St 3 or grit
blast to Sa 2 or 2½
Remove blistered coating and
damaged coating using strippers,
scrapers, grinders. Prepare
surface by wire brushing or
sweep blasting
Remove cracked coating using
strippers, scrapers, grinders.
Prepare surface by wire brushing
or sweep blasting
Remove wrinkled or detached
coating using strippers, scrapers.
Abrade or blast clean to required
cleanliness
See Vol. 4 for cleaning
See Vol. 4 for cleaning
Ri 3 and below – spot
repair
Ri 4 and below – spot
repair and full top coat
over repair area
Above Ri 4 – total recoat
Repair areas:
External
< Ri3 – spot repair
<Ri 4 – total area repair
and full top coat over
repair area
Repair only where cracks
are fine and localised.
If widespread or paint is
flaking – total area repair
and full top coat over
repair area
Ri 3 and below – spot
repair
Ri 4 and below – spot
repair and full top coat
over repair area
Above Ri 4 – total recoat

SP-1246 13 April 2010

Specification for Painting and Coating of Oil and Gas Production Facilities – Part 3 Version 2

4.3 Testing the Mechanical Properties of the Old Coating

Following the visual testing, the mechanical properties of the old coating and the condition of the steel surface
underneath should be tested for presence of contaminants that might compromise the integrity of the coating.

4.3.1 Measuring Thickness of the Old Coating

Test methods:

 Magnetic DFT gauges

 Electromagnetic gauges
 Eddy current gauges

If the coating thickness, on structures exposed to weathering, is considerably less than that originally specified
and generally less than 150 microns min. DFT, experience has shown that it is no longer sufficiently protective
and that a new coating is required.

If the coating is very thick, possibly from application of previous maintenance coatings, (>300microns), stresses
within the coating will be expected. If extensive cracking and flaking occur, the old coating should be
completely removed and a new coating system applied. If the coating system has been in place for >20 years it
should be completely replaced.

4.3.2 Adhesion (including intercoat) of the Old Coating

Test Method:

 450 cross-cut test according to ASTM D3359 method A (using adhesive tape to remove cut
coating)

If result is <3A then maintenance work can proceed. If the value is greater than 3A the adhesion is no longer
sufficient and complete removal of the old coating is required.

The intercoat adhesion is insufficient if parts of the layers can be easily separated from each other or if the edges
break off during scraping. The maintenance coating shall only be applied after the loose layers have been
removed.

4.3.3 Embrittlement of the Old Coating

Test Method:

 Chip test - a strip, as long as practicable, is cut from the coating by using an angled-knife or
blade.

The shorter the strips, the greater the embrittlement. In the case of brittle and very hard top coats over soft
priming coats (tension differential), a complete removal of the old coating is required.

4.3.4 Under Rusting or Insufficient Surface Preparation Prior to the Original Painting

Test Method: Remove an area of 25 cm2 of old coating with paint scraper.

The remains of millscale or the absence of a blast pattern indicate insufficient surface preparation prior to
applying the primer. In both cases, the old coating should be completely removed and the surface carefully
prepared before a complete new coating is applied.

4.3.5 Defects in Vessel and Tank Internal Coatings

Test Method: Visually inspect for blisters and localised staining.

SP-1246 15 April 2010
Specification for Painting and Coating of Oil and Gas Production Facilities – Part 3 Version 2

Initial coating breakdown may manifest itself as isolated blistering (often liquid filled) or rust staining initiated
at coating holidays. If rusting is seen to >Ri3 then the coating shall be totally removed and a new coating
applied.
Also apply 4.3.4 above to check blast profile of substrate.
Blistering will indicate disbondment and coating should be refurbished

4.3.6 GRE Lining

Test Methods: - Visual inspect for staining/blistering, presence of voids and disbondment.

If lining looks okay, on failure mode refer to section 22.5.1.4 then sweep blast and overcoat in accordance with
MPS-7. If there is doubt about the integrity of the lining then consult UER/CFDH Materials and Corrosion

4.4 Detection and Removal of Surface Salts

Almost all exposed structures will be contaminated with soluble salts. In marine and aqueous environments,
soluble chloride salts will always be present. Soluble salts are likely to be present on areas of bare steel or
damaged areas of existing coatings. It is essential that any such contaminants are removed prior to surface
preparation and coating. Presence of salts can be tested by using the appropriate parts of ISO-8502. As a “rule
of thumb” the following can be used which then need to be quantified using one of the methods detailed in ISO-
8502.

4.4.1 Test for Salt Contamination

As a first indication, the presence of soluble salts can be detected by moistening the cleaned steel surface and
pressing a filter paper impregnated with a 5% potassium ferrocyanide solution onto the almost dry area. If
ferrous salts are present, these will show up as blue spots on the filter paper. If this is found then a more
accurate determination using the Bressle test method must be used.

4.4.2 Removal of Soluble Salts and Conductivity Tests

Sound existing coatings shall be thoroughly washed down with low/medium pressure, fresh water. Damaged and
rusted areas shall be thoroughly washed down both prior to, and after, surface preparation.

In the case of heavily pitted steel, steam cleaning is required to ensure removal of deeper, more adherent
contaminants. Test residues for soluble salts using the Bressle test method. The maximum allowable level of
chlorides is 60-80mg/m2.

4.5 Coating Compatibility

For local spot repair and rehabilitation, the selected maintenance coatings systems shall be the same as the
original (i.e. as the Schedules given in Part 2 for New Construction) or shall be fully compatible.

To decide whether a certain system is suitable for maintenance of an old system, the Contractor and Coating
Vendor shall ensure that all maintenance coatings are compatible with the existing coating system. The old
coating shall not adversely react to solvents and resins of the new applied coating.

The Contractor shall conduct sufficient testing on small areas and removed samples of the existing coating to
prove the compatibility of the Vendor’s proposed maintenance coating. If the structure in question is large and
subject to different degrees of exposure, several such tests should be carried out to ensure total representation.

The interval between the application and the evaluation of such tests should be long enough for the actual
exposure to take effect and also allow the coat of paint to dry thoroughly.

Note: In general, when using, surface tolerant coatings, such a test can be obviated when using
maintenance systems MPS-1/2/13 (see Section 5), because of the good compatibility of the first layer product
with old coatings.

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4.5.1 Overcoating Existing Coating Systems

Existing coatings may be overcoated to achieve the following:

- increase film thickness

- provide an impervious coat
- improve corrosion resistance
- provide fouling resistance
- renew the gloss
- change topcoat colour

In all applications, it will be necessary to identify the original coating and to seek advice from the manufacturers
and UER approval on the appropriate precautions to be taken before overcoating with a compatible system
according to the appropriate Schedules.

4.5.1.1 Overcoating Epoxies and Polyurethanes

Remove all dirt, oil, grease and foreign matter as in Part 4. Stronger solvents based on methyl alcohol or MEK
may be used. Allow surface to dry thoroughly before applying a compatible overcoat.

4.5.1.2 Overcoating Epoxy Mastic

Remove all dirt, oil, grease and foreign matter as in Part 4. Allow surface to dry thoroughly before applying
overcoat.

4.5.1.3 Overcoating Silicate-based Paints

Check old zinc silicate coatings for adhesion. Thoroughly wire brush and remove zinc salts with fresh water.
Dry surface and overcoat with same or similar compatible system.

4.5.1.4 Overcoating GRE Lining

GRE vessel linings fail generally by blistering and delaminating or by disbonding. Such failures usually warrant
complete removal and refurbishing. Where overcoating is prescribed, it is generally for improving structural
integrity or for coating surrounding areas adjacent to local repairs. In such cases, precautions need to be taken to
ensure complete removal of oil, sludge and other contamination Prior to sweep blasting and applying a flood
coat of epoxy resin. A detailed method statement must be submitted for approval by PDO before overcoating is
carried out.

4.5.2 Paint Applicability

Because of possible proximity with other existing structures and possibly sensitive equipment, there is always a
risk of damage due to paint overspray. For this reason, paints, intended for maintenance work, should be
capable of being applied by brush and roller in addition to being sprayable. To void overspray and paint losses,
it is desirable to apply paint to complex structures by brush or roller rather than spraygun.

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Specification for Painting and Coating of Oil and Gas Production Facilities – Part 3 Version 2

5 Selection Guide for Maintenance Painting Schedules

5.1 Schedule Selection
This Section gives maintenance painting schedules (MPS) for the spot repair and renovation of existing
protective coating systems on carbon and low alloy steels where verifying degrees of rusting have occurred. The
extent of repair of coatings suffering other defects, such as blistering, cracking and detachment shall be as
shown in Table 4, in Section 4.2 above.

Where the need for refurbishment has been identified, i.e. rust spotting to Ri 4 and above for external and Ri 3
for internal, then it will be necessary to remove what remains of the existing system and re-coat as required in
Part 2 of this Specification for new construction.

The following factors will need to be considered when selecting a maintenance coating:

- compatibility with existing coating system

- anticipated operating temperature
- adhesion to substrate
- anticipated period before next maintenance
- remaining useful life of equipment/structure

The options for maintenance repair of coatings used to protect tank and vessel internals and buried structures
will largely be governed more by economic and logistic factors than by the need to restore corrosion protection.
For these structures repair options shall be approved by UER/CFDH Materials and Corrosion.
Spot repair and renovation of these surfaces, in preference to total refurbishment, is rarely justified when
considered in relation to the costs associated with:

- selective decommissioning and isolating equipment,

- expected production losses during shutdown,
- preparing equipment for inspection and maintenance,
- excavation of pipelines, piping and equipment,
- recommissioning and reinstatement.

The repair/renovation options may be justified when:

- damage is restricted to clearly specific areas, ie weld seams, nozzle fittings, areas of
mechanical damage,
- the bulk of the existing coating is sound,
- anticipated high costs of coating removal, surface preparation and coating application,
- limited tolerable equipment outage and shutdown periods,
- complimentary mitigation measures of cathodic protection and inhibitor treatment are still
effective,
- Imminent future major shutdown of equipment.

Experience has shown that for buried structures, such as piping, flowlines and vessels, where best performance
is required, coating maintenance will generally require the existing coating be to completely removed, the
substrate properly derusted and prepared and a new coating applied. Even for local areas, such as welds, where
coatings may prematurely break down, spot repair and renovation are not recommended. Coating of buried
sections of above ground pipelines and flowlines is covered in GU-368 and repair options for pipelines are
given in table.3 of this Part of the specification. For repair of vessels consult UER/CFDH Materials and
Corrosion

For these reasons, total coating refurbishment provides the only viable maintenance options. Coating
rehabilitation will be as for new construction, as presented in Part 2 of this Specification or as the subject of
separate specification dedicated to the particular requirements of each project.

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Table 5 recommends the appropriate maintenance coating for the repair/renovation of an existing paint
system.
Table 5 Selection for Maintenance Coating Schedules
Designated Use Existing Surface Maintenance
Coating/ Condition Schedule
Schedule1
Maintenance coating for epoxy and polyurethane systems for PCS-1 Ri 3 MPS-1
above ground equipment and structural steelwork for Ri 4 MPS-2
temperatures up to 100°C
Maintenance coating for zinc silicate/Aluminium silicone PCS-3 Ri 3/4 MPS-3
systems for above ground structures at 100-400°C
Maintenance coating for aluminium mastic systems for steel PCS-4 Ri 3/4 MPS-4
structures under insulation at below ambient up to 100°C
Maintenance coating for silicone systems for steel structures PCS-5 Ri 3/4 MPS-5
at temperatures >400°C
Maintenance coating for weathered galvanised and stainless PCS-6 - MPS-6
steel structures and fittings2
Maintenance of internal glass fibre reinforced epoxy linings PCS-7A/7B Ri 2/3 MPS-7
for tanks/vessels in corrosive service up to 60°C3
Maintenance of internal epoxy coatings for tanks/vessels in PCS-7A/7B Ri 2/3 MPS-8
corrosive service up to 60°C
Maintenance of internal glassflake linings for vessels in PCS-8 Ri 2/3 MPS-9
corrosive service for temperatures 60 to 93°C
Maintenance of internal coatings for potable water storage PCS-10 Ri 2/3 MPS-10
tanks
Maintenance coatings for topside areas of marine structures PCS-11A Ri 3/4 MPS-1
and craft
Maintenance of coatings for submerged marine service PCS-11B Ri 3/4 MPS-11

Gas pipeline flow coat PCS-12 N/A

Pipeline Repair4 MPS-12

Notes:
1. Refer to Part 2
2. For damaged galvanising use zinc rich epoxy.
3. General repair can be undertaken by sweep blasting and applying top coat of epoxy resin.
4. Refer to table.3 for details of options.
5. For buried vessels consult UER/CFDH Materials and Corrosion

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Table 6 Recommended Procedures for Coating Repair and Renovation

Schedule Surface Preparation Paint System

Existing Intact Paint Surface Steel Substrate First Coat (Spot repair) Overcoat System
MPS-1 Remove all dirt, oil and grease by detergent or solvent washing. Power wire brush to St 2 Surface tolerant Al-pigmented Spot repair with high build polyamide cured epoxy or
Rinse with fresh water. Dry thoroughly, lightly abrade or sweep blast epoxy mastic to 50μ DFT polyurethane to 150μ total DFT
to remove gloss and feather edges. For Ri<3
MPS-2 Remove all dirt, oil and grease by detergent or solvent washing. Grit or vacu-blast to Sa 2 Surface tolerant Al-pigmented Total area repair with one coat HB polyamide cured epoxy 75μ
Rinse with fresh water. Dry thoroughly, lightly abrade or sweep blast epoxy mastic to 50μ DFT DFT and one coat HB polyamide cured epoxy or polyurethane
to remove gloss and feather edges For Ri.>3 200μ total DFT
MPS-3 Wire brush sound coating, water wash, fresh water rinse and dry Grit or vacu-blast to Sa Alkyl zinc silicate to 50μ DFT Total area repair with two coats aluminium pigmented silicate to
2½ 100μ total DFT
MPS-4 Remove all dirt and debris by detergent or solvent washing. Rinse Grit or vacu-blast to Sa 2 Surface tolerant Al-pigmented Not required
with fresh water. Dry thoroughly, lightly abrade or sweep blast, epoxy mastic to 125μ DFT
feather edges
MPS-5 Stiff bristle-brush sound coating, fresh water rinse and dry Sweep blast or steam Silicone acrylic to 25μ DFT Total area repair with one coat silicone acrylic to 50μ total DFT
clean.

MPS-6 Remove all dirt, oil, grease, zinc salts and corrosion deposits. Power wire brush or grit Surface tolerant Al-pigmented
Degrease and rinse with fresh water. Dry thoroughly, lightly abrade or vacu-blast to St 3 epoxy mastic to 50μ DFT
or sweep blast, feather edges
MPS-7 Remove all dirt, oil and grease by detergent or solvent washing. Grit or vacu-blast to Epoxy polyamide holding Apply approved epoxy resin system to repair areas. Brush or
Rinse with fresh water. Dry thoroughly, lightly abrade or sweep blast Sa2.5 primer to 30μ DFT. Fill roll in two layers of chopped strand reinforcing glass mat and
and feather edges. Vacuum to remove dust and debris heavily pitted areas with sand- one layer finishing tissue to required total thickness as PCS-7a.
filled epoxy putty General repair can be undertaken by sweep blasting and
applying top coat of epoxy resin.
(Repair as UER advice/Contractor Method Statement)
MPS-8 Remove all dirt, oil and grease by detergent or solvent washing. Grit or vacu-blast to Polyamide cured epoxy primer For Ri 3 damage: Repair with two coats high build, high solids,
Rinse with fresh water. Dry thoroughly, lightly abrade or sweep blast Sa 2.5 to 75μ DFT solvent-free epoxy to original film thickness to 25mm around
around defects, feather edges. Vacuum to remove dust and debris defect

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Table 6 cont.

Schedule Surface Preparation Paint System

Existing Intact Paint Surface Steel Substrate First Coat (Spot repair) Overcoat System
MPS-9 Remove all dirt, oil and grease by detergent or solvent washing. Grit or vacu-blast to Total area repair with two coats of glass filled polyester/vinyl
Rinse with fresh water. Dry thoroughly, lightly abrade or sweep blast Sa 2.5 ester to original film thickness
around defects, feather edges. Vacuum to remove dust and debris
MPS-10 Remove all dirt, sludge and corrosion deposits by detergent or Power wire brush to St 3 Surface tolerant Al-pigmented Total area repair with two coats of potable water quality
solvent washing. Rinse with fresh water. Dry thoroughly, lightly epoxy mastic to 75μ DFT polyamide cured epoxy to 325μ total DFT
abrade or sweep blast around defects, feather edges. Vacuum to
remove dust and debris
MPS-11 Remove all dirt and marine growth by power water jetting, brushing Grit blast to Sa 2.5 at High solids modified epoxy At defects, one coat high solids modified epoxy to 150μ DFT
or scraping. Remove old antifouling and non-adherent underlying defects in underlying to150μ DFT. For fixed and fouling control coating to 100μ DFT.
coating. Rinse with fresh water. coating structures, apply quick curing, For fixed structures, no topcoat other than optional fouling
wet surface tolerant HS epoxy control system
to 500μ DFT
MPS-12 Remove all dirt, sand and corrosion products by hand power tools. Grit blast to SA 2.5 Apply heat shrink sleeve For larger areas apply PR-1180 approved system .Use heat
Rinse with fresh water to remove salt contaminants, dry thoroughly. shrink sleeves to overlap the repair to the existing coating.
Blast to Sa21/2 and sweep blast to feather edges of existing coating. See table.3 for details

Notes :
- All parts of the coating system shall be from the same manufacturer

- Intercoat adhesion problems occur if maximum overcoating interval specified by the manufacturer is exceeded.

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Specification for Painting and Coating of Oil and Gas Production Facilities – Part 4 Version 2

6 Related Business Control Documents

PDO and SIEP Documents

GU-368 Guidelines For The Protection Of Buried Sections Of Surface Laid

Pipelines/Flowlines

DEP 31.40.30.37 EXTERNAL FIELD JOINT AND REHABILITATION COATING

SYSTEMS FOR LINE PIPE

PR-1180
Performance Testing of Coating Systems for Pipeline Rehabilitation

DEP 31.40.30.31- Technical Specification for External Polyethylene and Polypropylene

Gen. Coating for Line Pipe

Technical Specification for External Fusion-bonded Epoxy Powder

DEP 31.40.30.32- Coating for Line Pipe
Gen

International Standards

ISO 4628-2 Paints and varnishes – Evaluation of degradation of paint coatings –

Designation of intensity, quantity and size of common types of defect
– Part 2: Designation of degree of blistering

ISO 4628-3 Paints and varnishes – Evaluation of degradation of paint coatings –

Designation of intensity, quantity and size of common types of defect
– Part 3: Designation of degree of rusting

ISO 4628-4 Paints and varnishes – Evaluation of degradation of paint coatings –

Designation of intensity, quantity and size of common types of defect
– Part 4: Designation of degree of cracking

ISO 4628-5 Paints and varnishes – Evaluation of degradation of paint coatings –

Designation of intensity, quantity and size of common types of defect
– Part 5: Designation of degree of flaking

ISO 4628-6 Paints and varnishes – Evaluation of degradation of paint coatings –

Designation of intensity, quantity and size of common types of defect
– Part 6: Rating of degree of chalking by tape method

ISO 8501-1 Preparation of steel substrates before application of paints and related
substances – Representative photographic examples of the change of
appearance of steel when blast-cleaned with different abrasives

ISO-8502 all parts Preparation of steel substrates before application of paints and related
products – Tests for the assessment of surface cleanliness

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ISO 8504-3 Preparation of steel substrates before application of paints and related
substances – Surface preparation methods - Part 3: Hand - and power-
cleaning

European Rust Comité Européen des Associations de Frabricants

Scale

ASTM 610-01 Standard Test Method for Evaluating Degree of Rusting on Painted
Steel Surfaces

ASTM D3359 Standard Test Method for Measuring Adhesion by Tape Test

BS 6920 Suitability of non-metallic products for use in contact with water

intended for human consumption

7 Appendix A Glossary of Definitions, Terms and Abbreviations

7.1 Standard Definitions
must/shall Indicates a mandatory requirement.

should Indicates a preferred course of action.

may Indicates one acceptable course of action.

SIEP Shell International Exploration and Production bv.

PDO Petroleum Development Oman.

Contractor The PDO appointed Contractor for a defined piece of work.

Vendor The supplier of materials or equipment - not necessarily the Manufacturer.

Manufacturer The company responsible for the manufacture - not necessarily the Vendor.

Paint Vendor The supplier of paint and coating materials.

Paint Vendor’s Data sheet, published and maintained by the Paint Vendor, detailing the
Technical Data Sheet properties of the paint/coating materials and the requirements for their
application. These data sheets also state the conditions for surface preparation
prior to application of paint/coating materials and associated acceptance
criteria.

Painting Contractor The company responsible for a defined piece of painting, coating or lining
work.

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7.2 Abbreviations
ASTM American Society for Testing and Materials

CFDH Corporate Functional Discipline Head

BS British Standards

DEP Design and Engineering Practice (SIEP)

DFT Dry Film Thickness

ISO International Organisation for Standardisation

PE Polyethylene

PP Polypropylene

PERP Polyethylene Repair Patch

UER CFDH Materials & Corrosion

μm micron

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8 User Comment Form

User Comment Form

If you find something that is incorrect, ambiguous or could be better in this Procedure, write your comments
and suggestions on this form. Send the form to the Document Control Section (DCS). They make a record of
your comment and send the form to the correct CFDH. The form has spaces for your personal details. This lets
DCS or the CFDH ask you about your comments and tell you about the decision.
Procedure Details Title: Issue Date:
Number:

Page Number: Heading Number: Figure Number:

Comments:

Suggestions:

User’s personal details

Name: Ref. Signature: Date:
Ind.:
Phone:
Document Control Section Actions
Comment Date: CFDH
Number: Ref. Ind.:

Recd.: To CFDH:
CFDH Actions
recd. Decision: Inits.: Ref. Date:
Date: Ind.
Reject: 
Accept, revise at next issue: 

Accept, issue temporary amendment
Comments:

Originator Date: Inits.: Document Date: Inits.:

Advised: Control
Advised.

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