CARIGALL STANDARD PROCEDURE NO. : CSP-10 — 5 cARIGAL PROCEDURE REVISION.”: 0 JACKET / TOPSIDES ‘TEST PANEL / COATING SYSTEM QUALIFICATION PROCEDURE FOR PETRONAS CARIGALI SDN BHD KUALA LUMPUR In the event of any ambiguity, inconsistency or conflict between this procedure and the Contract Document and / or the Petronas Technical Standards (PTS), the Contract Document and / or PTS shall take precedence over this procedure. CARIGALI's interpretation shall be final ‘REV. [DATE| ‘PREPARED BY ‘REVIEWED BY ‘APPROVED BY NAME] SIGNATURE | DATE [NAME] SIGNATURE | DATE || NAME | SIGNATURE | DATE. © fewadara | Aran lwe.ac lore | -f*\_[4/eind ago aE ee Hun eohioam A :CARIGALI STANDARD PROCEDURE NO. : CSP-10 CARIGALI PROCEDURE REVISION. : 0 JACKET / TOPSIDES TEST PANEL / COATING SYSTEM QUALIFICATION PROCEDURE FOR PETRONAS CARIGALI SDN BHD 5 KUALA LUMPUR In the event of any ambiguity, inconsistency or conflict between this procedure ‘and the Contract Document and / or the Petronas Technical Standards (PTS), the Contract, Document and / or PTS shall take precedence over this procedure. CARIGALI's interpretation shall be final REV. [DATE] ‘PREPARED BY REVIEWED BY ‘APPROVED BY NAME] SIGNATURE | DATE |[ NAME] SIGNATURE | DATE || NAME | SIGNATURE | DATE © feadata | Acar lws-aclere | -\_ [4/5rad aco] B® | e/asrmows ITEST PANEL / COATING sysTeM| PROCEDURE NO.: CSP-10 ‘CARIGAL! QUALIFICATION PROCEDURE | peyision. : 0 JACKET / TOPSIDES PAGE 1. OF 17 TABLE OF CONTENTS SECTION DESCRIPTION PAGE , 10 PURPOSE 3 a 2.0 SCOPE 3 {30 REFERENCE 3 4.0 DEFINITIONS 3 5.0 PROCEDURE 3 Sl Test Panel 3 5.2 Surface Preparation 4 53 Coating / Painting 5 5.4 Inspection / Testing 6 5.5 Inspection Equipment u 5.6 Calibration 12 5.7 Painting System 12 5.7.1 Two-Coat System 12 5.7.2 Three-Coat System 3 5.7.3 Four-Coat System 15 5.7.4 Galvanized Steel 15 5.7.5. Stainless Steel 16 6.0 SPECIAL REQUIREMENTS 7ITEST PANEL / COATING SYSTEM| PROCEDURE NO, : CSP-10 Appendix IV CARIGALI QUALIFICATION PROCEDURE | gevision. : 0 JACKET / TOPSIDES ne 8 on Ip 70 RECORDS 7 Appendices , Appendix I Test Panel Inspection Report Z Appendix It Adhesive Strength Test : Appendix IIT Cross Cut Holiday Test ResultPROCEDURE NO. : CSP-10 prrnonas [TEST PANEL / COATING SYSTEM| CARIGALT QUALIFICATION PROCEDURE | revision, : 0 JACKET / TOPSIDES PAGE 3 OF 17 1.0 PURPOSE To demonstrate by trial, the surface preparation and coating requirements of steel structures based on CARIGALT's specification and in accordance to paint manufacturer's recommendation on the coating systems {2.0 SCOPE This procedure covers the qualification of coating systems prior to application : on steel materials for offshore facilities. 3.0 REFERENCES PTS 30.48.00.31-P Painting and Coating BS 3900 ‘Methods of test for paints Part E6 : Cross Cut Test PART E10 : Pull-Off test for Adhesion SSPC-SP1 Solvent Cleaning ISO 8501 ‘sual Assessment of Surface Cleanliness 4.0 DEFINITIONS DFT - Dry Film Thickness WET - Wet Film Thickness 5.0 PROCEDURES 5.1 Test Panel i) A minimum of one (1) panel shall be prepared for each different paint system, each panel shall not be less than 1 metre square area[TEST PANEL / COATING SYSTEM| prrncnas CARIGALI QUALIFICATION PROCEDURE | revision. » 0 JACKET / TOPSIDES PAGE 4 OF 17 ii) Each pane! shall be surface treated and cleaned to the correct standard, ili) ‘Two (2) coats of clear varnish shall be applied to preserve the surface preparation approximately one third of the panel area. 7 The remaining area shall then be painted with the appropriate } primer in the manner prescribed in this procedure. iv) Succeeding coats shall be applied in the specified manner and ? to the specified thickness as described in this procedure. vy)" CONTRACTOR shall notify CARIGALI at least one (1) week in advance prior to conduct the qualification tests of each paint system. 5.2. Surface Preparation _ 5.2.1 Check the test panel on its suitability for use. 5.2.2 Solvent cleaning in accordance with SSPC-SP1 shall be used to remove any oil, grease and other contamination present on the steel surface before blasting, 5.2.3 Ensure that correct sizeof abrasive is being used. It shall be dry and uncontaminated, Suitable abrasives for use in blast cleaning are i) Steel grit ii) Steel shot iii) Malleable iron shot iv) Crushed chilled-iron grit v) Chopped steel wire vi) Aluminium oxide (corundum) vii) Blast furnace slag viii) Copper slag ix) Asilgrit x) Garnet PROCEDURE NO. : CSP-10= prions CARIGALI |TEST PANEL / COATING SYSTEM QUALIFICATION PROCEDURE | pevision, - 0 JACKET / TOPSIDES PAGE 5 OF 17 53 3.24 525 5.26 5.2.7 Record down weather conditions prior to blasting The grade of surface finished shall be in accordance to ISO 8501 $22.5. Check surface profile measurements using a surface profile gauge or profile comparator, ensuring that they are within specifications. The preferred peak to valley height shall be 30-80 microns except for area to be coated with glassflake polyster which is 40-100 microns. Prior to application of paint, record the substrate temperature. Spraying may commence when the steel temperature is 3°C above dew point and when the relative humidity is lower than 85% or does not exceed thes paint manufacturer's recommendation. Coating and Painting 53.1 53.4 53.5 53.6 Check spray gun tip size on its suitability for use with the coating concerned. Ensure that equipment (Conventional / Airless) used is as per Paint Manufacturer's recommendation, Agitate paint base with power stirrer (explosive proof type / pneumatic) followed by addition of curing agent. Record down batch numbers of base and curing agent, and percentage of thinning if required in the test panel inspection report (see Appendix 1), Determine volume solids of the paint in order to determine required WFT to obtain minimum specified DFT. Spray the paint on a sample plate/beam to ensure that correct atomization and flow of paint is obtained before spraying onto test plate with a minimum distance of 8" from test panel to spray nozzle PROCEDURE NO. : CSP-10prmons CARIGALI Ings PANEL / COATING SysTEM| PROCEDURENO.: CSP-10 QUALIFICATION PROCEDURE REVISION. : 0 JACKET / TOPSIDES PAGE 6 OF 17 54 5.3.7 Record number of passes made to obtain required WFT. 5.3.8 Clean system with recommended cleaner immediately after spraying, 5.3.9 Allow the coating to cure for a minimum of 12 hours at 32°C or in accordance with the paint manufacturer's recommendation before application of the subsequent paint or coating, 5.3.10 Tape-up a minimum 8" portion of painted surface and lightly abrade the remaining area prior to application of subsequent coat, to distinguish the different coating application. Please refer to sample test panel Figure 1 5.3.11 Observe overcoating intervals as specified by the paint manufacturer's recommendation, 5.3.12 Repeat steps 5.3.1 to 5.3.10 when spraying subsequent coats. Anspeetion / Testing 5.4.1 Visual Inspection Individual coat and completedcoatings shall be visually inspected for appearance, Coats and coatings shall be smooth and free from dry spray, “pinholes, blisters, craters and excessive sagging, 5.4.2 Surface Profile Measurements This method is used to measure the surface profile of abrasive blasted steel surface. Following are the applicable method in determining the required surface profile. i) Surface profile comparator method A. keane-Tator comparator 372 or its approved equivalent consists of a reference disc, with blasted segments for which the roughness is given within an interval, The roughness shall be determined byprraonas CARIGALI ITEST PANEL / COATING SYSTEM| QUALIFICATION PROCEDURE | peyision, : 0 PROCEDURE NO, : CSP-10 JACKET / TOPSIDES PACER OFIIT 54.3, 5.4.4 comparing the comparator segment and the blast-cleaned surface. i) Press-O-Film Method This method consists of a compressible plastic tape which is placed on the blast-cleaned steel surface and compressed with a roller so that the tape retains a print of the surface, The replica shall then be removed and its thickness be measured in a micrometer screw gauge, the reading obtained is the maximum peak to valley heights of the blasted surface. Wet Film Thickness (WFT) Measurements The comb-type gauge shall be used. The surface selected for measurement should be smooth. The comb is placed in the newly applied wet paint film. The wet film thickness will be indicated where the tooth has touched the paint. To calculate the desired wet film thickness from Dry Film Thickness, the formula is, Wet Film Thickness = Dry Film Thickness x 100% Volume % solids Dry Film Thickness (DFT) Measurements The DFT of a non-magnetic coating applied on a magnetic substrate shall be determined or checked with calibrated film thickness gauges, using the magnetic resistance gauge or eddy current principle, such as 'Elcometer’, ‘Lepstoskop’, ‘Mikrotest’, etc. The gauges for DFT checks shall be calibrated at least twice daily in accordance with the manufacturer's recommendation. To determine the dry film thickness (DFT) from the measured wet film thickness, the formula is DFT = Wet Film Thickness x Volume % solids 100%CARIGALI [TEST PANEL / COATING SYSTEM} QUALIFICATION PROCEDURE | pevision. : 0 JACKET / TOPSIDES PAGE 8 OF 17 PROCEDURE NO. : CSP-10 5.45 54.6 Temperature and Relative Humidity ‘Temperature and Relative Humidity shall be measured by means of a temperature gauge and a hygrometer (e.g Elcometer type 113 and 116 respectively). Readings shall be taken at regular intervals depending on changes in climatic conditions. Inspection of Coating Continuity i) Wet Sponge - Low Voltage - Inspection This method of detecting discontinuities such as pinholes and holidays in internal linings shall be used to check coating systems having a DFT less than 500 microns. The instrument is earthed to the object. The surface shall be well wetted with normal tap water, preferably containing a small amount of wetting agent (such as Teepol) to ensure penetration of faults or pinholes. The saturated sponge of the tester shall then be systematically passed over the entire coated surface and as a coating discontinuity is approached, the detector will give a visual and / or audible alarm mode. All such indications shall be suitably marked immediately for repair purposes. High Voltage Electrical Inspection Detectors of this type are most often used on all coating systems having a DFT of $00 microns or higher. It isto be used only for the detection of discountinuities in the coating film such as pinholes, holidays, cracks, etc., and to detect hidden or non-visible defects such bubble or blister type voids, thin spots and foreign inclusions or contaminants, The holiday detector instrument shall be a portable, low amperage, adjustable high voltage pulse type, with an audible signal device.PROCEDURE NO. : CSP-10 PETROMAS TEST PANEL / COATING SYSTEM| CARIGALI QUALIFICATION PROCEDURE | pevision. : 0 JACKET / TOPSIDES PAGE 9 OF 17 In order to avoid burn through of the coating, the testing equipment should be carefully and frequently calibrated as follows : a) Making a small pinhole in the coating, The coating thickness at this pinhole should be at least the average thickness specified b) Using the same procedure and conditions, humidity and travel speed, etc,, increase the voltage on the pinhole tester until pinhole alarm is obtained at the manufactured pinhole. The minimum voltage Tequired to detect manufactured pinholes should be doubled for the actual pinhole inspection. 5.4.7 Curing The degree of curing of epoxy resin-based paint system can be checked by the determination of the resistance of the coating to methyl ethyl ketone (MEK). After rubbing the - coating for-one minute with 2 rag soaked in MEK, the coating, shall not be softened, test by scraping with a finger nail } 54.8 Pull-Off Test \/ This method is used to measure the adhesive / cohesive WV strength of coating systems. The test is required to obtain the specific value of the strength of adhesion to the substrate or between coats. Listed below are the minimum steps to conduct a pull-off test i) Seven days afier application of final coat, attached dollies on each coating; three (3) dollies per coating, ii) Ensure that the dollies are cleaned and abraded with sand paper before applying epoxy glue €.g. Araldite ‘two pack epoxy glue iil) Lightly abrade the area of attachment and record the coating thickness.rons res PANEL / COATING SYSTEM| PROCEDURE NO. : CSP-10 CARIGAL! QUALIFICATION PROCEDURE | pevision. : 0 JACKET / TOPSIDES ee oe iv) Press down dolly firmly on coating and remove excessive glue, ¥) Allow glue to be cured with a minimum of 24 hours before commencing pull-off test. vi) The force required to remove the dollies shall be recorded and reported as an average of at least three pull-offs. The area and mode of failure shall also be reported Note The minimum required adhesion strength for glassflake polyester coating is 500 psi (35kg/em*) and 300 psi (21 kglem’) and for all other paints, 5.4.9 Cross Cut Test The cross cut test may be conducted as an alternative to the pull-off test at the discretion of CARIGALI, Lines are cut into the coated test panel at angle of 90° to each other forming a cross-cut area of 25 small squares at 2em x 2cm per square. Adhere an adhesive tape on the cross-cut area and abruptly pull-off the tape and assesses as @ minimum, the results as shown in BS3 900 Part E6 Remaining Cross Cut 25/25 - 21/25 5 (acceptable) 20/25 - 16/25 4 (acceptable) 15/25 - 11/25 3 (unacceptable) 10/25 - 6/25 2 (unacceptable) 55 - 0/25 1 (unacceptable)ITEST PANEL / COATING SYSTEM) PROCEDURE NO. : CSP-10 prmnonas CARIGALI QUALIFICATION PROCEDURE | pEvision. : 0 JACKET / TOPSIDES Pe ceimoonT 5.5 Inspection Equipment Contractor may utilise approved inspection equipment or its equivalent, i.e. Eleometer, Mikrotest, etc. other than describe herein for the inspection of test panel / coating system. 5.5.1 5.5.2 554 5.35 Surface Profile Surface Profile Gauge Model 123, provides reliable ‘measurements peak-to-valley height 0-600 microns after, blasting. A Keane Tator Profile comparator may also be used to assess the surface profile. Wet-Film Thickness Gauge ‘The Wet Film Thickness Gauge (comb type) Model 115 is @ measuring instrument which resembles a comb with teeth in between decreasing in length from one to the other. It is used to monitor the wet film thickness on newly applied paint. im TI bry ness Gauge A. magnetic or electro-magnetic gauge maybe used to determine the dry coating thickness, iex elcometer 245, A-345. digital thickness gauge, electro physiks digital thickness gauge model 3001 complete-with F5-Probe (0-5 ‘mm range). ‘Wet and Dry Bulb Hydrometer The Elcometer 116 Whirling Hygrometer employs the ‘wet-and-dry bulb principle to determine the relative humidity of the atmosphere (together with necessary table charts, etc.) ‘Temperature Gauge ‘The Elcometer Model 113 magnetic steel thermometer dicates the substrate surface temperature.[TEST PANEL / COATING SYSTEM] PROCEDURE NO. CSP-10 prrmonas CARIGALI QUALIFICATION PROCEDURE | revision. : 0 JACKET / TOPSIDES DV @ 5.5.6 Pressure Gauge A needle pressure gauge is used to detect air pressure at blasting nozzles ' Pul-OW Test of ‘The Elcometer 106 is used to measure the adhesive / cohesive . strength of coating system 5.6 Calibration Profile height and film thickness gauges shall be calibrated on each occasion before use on individual items and thereafter, dependent on frequency of use. Reference panels for profile height and reference foils for film thickness shall be representative of the actual work. 5.7 Painting System 5.7.1 Two - Coat System i) Surface Preparation Dry blast clean to ISO 8501 Sa 2.5 oF equivalent at the time of coating ii) Coating System 1 : (Splash Zone) ‘No of Coats Type of Paint DFT TOTAL (Micron) (Micron) Ast Glass flake polyester 750 2nd Glass flake polyester 750 1500|TEST PANEL / COATING SYSTEM| PROCEDURE NO. : CSP-10 5.7.2 rernonas CARIGALI QUALIFICATION PROCEDURE | pevision. : 0 JACKET / TOPSIDES PAGE 13 OF 17 iii) Coating System 2 : Potable Water (Internal Lining) No.of Coats Type of Paint DFT TOTAL (Micron) (Micron) Ist Amine Adduct Cured Epoxy 125 i 2nd Amine Adduct Cured Epoxy 125 250 iv) Coating System 3 : (Carbon Stee! and Alloy Steel, Operating Temperature > 80°C) . Noof Coats Type of Paint DFT TOTAL (Micron) (Micron) ist Silicon Aluminium 50 5 2nd Silicon Aluminium 50 100 Three - Coat System i Surface Preparation Dry Blast clean to ISO'8501 Sa 2.5 or Equivalent at the time of Coating ii) Coating System 1: (Carbon Stee! and Alloy Steel, Operating Temperature > 80°C) Noof Coats Type of Paint DET TOTAL (Micron) (Micron) Ist Inorganic Zine Silicate 65 2nd Silicone Acrylics 40 3rd Silicone Acrylics 40 145prions CARIGALI ITEST PANEL / COATING SYSTEM] PROCEDURE NO, : CSP-10 QUALIFICATION PROCEDURE | revision, : 0 JACKET / TOPSIDES PGE ett Or7 iii) Coating System 2: Above Ground Storage Tank (Carbon Steel) (Internal Lining) No.of Coats Type of Paint DET = TOTAL (Micron) (Micron) Ist Zinc Rich Epoxy 50 2nd Amine adduct cured epoxy 100 3rd ‘Amine adduct cured epoxy 100 250 iv) Coating System3: Carbon Steel, Operating Temperature < 80°C. (Insulated Facilities at Offshore i.e. Vessels and Pipes etc.) ‘Type of Paint TOTAL . cron) (Micron) Ist Inorganic Zine Silicate 65. 2nd Epoxy 50 3rd Epoxy 125 240 vy) Coating System 4 : External Painting above Ground Storage Tank, Carbon Steel (Bottom Plates) No.of Coats Type of Paint DFT ‘TOTAL (Micron) (Micron) Ist Inorganic Zine Silicate 65 2nd Coal Tar Epoxy 150 3rd Coal Tar Epoxy 150 365 vi) Coating System 5 : External Painting above Ground (Shell & Roof Plates) No.of Coats Type of Paint DET TOTAL (Micron) (Micron) Ist Inorganic Zine Siticate 65 2nd Epoxy 150 3rd Polyurethane 50 265pemonas CARIGALI, ITEST PANEL / COATING SYSTEM| QUALIFICATION PROCEDURE JACKET / TOPSIDES PROCEDURE NO. : CSP-10 REVISION. : 0 PAGE 15 OF 17 5.7.3 5.74 Four Coat System i) Surface Preparation Dry blast clean to ISO 8501 Sa 2.5 or Equivalent at the time of Coating, i). Coating System 1: Carbon Temperature < 80°C No.of Coats. Type of Paint Ist Inorganic Zine Silicate 2nd Epoxy 3rd Epoxy 4th Polyurethane Galvanized Steel i Surface Preparation Steel, Operating DET TOTAL (Micron) (Micron) 65 50 128 50 290° Solvent clean and wash with clean fresh water. Abrade surface to provide anchor pattern, ii) ——_Cwating System No.of Coats Type of Paint Ist Epoxy wash primer 2nd Epoxy ard Polyurethane DFT TOTAL (Micron) (Micron) 10 50 50 110prracnas CARIGALI |TEST PANEL / COATING SYSTEM| QUALIFICATION PROCEDURE | pevision, - 0 JACKET / TOPSIDES PAGE 16 OF 17 PROCEDURE NO. : CSP-10 575 Stainless Steel i) Surface Preparation Sweep blast with dry, non-iron containing grit or other means to provide an anchor profile of at least 30 microns. ii) Coating System 1: (Non-Insulated facilities with operating Temperature at < 80°C) No.of Coats Type of Paint DFT TOTAL (Micron) (Micron) Ist ‘Non-inhibitive epoxy 50 2nd Non-inhibitive epoxy 50 3rd Polyurethane 50 150 iil) Coating System 2: (Insulated facilities with ‘operating temperature at < 80°C) No.of Coats ‘Type of Paint DET TOTAL (Micron) (Micron) Ist 50 . 2nd ‘Non-inhibitive epoxy 50 100 iv) Coating System 3. : (Non-Insulated Facilities with operating temperature at > 80°C) No.of Coats Type of Paint DFT TOTAL (Micron) (Micron) Ist Silicon Acrylic 50 2nd Silicon Acrylic 30 100erzows TEST PANEL / COATING SYSTEM] "ROCEDURE NO. : CSP-10 CARIGALL QUALIFICATION PROCEDURE | gevision, : 0 JACKET / TOPSIDES PAGE 17 OF 17 6.0 SPECIAL REQUIREMENTS i) CONTRACTOR shall submit the following information to CARIGALI before conducting qualification tests . 2) Method of application and surface preparation i “ b) Paint Catalogs and product data sheet ] °) Date and location 4) Type of inspection, testing, methods and acceptance criteria ii) The succeeding coat shall not be applied until the preceeding coat has sufficiently dry. iii) The paint shall not be forced dry under conditions that will cause cracking, wrinkling, blistering, or detrimentally affect the condition of the paint, iv) Paint shall be protected practically to the fullest extent from rain, 10 condensation and contamination until dry. RECORDS CONTRACTOR's QA/QC Department shall submit a full report of all products / systems tested and provide recommendation of the products / systems to be used for CARIGALT's review and approval. The Test Panel shall be retained and properly stored as a visual guide of standards to be achieved for the duration of the project.