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LINING AND PAINTING Water Conditioning GRD2000 TECHNICAL SPECIFICATIONS

Technical Bulletin 6.07, Rev. 0 December 1998

Lining and Painting

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LINING AND PAINTING Water Conditioning GRD2000 TECHNICAL SPECIFICATIONS

Technical Bulletin 6.07, Rev. 0 December 1998

Table of Contents
Section 1.0 2.0 3.0 Scope References Preparation of Equipment
3.1 3.2 3.3 3.4 3.5 3.6 Joints Corners Nozzles Weld Spatter Bolt Holes Blasting

Page
2 2 3 3 3 3 3 3 3 4 4 5 5 5 5 7 8 8 9 10 10 10 10 11 11 13 13 13 13 14

4.0

Rubber Lining
4.1 4.2 4.3 4.4 4.5 4.6 Materials Surface Preparation Installation Curing Inspection Repairs

5.0

Sprayed Linings
5.1 5.2 5.3 5.4 5.5 5.6 Materials Surface Preparation Application Curing Inspection Repairs

6.0

Paint Systems
6.1 6.2 6.3 6.4 6.5 6.6 Materials Surface Preparation Application Curing Inspection Repairs

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LINING AND PAINTING Water Conditioning GRD2000 TECHNICAL SPECIFICATIONS

Technical Bulletin 6.07, Rev. 0 December 1998 1.0 Scope
This specification establishes the minimum requirements for the lining and painting of welded carbon steel vessels, carbon steel pipe and welded carbon steel structures.

2.0 References
The latest edition or revision of the following references are part of this specification: Rubber Manufacturers Association (RMA) Bulletin 1 Specifications for Welded Steel Tanks Bulletin 2 Specification for Pipe and Fittings Bulletin 4 General Procedure for Application of Elastomeric Sheet Lining Bulletin 5 Elastomeric Sheet Lining and Repair Before and After Vulcanization Bulletin 6 Standard for Surface Appearance of Elastomeric Sheet Linings Bulletin 7 General Precautionary Measures for Use with Elastomeric Materials Bulletin 8 Storage of Elastomeric-Lined Equipment Bulletin 9 Chemical Resistance of Elastomeric Sheet Linings Bulletin 10 Abrasion Resistance of Elastomeric Sheet Linings Bulletin 12 Suggested Standard Specifications for Elastomeric-Lined Equipment Bulletin 13 Procedure for Spark Testing Elastomeric Sheet Linings Bulletin 15 Care and Use of Elastomeric-Lined Equipment Bulletin 16 Chemical Cure of Elastomeric Sheet Linings Steel Structures Painting Council (SSPC) SP5 White Metal Blast SP6 Commercial Blast SP10 Near White Blast

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LINING AND PAINTING Water Conditioning GRD2000 TECHNICAL SPECIFICATIONS

Technical Bulletin 6.07, Rev. 0 December 1998 3.0 Preparation of Equipment
3.1 Joints All joints over which a lining is to be applied shall be continuous welded, smooth and free of holes, porosity, high spots, lumps or pockets. All corners are to be ground to a minimum radius of 1/8". 3.2 Corners All corners shall have a minimum radius of I/8. 3.3 Nozzles All nozzles and manways could be flush with the inside of the vessel and radiused or may project in beyond the inside surface of the vessel provided all welds and corners are properly radiused. Lined vessels shall not have nozzles that are smaller than 1-1/2" NPS. 3.4 Weld Spatter All weld spatter shall be removed. 3.5 Bolt Holes Bolt holes that are to be rubber lined shall be drilled oversized to allow for rubber lining and all edges shall be radiused. 3.6 Blasting Before surfaces are to be blasted, all oil, grease and other detrimental materials shall be removed. All surfaces to be lined or painted shall be thoroughly sandblasted in accordance with the applicable SSPC standard to remove scale, oxidation and all other foreign matter. All surfaces shall be vacuum-cleaned prior to application of the primer. The primer shall be applied prior to any oxidation of the substrate.

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LINING AND PAINTING Water Conditioning GRD2000 TECHNICAL SPECIFICATIONS

Technical Bulletin 6.07, Rev. 0 December 1998 4.0 Rubber Linings
4.1 Materials One of the following lining systems shall be used: Soft Rubber This is a black soft natural sheet stock. It is used primarily as a tank lining material for resistance to chemical agents and abrasion at temperatures from 33F up to 140F. Abrasion Resistance Water Resistance Tensile Strength Elongation Thickness Primer Intermediate Adhesive Thinner Surface Preparation Hardness After Cure Excellent Good 2000 psi minimum 500% 3/16" Density 0.96 lbs/sq ft 1/4" 1.26 lbs/sq ft As Recommended by Lining Manufacturer As Recommended by Lining Manufacturer As Recommended by Lining Manufacturer Xylol, Trichloroethylene, or Standard Rubber Solvent Naphtha SSPC-SP5 White metal blast 35 to 45 Shore A Durometer

Flexible Ebonite This is a high-grade duplex rubber sheet lining consisting of one layer of hard rubber backed with a layer of tie-gum rubber. It is used primarily as a tank lining material for resistance to chemical agents and some abrasion at temperatures from 33F up to 180F. Abrasion Resistance Water Resistance Tensile Strength Elongation Thickness Good Good 1500 psi minimum 10% 1/8 NOTE: For pipe and steel supports only. 3/16" Density 1.20 lbs/sq ft 1/4" 1.60 lbs/sq ft As Recommended by Lining Manufacturer As Recommended by Lining Manufacturer As Recommended by Lining Manufacturer Xylol, Trichloroethylene, or Standard Rubber Solvent Naphtha SSPC-SP5 White metal blast 75 to 85 Shore A Durometer

Primer Intermediate Adhesive Thinner Surface Preparation Hardness After Cure

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LINING AND PAINTING Water Conditioning GRD2000 TECHNICAL SPECIFICATIONS

Technical Bulletin 6.07, Rev. 0 December 1998
4.2 Surface Preparation All steel surfaces to be lined must be sandblasted in accordance with SSPC-SP5. This is defined as removing all rust, scale, paint, etc. to clean white metal which has a uniform gray-white appearance. Streaks and stains of rust or other contaminants are not allowed. 4.3 Installation After thoroughly preparing the surface by sandblasting apply one coat of Primer to the surface. One uniform coat of Intermediate is then applied over the Primer. Allow sufficient drying time between coats. The third coat in this system is Adhesive which is applied uniformly over the Intermediate. Minimum drying time of this material is 20 minutes and will remain tacky for several hours. No solvent wiping of this top coat is necessary prior to the application of the rubber stock. Cut all rubber sheet patterns to the proper size, allowing for 1-1/2" overlapped joints skived at a 45 angle. Solvent wipe the rubber sheet and allow to dry before applying substrate. Place the pattern in the proper position on the metal. Fold back the sheet, turn down the cloth and stitch the sheet to the metal with firm even strokes, being careful not to trap any air under the sheet. When stitching the sheet into a corner or radius fold the sheet into the corner, do not stitch the sheet to each side and force the sheet into the corner. NOTE: When lining articles where a 1-1/2" skived overlapped seam cannot be applied, special care must be taken to apply the skived joint.

4.4

Curing All linings shall be exhaust-steam-cured or autoclave-cured. Cure time is dependant upon the outside temperatures which affect metal temperatures, thickness of rubber and/or metal and the type of adhesion system used. Great care must be taken to insure that the temperatures recommended by the rubber manufacturer are reached and maintained for the appropriate length of time. In the event that exhaust steam is used, means should be provided for removal of condensate during cure.

4.5

Inspection 4.5.1 Inspection Before Cure Visual Inspection: Upon completion of the lining operation the rubber lined surfaces shall be visually inspected with special attention to the following areas: All carbon steel surfaces shall be entirely covered with rubber. The lining shall be examined for imperfections such as blisters, poor adhesion, loose joints, etc.

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LINING AND PAINTING Water Conditioning GRD2000 TECHNICAL SPECIFICATIONS

Technical Bulletin 6.07, Rev. 0 December 1998
Spark Test: The lining shall be examined for continuity and freedom from pinholes by passing an electrostatic spark tester over the surface of the lining. The rubber surface shall be free of moisture and foreign matter before the test is started. 4.5.2 Inspection After Cure Visual Inspection: The lining shall be examined for imperfections such as blisters, poor adhesion, loose joints, etc. Spark Test: The lining shall be examined for continuity and freedom from pinholes by passing an electrostatic spark tester over the surface of the lining. The rubber surface shall be free of moisture and foreign matter before the test is started. Hardness Test: The lining shall be tested with a Shore A or D Durometer to determine the proper state of the cure. A Shore A should be used on soft rubber and a Shore D should be used on hard rubber. Durometer readings shall be taken after the cured rubber has cooled to room temperature. 4.5.3 Spark Testing of Rubber-Lined Vessels Before and after rubber lining is cured it must be tested with an electrostatic spark tester. The purpose of the test is to determine the presence of pinholes, punctures, cuts, etc. that expose passages to the base metal. There are various models of high frequency generators used for testing leaks in rubber. The commonly used models consist of a generator with a Telsa coil added to the circuit. Output voltage can be fixed or variable depending on the particular test equipment. A variety of electrode accessories are available but normally a T- or L-shaped electrode is used on large surfaces. It is recommended that a pointed probe be used on overlapped or skived joints. To test the lining it is necessary to first determine the required output voltage of the tester. This is done by adjusting the output control on the spark tester until sparking is obtained with a gap of approximately 1/2" between the tip of the electrode and a piece of unlined carbon steel. To test the lining keep the electrode in light contact with the rubber and move back and forth at the rate of approximately 1 ft/sec. It is important that the electrode be kept in motion, otherwise there may be a chance of dielectrically breaking down the rubber. During testing the spark will be bluish and the sound will be an even buzzing. If fault or pinholes are present the corona discharge will start to fade and the spark will change to white. The white spark will then be concentrated in a line to the fault and the sound will change to a sputtering and cracking noise. No moisture or foreign matter should be present on the rubber surface at the time of testing.

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LINING AND PAINTING Water Conditioning GRD2000 TECHNICAL SPECIFICATIONS

Technical Bulletin 6.07, Rev. 0 December 1998
4.6 Repairs 4.6.1 Repairs Before Cure If pinhole defects are detected prior to curing, uncured button patches shall be used to cover at least 1-1/2" outside the periphery of defective areas where practical. The patches shall be cemented and rolled in placed. The repaired area shall then be tested as described in Section 4.5. 4.6.2 Repairs After Curing If pinhole defects are detected they shall be repaired with button patches as described above. If a significant defect in the lining stock is found, the lining shall be cut away, the surface cleaned, and a new piece of uncured stock placed in with adhesive. A new piece shall be laid over the entire area covering at least 1-1/2" extending from the edge of the laid-in patch. The laid-in patch and the covering piece shall be firmly rolled to a neat appearance. The repaired area shall then be tested as described in Section 4.5.

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LINING AND PAINTING Water Conditioning GRD2000 TECHNICAL SPECIFICATIONS

Technical Bulletin 6.07, Rev. 0 December 1998 5.0 Sprayed Linings
5.1 Materials One of the following lining systems shall be used: Plasite 7133 Epoxy-Polyamide Plasite 7133 is a combination of epoxy and polyamide type resins with selected pigments. It is used primarily as a tank lining material for high chemical resistance and non-toxic applications at temperatures from up to 250F. This coating is resistant to the standard cleaning for sanitation purposes and will withstand normal atmospheric steam cleaning procedures. Chemical Resistance Excellent for water Excellent for 50% sodium hydroxide Excellent for 26% sodium chloride 8 to 10 mils DFT in two or three coats This system is self-priming Plasite 71 for airless or conventional spray SSPC-SP5 White metal blast Per the Manufacturers recommendations

Thickness Primer Thinner Surface Preparation Curing Time

Plasite 7156 Amine Adduct Cured Epoxy Plasite 7156 is an epoxy coating polymerized with an amine adduct-type curing agent. It is used primarily as a tank lining material for high chemical resistance and non-toxic applications at temperatures up to 250F. This coating is resistant to the standard cleaning for sanitation purposes and will withstand normal atmospheric steam cleaning procedures. Chemical Resistance Excellent for water Excellent for 50% sodium hydroxide Not recommended for service with corrosive acids 10 to 12 mils DFT in two coats This system is self-priming Plasite 71 for airless or conventional spray SSPC-SP5 White metal blast Per manufacturers recommendations. Forced curing is recommended to obtain maximum resistance.

Thickness Primer Thinner Surface Preparation Curing Time

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LINING AND PAINTING Water Conditioning GRD2000 TECHNICAL SPECIFICATIONS

Technical Bulletin 6.07, Rev. 0 December 1998
Carboline Super Hi-Gard 891 This is a cross-linked epoxy coating. It is used as a lining in filters and softeners used in the pharmaceutical industry. Chemical Resistance Excellent Excellent Excellent Very good Not Recommened 12 to 18 mils DFT in three coats Not required Thinner #2 for spray applications SSPC-10, 40 to 75 micron blast profile Per manufacturers recommendations Water Salt Solutions Sugar Solutions Alkalies Acids & Solvents

Thickness Primer Thinner Surface Preparation Curing Time

Amercoat 78 HB Amine Cured Coal Tar Epoxy This material may be used as a lining for pretreatment and waste treatment equipment such as Clarifiers, Gravity Filter and Raw Water Tanks. Suitable for immersion service with Thickness Primer Thinner Surface Preparation Curing Time - Salt solutions - Brackish water 16 mils DFT in one or two coats Not required Not required SSPC-10, 50 to 100 micron profile Per manufacturers recommendation

Heresite P-403 Heresite P-403 is a baked phenolic. It is used primarily as a tank lining material for a variety of chemical resistance applications at temperatures from 33F up to 400F. Abrasion Resistance Chemical Resistance Thickness Primer Thinner Surface Preparation Curing Time 5.2 Surface Preparation As defined above. Fair Excellent for Acids 6 to 8 mils DFT in multiple coats This system is self-priming Heresite S-215 for airless or conventional spray equipment SSPC-SP5 White metal blast Intermediate bake for 10 to 20 minutes Final bake for 1-1/2 hours

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LINING AND PAINTING Water Conditioning GRD2000 TECHNICAL SPECIFICATIONS

Technical Bulletin 6.07, Rev. 0 December 1998
5.3 Application After thoroughly preparing the surface by sandblasting and vacuuming the debris away apply a mist bonding pass. Allow to dry or flash off approximately 1 minute, but not long enough to allow the film to dry completely. Apply crisscross multi-passes moving the spray gun fairly rapidly maintaining a wet appearance. The epoxy polyamide coating should be allowed to dry and the baked phenolic coating should be baked. Additional coats should be applied as described above until the desired thickness is obtained. 5.4 Curing The epoxy polyamide coating may be baked or forced-air cured. The forced-air cure method is acceptable provided the metal temperature does not fall below 70F and when the service liquid is not sensitive to taste or odor pickup. Baking shall be used when the service Iiquid is sensitive to taste and odor pickup. The baked phenolic coating shall be baked. 5.5 Inspection Visual Inspection: Upon completion of the lining operation the lined surfaces shall be visually inspected with special attention to the following areas: All carbon steel surfaces shall be entirely covered. The lining shall be examined for imperfections such as overspray, runs, sags, pinholes, fisheyes, orange peel, blisters, etc.

Sponge Test: The lining shall be examined for continuity and freedom from pinholes by passing an electrical sponge tester over the surface of the lining. The lined surface shall be free of moisture and foreign matter before the test is started. Thickness Test: The lining shall be tested with a non-destructive magnetic gauge to determine the total dry film thickness. 5.6 Repairs If a surface defect in the lining is discovered, the defect shall be buffed out and the lining shall be repaired by spray or brush application. If a pinhole in the lining is discovered it shall be repaired by brush application. The repaired area shall then be cured and tested as described above.

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LINING AND PAINTING Water Conditioning GRD2000 TECHNICAL SPECIFICATIONS

Technical Bulletin 6.07, Rev. 0 December 1998 6.0 Paint Systems
6.1 Materials One of the following paint systems shall be used: Epoxy Polyamide This is a two component, cross-linked epoxy polyamide paint system. It is recommended as a high solids, semi-gloss, esthetic topcoat for components (excluding Regeneration Skids) installed indoors. Abrasion Resistance Weathering Temperature Resistance Chemical Resistance Very Good Very Good (chalks) 200F continuous Exposure Spillage Fumes acids good good alkalies excellent excellent solvents good excellent salt soln excellent excellent water excellent excellent Two component, cross-linked epoxy polyamide, 2 to 3 mil thick Two component, cross-linked epoxy Polyamide, 2 to 3 mil thick Blue A181 SSPC-SP6 commercial blast Primer Topcoat Carboline 893 Carboline 890

Primer Topcoat Colour Surface Preparation Acceptable Manufacturers

Siloxane This is a weatherable epoxy coating that embodies the properties of a high performance epoxy and an acrylic polyurethane. It is recommended for outdoorcoastal applications. Weathering Temperature Resistance Chemical Resistance Very Good 200F continuous (250F intermittent) Exposure Spillage Fumes acids excellent excellent alkalies excellent excellent solvents excellent excellent salt soln excellent excellent water excellent excellent 2 to 3 mil thick 5 to 6 mil thick Blue A181 SSPC-SP6 commercial blast Primer Topcoat Ameron 68 A Ameron PSX700

Primer Topcoat Colour Surface Preparation Acceptable Manufacturers

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LINING AND PAINTING Water Conditioning GRD2000 TECHNICAL SPECIFICATIONS

Technical Bulletin 6.07, Rev. 0 December 1998
Siloxane (Acrylic/Polyurethane) This Is a system that has outstanding weathering resistance and color retention. It is a hard, glossy, attractive topcoat for areas that require excellent resistance to splash, spillage and fumes of acid, caustic or salt. In outdoor non-coastal service, this system weathers exceptionally well. Weathering Temperature Resistance Chemical Resistance Good 200 F continuous Exposure Spillage Fumes acids very good excellent alkalies very good excellent solvents very good excellent salt soln excellent excellent water excellent excellent Two component, cross-linked epoxy polyamide, 2 to 3 mil thick Siloxane acrylic/polyurethane, 2 to 3 mil thick Blue A181 SSPC-SP6 commercial blast Primer/Intermediate Topcoat Carboline 893 Ameron PSX700

Primer Topcoat Colour Surface Preparation Acceptable Manufacturers

Flake Filled Novolac Epoxy Coating This is a 100% solids, flake-filled, high-functionality, Novolax Epoxy coating recommended for bulk acid and caustic storage tanks. A 30 to 40 mil DFT is recommended. Temperature Resistance Chemical Resistance 300 oF Continuous Exposure Spillage Fumes acids excellent excellent alkali excellent excellent salts excellent excellent oils excellent excellent solvents excellent excellent Primer 67, 3 to 4 mils WFT 100 XT 15 to 20 mil WFT 100 XT 15 to 20 mil WFT ANSI #61 Gray SSPC SP5, Minimum 3 mil profile Primer Base Coat/Top Coat Dudick 67 Dudick 100XT

Primer Base Coat Top Coat Colour Surface Preparation Acceptable Manufacturers

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LINING AND PAINTING Water Conditioning GRD2000 TECHNICAL SPECIFICATIONS

Technical Bulletin 6.07, Rev. 0 December 1998
Glass Flaked Novolac Epoxy This is a high-performance Novolac Epoxy coating recommended for use on acid and caustic Regeneration Skids and other areas of high spillage. Chemical Resistance Exposure Spillage Fumes acids excellent excellent alkalis excellent excellent not required 12 to 15 mils DFT 5742 Gray SSPC SP10, Minimum 2-3 mil profile Carboline 1205

Primer Top Coat Colour Surface Preparation Acceptable Manufacturers

6.2

Surface Preparation All steel surfaces to be coated must be sandblasted in accordance with SSPCSP6 unless noted otherwise. This is defined as about 2/3 of a white metal blast which allows for very slight residues of rust and paint in the form of staining.

6.3

Application After thoroughly preparing the surface by sandblasting and brushing the debris away apply the primer with conventional spray equipment. Allow this coat to dry thoroughly before applying the intermediate and/or the topcoat. Apply additional coats as needed to obtain the required thickness allowing each coat to dry before applying the next.

6.4

Curing The paint systems described above may be air-cured or force-cured. Curing times vary depending on the type of paint from 8 hours at 75F to 1 week at 75F. Follow the manufacturers recommended procedures for curing.

6.5

Inspection Visual Inspection: Upon completion of the painting operation the painted surfaces shall be visually inspected with special attention to the following areas: All carbon steel surfaces shall be entirely covered. The paint shall be examined for imperfections such as overspray, runs, sags, pinholes, fisheyes, orange peel, blisters, etc.

Thickness Test: The paint shall be tested with a non-destructive magnetic gauge to determine the total dry film thickness.

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LINING AND PAINTING Water Conditioning GRD2000 TECHNICAL SPECIFICATIONS

Technical Bulletin 6.07, Rev. 0 December 1998
6.6 Repairs If a surface defect in the paint is discovered, the defect shall be buffed out and the paint shall be repaired by spray or brush application. If a pinhole in the paint is discovered it shall be repaired by brush application. The repaired area shall then be tested as described in Section 6.5.

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